Toyota - Camry - Workshop Manual - 2002 - 2006

19−1 STARTING & CHARGING − STARTING SYSTEM (2AZ−FE)(From July, 2003) STARTING SYSTEM (2AZ−FE)(From July, 2003) 190RS−03 INSPECTION Terminal C Terminal 50 A60459 Disconnect Terminal C 1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do the pull−in test. (1) Disconnect the lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnetic switch. (b) Do the hold−in test. (1) Leave the battery connections in step (a), but disconnect the negative (−) lead from terminal C. Check that the pinion gear remains extended. If the clutch pinion gear returns inward, replace the magnetic switch. A81044 (c) Check the clutch pinion gear return. (1) Disconnect the negative (−) lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch. Disconnect A81045 (d) Terminal 30 Terminal 50 A60462 Do the no−load performance test. (1) Connect the lead wire to terminal C. Make sure that the lead is not grounded. (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V WhereEverybodyKnowsYourName 19−2 STARTING & CHARGING 2. (a) 2 1 5 3 INSPECT STARTER RELAY ASSY Check the resistance of the ST relay. Standard: Specified Condition 3−5 10 kΩ or higher 3−5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) 1 3 STARTING SYSTEM (2AZ−FE)(From July, 2003) Tester Connection 5 2 − If the result is not as specified, replace the relay. B60778 3. (a) ACC LOCK ON START 4 3 2 1 8 7 6 5 B52423 INSPECT IGNITION OR STARTER SWITCH ASSY Inspect the switch resistance. Standard: Tester Connection Switch Condition Specified Condition − LOCK 10 kΩ or higher 2−3 ACC Below 1 Ω 2−3 2−4 6−7 ON Below 1 Ω 1−2 1−4 6−7 6−8 START Below 1 Ω If the result is not as specified, replace the switch assy. WhereEverybodyKnowsYourName 19−13 STARTING & CHARGING − CHARGING SYSTEM (2AZ−FE)(From July, 2003) CHARGING SYSTEM (2AZ−FE)(From July, 2003) 1902O−05 PRECAUTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
Check that the charging cable is tightened on terminal B of the generator and the fuse box. WhereEverybodyKnowsYourName 19−14 STARTING & CHARGING − CHARGING SYSTEM (2AZ−FE)(From July, 2003) 190RZ−02 ON−VEHICLE INSPECTION 1. (a) CHECK BATTERY CONDITION Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery. (b) Check the electrolyte quantity of each cell. For batteries that are maintenance−free: If the electrolyte quantity is below the recommended amount, replace the battery. For batteries that are not maintenance−free: If the electrolyte quantity is below the recommended amount, add distilled water. CAUTION: If the battery has gone flat or if the engine cannot be started easily, the engine may not be recovered properly. Recharge the battery and perform inspections again before returning the vehicle to the customer. 2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, high−current fuses and fuses for continuity. 3. (a) REPLACE BELT B00543 INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found:
If the belt has worn out until the wire can be seen.
If the cracks reach the wire more than one place.
If the belt has chunks missing from the ribs. (b) Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley. CORRECT INCORRECT B75171 4. VISUALLY CHECK GENERATOR WIRING (a) Check that the wiring is in good condition. 5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. 6. INSPECT CHARGE WARNING LAMP CIRCUIT (a) Turn the ignition switch ON. Check that the charge warning lamp turns on. (b) Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit. WhereEverybodyKnowsYourName 19−15 STARTING & CHARGING − CHARGING SYSTEM (2AZ−FE)(From July, 2003) 7. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer’s instrucBattery tions. (a) If a tester is not available, connect a voltmeter to the Generator charging circuit as follows. Voltmeter (1) Disconnect the wire from terminal B of the generator and connect it to the negative (−) lead of the ammeA91025 ter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative (−) lead of the voltmeter. (b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V 8. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high−beam headlamps and turn the heater blower switch to the HI position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT:
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometims be less than the standard amperage. Ammeter Disconnect Wire from Terminal B WhereEverybodyKnowsYourName 19−16 STARTING & CHARGING − GENERATOR ASSY (2AZ−FE)(From July, 2003) GENERATOR ASSY (2AZ−FE)(From July, 2003) 190S0−02 COMPONENTS Washer
Generator Drive End Frame Bearing 2.3 (23, 20 in.⋅lbf) x4 Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Generator Brush Holder Assy Terminal Insulator 5.8 (59, 51 in.⋅lbf) x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A90290 WhereEverybodyKnowsYourName 19−17 STARTING & CHARGING − GENERATOR ASSY (2AZ−FE)(From July, 2003) 190S1−03 REPLACEMENT 1. REMOVE DRIVE BELT (See page 14−5) 2. (a) (b) REMOVE GENERATOR ASSY Disconnect the engine wire as shown in the illustration. Remove the 2 bolts and generator. A60061 INSTALL GENERATOR ASSY Confirm that the wire harness of the crankshaft position sensor is placed as shown in the illustration. (b) Install the generator. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for M8 Clamp 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) for M10 9 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for wiring harness clamp Rib 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) for generator wire A52071 NOTICE: Be careful not to put the wire harness in when install the generator. INSTALL DRIVE BELT (See page 14−5) INSPECT DRIVE BELT (See page 19−14) Wire Harness 4. 5. 3. (a) WhereEverybodyKnowsYourName 19−18 STARTING & CHARGING − GENERATOR ASSY (2AZ−FE)(From July, 2003) 190S2−02 OVERHAUL 1. SST (1−A) SST (1−B) REMOVE GENERATOR PULLEY SST 09820−63010 (09820−06010, 09820−06020) HINT: Turn Hold A81658 SST (1−A, B) 09820−06010 SST (2) 09820−06020 (a) Hold SST (1−A) with a torque wrench, and tighten SST (1−B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (b) Clamp SST (2) in a vise. (c) Insert SST (1−A, B) into SST (2), and attach the pulley nut to SST (2). SST (2) Insert SST (1) A81659 (d) To loosen the pulley nut, turn SST (1−A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one−half turn. (e) Remove the generator from SST (2). SST(1−A) Turn A81660 (f) (g) SST (1−A) Turn SST (1−B) and remove SST (1−A, B). Remove the pulley nut and generator pulley. SST (1−B) Turn Hold A81661 WhereEverybodyKnowsYourName 19−19 STARTING & CHARGING Generator Pulley − GENERATOR ASSY (2AZ−FE)(From July, 2003) 2. (a) (b) REMOVE GENERATOR REAR END COVER Place the generator on the generator pulley. Remove the 3 nuts and the generator rear end cover. 3. (a) REMOVE TERMINAL INSULATOR Remove the terminal insulator from the generator rectifier end frame. 4. (a) REMOVE GENERATOR BRUSH HOLDER ASSY Remove the 2 screws and the generator brush holder. 5. (a) REMOVE GENERATOR COIL ASSY Remove the 4 bolts. (b) Using SST, remove the generator rectifier end frame. SST 09950−40011 (09951−04020, 09952−04010, 09953−04020, 09954−04010, 09955−04071, 09957−04010, 09958−04011) A81662 A81146 A81147 A81148 SST Turn Hold A81663 WhereEverybodyKnowsYourName 19−20 STARTING & CHARGING 6. (a) Generator Washer − GENERATOR ASSY (2AZ−FE)(From July, 2003) REMOVE GENERATOR ROTOR ASSY Remove the generator washer and the generator rotor. A81664 7. (a) INSPECT GENERATOR BRUSH HOLDER ASSY Check the brush length. (1) Using a vernier caliper, measure the exposed brush length. Specified brush length: 4.5 to10.5 mm (0.177 to 0.413 in.) If the exposed brush length is less than minimum, replace the generator brush holder. Length A79305 8. INSPECT GENERATOR ROTOR ASSY (a) Check the bearing is not rough or worn. If necessary, replace the generator rotor. A79306 (b) Check the rotor for open circuit. (1) Using an ohmmeter, measure the resistance between the slip ring. Standard: 2.3 to 2.7 Ω at 20
C (68
F) If the resistance is not as specified, replace the generator rotor. Slip Ring A81665 Slip Ring (c) Check the rotor for ground. (1) Using an ohmmeter, check the resistance between the slip ring and the rotor core. Standard: 10 kΩ or higher If the resistance is not as specified, replace the generator rotor. (d) Inspect slip rings. (1) Check that the slip rings are not rough or scored. If rough or scored, replace the generator rotor. Rotor Core 10 kΩ or Higher A81666 WhereEverybodyKnowsYourName 19−21 STARTING & CHARGING − GENERATOR ASSY (2AZ−FE)(From July, 2003) (e) Check the slip ring diameter. (1) Using a vernier caliper, measure the slip ring diameter. Specified diameter: 14.0 to 14.4 mm (0.551 to 0.567 in.) If the diameter is less than minimum, replace the generator rotor. Diameter A75676 9. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. A81155 10. (a) REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and the retainer plate. (b) Using SST, tap out the bearing. SST 09950−60010 (09951−00250), 09950−70010 (09951−07100) 11. (a) INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950−60010 (09951−00470), 09950−70010 (09951−07100) A81156 Wooden Block SST A81667 SST A81668 WhereEverybodyKnowsYourName 19−22 STARTING & CHARGING − GENERATOR ASSY (2AZ−FE)(From July, 2003) (b) Install the retainer plate with the 4 screws. Torque: 2.3 N⋅m (23 kgf⋅cm, 20 in.⋅lbf) 12. (a) INSTALL GENERATOR ROTOR ASSY Place the generator drive end frame on the generator pulley. Install the generator rotor and the generator washer. A81156 Generator Washer Generator Pulley (b) A81670 Deep Socket Wrench 21 13. (a) INSTALL GENERATOR COIL ASSY Using a deep socket wrench 21 and a press, press in the generator rectifier end frame carefully. (b) Tighten the 4 bolts. Torque: 5.8 N⋅m (59 kgf⋅cm, 51 in.⋅lbf) 14. (a) INSTALL GENERATOR BRUSH HOLDER ASSY While pushing the 2 brushes to inside the brush holder, insert a pin (φ1.0 mm (0.039 in.)) into the brush holder hole. A81671 A81148 Pin (φ1.0 mm (0.039 in.)) A79315 WhereEverybodyKnowsYourName 19−23 STARTING & CHARGING Pin (φ1.0 mm (0.039 in.)) (b) − GENERATOR ASSY (2AZ−FE)(From July, 2003) Install the generator brush holder with the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) Pull out the pin (φ1.0 mm (0.039 in.)) from the generator brush holder. (c) A81672 15. (a) INSTALL TERMINAL INSULATOR Install the terminal insulator to the generator rectifier end frame. NOTICE: Pay attention the mounting orientation of the terminal insulator. A81146 16. (a) INSTALL GENERATOR REAR END COVER Install the generator rear end cover with the 3 nuts. Torque: 4.6 N⋅m (47 kgf⋅cm, 41 in.⋅lbf) 17. INSTALL GENERATOR PULLEY SST 09820−63010 (09820−06010, 09820−06020) A81164 SST (1−A) SST (1−B) HINT: Turn Hold A81658 SST (1−A, B) 09820−06010 SST (2) 09820−06020 (a) Install the generator pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (1−A) with a torque wrench, and tighten SST (1−B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. WhereEverybodyKnowsYourName 19−24 STARTING & CHARGING Insert − GENERATOR ASSY (2AZ−FE)(From July, 2003) (c) (d) Clamp SST 2 in a vise. Insert SST (1−A, B) into SST (2), and attach the pulley nut to SST (2) (e) Tighten the pulley nut by turning SST (1−A) in the direction shown in the illustration. Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf) Remove the generator from SST (2). SST (2) SST (1) A81659 (f) SST(1−A) Turn A81673 (g) (h) SST (1−A) SST (1−B) Turn SST (1−B), and remove SST (1−A, B). Turn the generator pulley and check that the generator pulley moves smoothly. Turn Hold A81661 WhereEverybodyKnowsYourName 19−25 STARTING & CHARGING − STARTING SYSTEM (1MZ−FE/3MZ−FE) STARTING SYSTEM (1MZ−FE/3MZ−FE) 190S5−02 INSPECTION Terminal C Terminal 50 A60459 Disconnect Terminal C 1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do the pull−in test. (1) Disconnect the lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnetic switch. (b) Do the hold−in test. (1) Maintain the battery connections in step (a), but disconnect the negative (−) lead from terminal C. Check that the pinion gear remains extended. If the clutch pinion gear returns inward, replace the magnetic switch. A81044 (c) Check the clutch pinion gear return. (1) Disconnect the negative (−) lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch. Disconnect A81045 (d) Terminal 30 Terminal 50 A60462 Do the no−load performance test. (1) Connect the lead wire to terminal C. Make sure that the lead is not grounded. (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V WhereEverybodyKnowsYourName 19−26 STARTING & CHARGING 2. (a) 2 1 5 3 INSPECT STARTER RELAY ASSY Check the resistance of the ST relay. Standard: Specified Condition 3−5 10 kΩ or higher 3−5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) 1 3 STARTING SYSTEM (1MZ−FE/3MZ−FE) Tester Connection 5 2 − If the result is not as specified, replace the relay. B60778 3. (a) ACC LOCK ON START 4 3 2 1 8 7 6 5 B52423 INSPECT IGNITION OR STARTER SWITCH ASSY Inspect the switch resistance. Standard: Tester Connection Switch Condition Specified Condition − LOCK 10 kΩ or higher 2−3 ACC Below 1 Ω 2−3 2−4 6−7 ON Below 1 Ω 1−2 1−4 6−7 6−8 START Below 1 Ω If the result is not as specified, replace the switch assy. WhereEverybodyKnowsYourName STARTING & CHARGING − IGNITION OR STARTER SWITCH ASSY (1MZ−FE/3MZ−FE) 19−27 IGNITION OR STARTER SWITCH ASSY (1MZ−FE/3MZ−FE) 190SQ−03 REPLACEMENT The installation procedures are the removal procedures in reverse order. 1. REMOVE DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) 3. (a) (b) (c) REMOVE IGNITION OR STARTER SWITCH ASSY Disconnect the ignition switch connector and unlock warning switch connector. Remove the clamp. Remove the 2 screws and ignition switch. B56503 WhereEverybodyKnowsYourName 19−28 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) STARTER ASSY (1MZ−FE/3MZ−FE) 190S7−02 COMPONENTS Starter Armature Assy Starter Commutator End Frame Assy 6.0 (61, 53 in.⋅lbf)
Snap Ring Washer Starter Commutator End Frame Cover Magnetic Switch Assy 6.0 (61, 53 in.⋅lbf) 7.5 (76, 66 in.⋅lbf) 10 (102, 7) Starter Field Frame Assy Planetary Gear Clutch & Bearing Center Starter Drive Housing Assy (w/ Clutch & Drive Lever & Center Bearing) Starter Armature Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A90289 WhereEverybodyKnowsYourName 19−29 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 190O8−03 REPLACEMENT NOTICE: Before changing the starter, check these items again:
Connector connection
Accessory installation 1. REMOVE BATTERY 2. REMOVE BATTERY TRAY (a) (b) (c) (c) 3. (a) (b) (c) (d) REMOVE AIR CLEANER INLET ASSY Disconnect the VSV connector. Remove the 2 wire harness clamps. Remove the vacuum hoses from the hose clamp. Remove the 2 bolts and air cleaner inlet. 4. (a) (b) (c) (d) (e) REMOVE AIR CLEANER ASSY Disconnect the MAF meter connector. Disconnect the 4 vacuum hoses. Loosen the 2 air cleaner cap bolts. Loosen the air cleaner hose clamp bolt and remove the air cleaner cap. Remove the air cleaner filter element. (f) (g) (h) Remove the wire harness from the 2 wire harness clamps. Disconnect the vacuum hose. Remove the 3 bolts and air cleaner case. (b) A81651 (b) (b) (b) (a) (d) (b) (c) (c) A81652 (f) (f) (g) A81653 WhereEverybodyKnowsYourName 19−30 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 5. (a) REMOVE AIR CLEANER BRACKET Remove the 2 bolts and air cleaner bracket. 6. (a) REMOVE AIR CLEANER INLET NO.1 Remove the bolt and cleaner inlet. 7. (a) (b) REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cap, and remove the nut and disconnect the starter wire. A78525 A78526 Terminal Cap (b) (a) A78527 (c) 8. (a) A78528 1 2 Remove the 2 bolts and starter. INSTALL STARTER ASSY Install the starter with the 2 bolts. Torque: 37 N⋅m (380 kgf⋅cm, 26 ft⋅lbf) for bolt (b) Connect the starter wire. (c) Install the terminal nut and cover the nut with the cap. Torque: 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) for nut 9. INSTALL AIR CLEANER INLET NO.1 (a) Install the cleaner inlet with the bolt. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) 10. INSTALL AIR CLEANER BRACKET (a) Install the air cleaner bracket with the 2 bolts. Tighten the 2 bolts little by little in the numerical order shown in the illustration. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) NOTICE: Fully tightening each bolt one by one may damage the air cleaner bracket and bolts. A78525 WhereEverybodyKnowsYourName 19−31 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 11. (a) (d) (d) (c) (b) (b) Air Cleaner Inlet No. 1 (b) Air Cleaner Case INSTALL AIR CLEANER ASSY Install the air cleaner case to the air cleaner inlet No. 1, as shown in the illustration. (b) Tighten the 3 bolts little by little in the numerical order shown in the illustration. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) NOTICE: Fully tightening each bolt one by one may damage the air cleaner case and bolts. (c) Connect the vacuum hose. (d) Install the 2 wire harness clamps. (e) Install the air cleaner filter element. (f) Connect the air cleaner hose No. 1 and tighten the air cleaner hose clamp bolt. (g) Tighten the 2 air cleaner cap bolts. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) (h) Connect the 4 vacuum hoses. (i) Connect the MAF meter connector. A81654 12. 13. 14. 15. (a) (b) INSTALL AIR CLEANER INLET ASSY Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) CHECK CONNECTION OF VACUUM HOSE INSTALL BATTERY TRAY INSTALL BATTERY Install the battery clamp with the bolt and nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in⋅lbf) Connect the wires to the battery terminals. Torque: 3.5 N⋅m (36 kgf⋅cm, 31 in.⋅lbf) WhereEverybodyKnowsYourName STARTING & CHARGING − IGNITION OR STARTER SWITCH ASSY (2AZ−FE)(From July, 2003) 19−3 IGNITION OR STARTER SWITCH ASSY (2AZ−FE)(From July, 2003) 190SP−03 REPLACEMENT The installation procedures are the removal procedures in reverse order. 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) 3. (a) (b) (c) REMOVE IGNITION OR STARTER SWITCH ASSY Disconnect the ignition switch connector and unlock warning switch connector. Remove the clamp. Remove the 2 screws and ignition switch. B56503 WhereEverybodyKnowsYourName 19−32 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 190O9−03 OVERHAUL 1. (a) REMOVE MAGNETIC SWITCH ASSY Remove the nut and disconnect the lead wire from the magnetic switch. (b) Remove the 2 screws holding the magnetic switch to the starter drive housing. Remove the magnetic switch. Remove the return spring and plunger from starter drive housing. A79718 (c) (d) A79719 2. (a) REMOVE STARTER FIELD FRAME ASSY Remove the 2 through−bolts, and pull out the field frame together with the commutator end frame assy. (b) Remove the field frame from the commutator end frame. A79720 A79721 WhereEverybodyKnowsYourName 19−33 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 3. (a) REMOVE STARTER AMATURE PLATE Remove the armature plate from the field frame. 4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the commutator end frame cover. A79722 (a) A79723 5. (a) Snap Ring Pliers (b) REMOVE STARTER ARMATURE ASSY Using snap ring pliers, remove the snap ring and plate washer. Remove the armature from the commutator end frame. A82440 6. (a) REMOVE PLANET GEAR Remove the 3 planetary gears from the starter drive housing assy. A81167 7. (a) INSPECT MAGNETIC SWITCH ASSY Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch. A58586 WhereEverybodyKnowsYourName 19−34 STARTING & CHARGING STARTER ASSY (1MZ−FE/3MZ−FE) (b) Check if the pull−in coil has an open circuit. (1) Check the resistance between terminals 50 and C. Standard: Below 1 Ω If the the result is not as specified, replace the magnetic switch. Terminal C Terminal 50 − Below 1 Ω A79725 (c) Check if the hold−in coil has an open circuit. (1) Check the resistance between terminal 50 and the switch body. Standard: Below 2 Ω If the the result is not as specified, replace the magnetic switch. Body Below 2 Ω Terminal 50 A79726 8. (a) INSPECT STARTER ARMATURE ASSY Check if the commutator has an open circuit. (1) Check the resistance between the segments of the commutator. Standard: Below 1 Ω If the result is not as specified, replace the armature assy. Below 1 Ω Segment A58372 (b) 10 kΩ or Higher Commutator Coil Core A58373 Check if the commutator is grounded. (1) Check the resistance between the commutator and armature coil core. Standard: 10 kΩ or higher If the result is not as specified, replace the armature assy. (c) Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No.400) or a lathe. (d) Length Using a vernier caliper, measure the commutator’s length. Specified length: 3.1 to 3.8 mm (0.122 to 0.150 in.) If the length is greater than the maximum, replace the starter armature. A58584 WhereEverybodyKnowsYourName 19−35 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) 9. INSPECT STARTER COMMUTATOR END FRAME COVER (a) Using a vernier caliper, measure the brush length. Specified length: 4.0 to 9.0 mm (0.158 to 0.359 in.) If the length is less than the minimum, replace the end frame assy. Length A76677 (b) Check the brush insulation. (1) Check the resistance between the positive (+) and negative (−) brush. Standard: 10 kΩ or higher If the result is not as specified, repair or replace the end frame assy. 10 kΩ or Higher A79766 10. (a) INSPECT CLUTCH&BEARING CENTER Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the clutch & bearing center. Lock Free A81655 Apply Grease 11. (a) (b) INSTALL PLANETARY GEAR Apply grease to the planet gears and pin parts of the planetary shaft. Install the 3 planetary gears. A81656 12. (a) (b) Snap Ring Pliers (c) INSTALL STARTER ARMATURE ASSY Apply grease to the plate washer and the armature shaft. Install the starter armature to the starter commutator end frame. Using snap ring pliers, install the plate washer and a new snap ring. A82440 WhereEverybodyKnowsYourName 19−36 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) (d) Using a vernier caliper, measure length of the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace it with a new snap ring. Length A58810 13. (a) INSTALL STARTER COMMUTATOR END FRAME COVER Install the end frame cover to the commutator end frame. A81178 Key keyway 14. (a) (b) INSTALL STARTER ARMATURE PLATE Insert the armature plate to the starter field frame. Align the keyway of the starter plate with the key inside the starter field frame, and install the starter plate. 15. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber of the end frame with the cutout of the field frame. Install the end frame to the field frame. A73991 Rubber Cutout (a) (b) A79727 16. (a) Cutout INSTALL STARTER FIELD FRAME ASSY Align the protrusion of the starter field frame with the cut out of the starter drive housing. Protrusion A79728 WhereEverybodyKnowsYourName 19−37 STARTING & CHARGING − STARTER ASSY (1MZ−FE/3MZ−FE) (b) Install the field frame with the 2 through bolts. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 17. (a) (b) INSTALL MAGNETIC SWITCH ASSY Apply grease to the plunger and the hook. Hang the plunger hook of the magnetic switch to the drive lever. Install the plunger and the return spring. A79720 (c) A79729 (d) Install the magnetic switch with the 2 screws. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (e) Connect the lead wire to the magnetic switch with the nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) A79719 A79718 WhereEverybodyKnowsYourName 19−38 STARTING & CHARGING − CHARGING SYSTEM (1MZ−FE/3MZ−FE) CHARGING SYSTEM (1MZ−FE/3MZ−FE) 190NY−03 PRECAUTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
Check that the charging cable is tightened on terminal B of the generator and the fuse box. WhereEverybodyKnowsYourName 19−39 STARTING & CHARGING − CHARGING SYSTEM (1MZ−FE/3MZ−FE) 190SA−02 ON−VEHICLE INSPECTION 1. (a) CHECK BATTERY CONDITION Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery. (b) Check the electrolyte quantity of each cell. For batteries that are maintenance−free: If the electrolyte quantity is below the recommended amount, replace the battery. For batteries that are not maintenance−free: If the electrolyte quantity is below the recommended amount, add distilled water. CAUTION: If the battery has gone flat or if the engine cannot be started easily, the engine may not be recovered properly. Recharge the battery and perform inspections again before returning the vehicle to the customer. 2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, high−current fuses and fuses for continuity. 3. (a) REPLACE BELT B00543 INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found:
If the belt has worn out until the wire can be seen.
If the cracks reach the wire more than one place.
If the belt has chunks missing from the ribs. (b) Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley. CORRECT INCORRECT B75171 4. VISUALLY CHECK GENERATOR WIRING (a) Check that the wiring is in good condition. 5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. 6. INSPECT CHARGE WARNING LAMP CIRCUIT (a) Turn the ignition switch ON. Check that the charge warning lamp turns on. (b) Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit. WhereEverybodyKnowsYourName 19−40 STARTING & CHARGING − CHARGING SYSTEM (1MZ−FE/3MZ−FE) 7. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer’s instrucBattery tions. (a) If a tester is not available, connect a voltmeter to the charging circuit as follows. Generator Voltmeter (1) Disconnect the wire from terminal B of the generator and connect it to the negative (−) lead of the ammeA91071 ter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative (−) lead of the voltmeter. (b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V 8. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high−beam headlamps and turn the heater blower switch to the HI position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT:
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometimes be less than the standard amperage. Ammeter Disconnect Wire from Terminal B WhereEverybodyKnowsYourName 19−4 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) STARTER ASSY (2AZ−FE)(From July, 2003) 190RU−02 COMPONENTS Starter Armature Assy Starter Commutator End Frame Assy 6.0 (61, 53 in.⋅lbf)
Snap Ring Washer Starter Commutator End Frame Cover Magnetic Switch Assy 6.0 (61, 53 in.⋅lbf) 7.5 (76, 66 in.⋅lbf) 10 (102, 7) Starter Field Frame Assy Planetary Gear Clutch & Bearing Center Starter Drive Housing Assy (w/ Clutch & Drive Lever & Center Bearing) Starter Armature Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A90289 WhereEverybodyKnowsYourName 19−41 STARTING & CHARGING − GENERATOR ASSY (1MZ−FE/3MZ−FE) GENERATOR ASSY (1MZ−FE/3MZ−FE) 190SB−02 COMPONENTS Washer
Generator Drive End Frame Bearing 2.3 (23, 20 in.⋅lbf) x4 Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Generator Brush Holder Assy Terminal Insulator 5.8 (59, 51 in.⋅lbf) x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A90290 WhereEverybodyKnowsYourName 19−42 STARTING & CHARGING − GENERATOR ASSY (1MZ−FE/3MZ−FE) 190O5−05 REPLACEMENT (a) (c) 1. (a) (b) (c) REMOVE GENERATOR ASSY Remove the wire harness clamp. Disconnect the generator connector. Open the terminal cap, remove the nut and disconnect the generator wire. (d) (e) Loosen bolts A and B. Loosen bolt C to lessen the tension of the V belt. (f) Remove bolts A and B, and the generator. 2. (a) INSTALL GENERATOR ASSY Temporarily install the generator with bolts A and B. (b) A79746 A B C A81657 A B A79747 A B A79747 WhereEverybodyKnowsYourName 19−43 STARTING & CHARGING (b) (c) A (d) B 3. C (e) (f) INSPECT DRIVE BELT (See page 19−39) A81657 − GENERATOR ASSY (1MZ−FE/3MZ−FE) Adjust the V belt tension by tightening bolt C (see page 14−140). Tighten bolts A and B. Torque: 58 N⋅m (592 kgf⋅cm, 43 ft⋅lbf) for bolt A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B Install the generator wire with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) Connect the generator connector. Install the wire harness clamp. WhereEverybodyKnowsYourName 19−44 STARTING & CHARGING − GENERATOR ASSY (1MZ−FE/3MZ−FE) 190TO−01 OVERHAUL 1. SST (1−A) SST (1−B) REMOVE GENERATOR PULLEY SST 09820−63010 (09820−06010, 09820−06020) HINT: Turn Hold A81658 SST (1−A, B) 09820−06010 SST (2) 09820−06020 (a) Hold SST (1−A) with a torque wrench, and tighten SST (1−B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (b) Clamp SST (2) in a vise. (c) Insert SST (1−A, B) into SST (2), and attach the pulley nut to SST (2). SST (2) Insert SST (1) A81659 (d) To loosen the pulley nut, turn SST (1−A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one−half turn. (e) Remove the generator from SST (2). SST(1−A) Turn A81660 (f) (g) SST (1−A) Turn SST (1−B) and remove SST (1−A, B). Remove the pulley nut and generator pulley. SST (1−B) Turn Hold A81661 WhereEverybodyKnowsYourName 19−45 STARTING & CHARGING Generator Pulley − GENERATOR ASSY (1MZ−FE/3MZ−FE) 2. (a) (b) REMOVE GENERATOR REAR END COVER Place the generator on the generator pulley. Remove the 3 nuts and the generator rear end cover. 3. (a) REMOVE TERMINAL INSULATOR Remove the terminal insulator from the generator rectifier end frame. 4. (a) REMOVE GENERATOR BRUSH HOLDER ASSY Remove the 2 screws and the generator brush holder. 5. (a) REMOVE GENERATOR COIL ASSY Remove the 4 bolts. (b) Using SST, remove the generator rectifier end frame. SST 09950−40011 (09951−04020, 09952−04010, 09953−04020, 09954−04010, 09955−04071, 09957−04010, 09958−04011) A81662 A81146 A81147 A81148 SST Turn Hold A81663 WhereEverybodyKnowsYourName 19−46 STARTING & CHARGING 6. (a) Generator Washer − GENERATOR ASSY (1MZ−FE/3MZ−FE) REMOVE GENERATOR ROTOR ASSY Remove the generator washer and the generator rotor. A81664 7. (a) INSPECT GENERATOR BRUSH HOLDER ASSY Check the brush length. (1) Using a vernier caliper, measure the exposed brush length. Specified brush length: 4.5 to10.5 mm (0.177 to 0.413 in.) If the exposed brush length is less than minimum, replace the generator brush holder. Length A79305 8. INSPECT GENERATOR ROTOR ASSY (a) Check the bearing is not rough or worn. If necessary, replace the generator rotor. A79306 (b) Check the rotor for open circuit. (1) Using an ohmmeter, measure the resistance between the slip ring. Standard: 2.3 to 2.7 Ω at 20
C (68
F) If the resistance is not as specified, replace the generator rotor. Slip Ring A81665 Slip Ring (c) Check the rotor for ground. (1) Using an ohmmeter, check the resistance between the slip ring and the rotor core. Standard: 10 kΩ or higher If the resistance is not as specified, replace the generator rotor. (d) Inspect slip rings. (1) Check that the slip rings are not rough or scored. If rough or scored, replace the generator rotor. Rotor Core 10 kΩ or Higher A81666 WhereEverybodyKnowsYourName 19−47 STARTING & CHARGING − GENERATOR ASSY (1MZ−FE/3MZ−FE) (e) Check the slip ring diameter. (1) Using a vernier caliper, measure the slip ring diameter. Specified diameter: 14.0 to 14.4 mm (0.551 to 0.567 in.) If the diameter is less than minimum, replace the generator rotor. Diameter A75676 9. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. A81155 10. (a) REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and the retainer plate. (b) Using SST, tap out the bearing. SST 09950−60010 (09951−00250), 09950−70010 (09951−07100) 11. (a) INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950−60010 (09951−00470), 09950−70010 (09951−07100) A81156 Wooden Block SST A81667 SST A81668 WhereEverybodyKnowsYourName 19−48 STARTING & CHARGING − GENERATOR ASSY (1MZ−FE/3MZ−FE) (b) Install the retainer plate with the 4 screws. Torque: 2.3 N⋅m (23 kgf⋅cm, 20 in.⋅lbf) 12. (a) INSTALL GENERATOR ROTOR ASSY Place the generator drive end frame on the generator pulley. Install the generator rotor and the generator washer. A81156 Generator Washer Generator Pulley (b) A81670 Deep Socket Wrench 21 13. (a) INSTALL GENERATOR COIL ASSY Using a deep socket wrench 21 and a press, press in the generator rectifier end frame carefully. (b) Tighten the 4 bolts. Torque: 5.8 N⋅m (59 kgf⋅cm, 51 in.⋅lbf) 14. (a) INSTALL GENERATOR BRUSH HOLDER ASSY While pushing the 2 brushes to inside the brush holder, insert a pin (φ1.0 mm (0.039 in.)) into the brush holder hole. A81671 A81148 Pin (φ1.0 mm (0.039 in.)) A79315 WhereEverybodyKnowsYourName 19−49 STARTING & CHARGING Pin (φ1.0 mm (0.039 in.)) (b) − GENERATOR ASSY (1MZ−FE/3MZ−FE) Install the generator brush holder with the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) Pull out the pin (φ1.0 mm (0.039 in.)) from the generator brush holder. (c) A81672 15. (a) INSTALL TERMINAL INSULATOR Place the generator drive end frame on the generator pulley. (b) Install the generator rotor and the generator washer. NOTICE: Pay attention the mounting orientation of the terminal insulator. A81146 16. (a) INSTALL GENERATOR REAR END COVER Install the generator rear end cover with the 3 nuts. Torque: 4.6 N⋅m (47 kgf⋅cm, 41 in.⋅lbf) 17. INSTALL GENERATOR PULLEY SST 09820−63010 (09820−06010, 09820−06020) A81164 SST (1−A) SST (1−B) HINT: Turn Hold A81658 SST (1−A, B) 09820−06010 SST (2) 09820−06020 (a) Install the generator pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (1−A) with a torque wrench, and tighten SST (1−B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. WhereEverybodyKnowsYourName 19−5 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) 190RV−02 REPLACEMENT NOTICE: Before changing the starter, check these items again:
Connector connection
Accessory installation 1. REMOVE BATTERY 2. REMOVE BATTERY TRAY 3. REMOVE AIR CLEANER ASSY 4. (a) REMOVE AIR CLEANER BRACKET Remove the 2 bolts and air cleaner bracket. A78525 5. (a) REMOVE AIR CLEANER INLET ASSY Remove the 2 bolts and air cleaner inlet. 6. (a) (b) (c) 7. (a) (b) A60064 (c) 8. (a) REMOVE STARTER ASSY Disconnect the starter connector. Remove the nut and disconnect the starter wire. Remove the 2 bolts and starter. INSTALL STARTER ASSY Install the and starter with the 2 bolts. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) Install the starter wire and the nut. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) Connect the starter connector. INSTALL AIR CLEANER BRACKET Install the air cleaner bracket with the 2 bolts. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) A78525 9. 10. (a) INSTALL AIR CLEANER ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) INSTALL AIR CLEANER INLET ASSY Install the air cleaner inlet with the 2 bolts. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) WhereEverybodyKnowsYourName 19−6 STARTING & CHARGING 11. 12. 13. (a) (b) − STARTER ASSY (2AZ−FE)(From July, 2003) CHECK CONNECTION OF VACUUM HOSE INSTALL BATTERY TRAY INSTALL BATTERY Install the battery clamp with the bolt and nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in⋅lbf) Connect the wires to the battery terminals. Torque: 3.5 N⋅m (36 kgf⋅cm, 31 in.⋅lbf) WhereEverybodyKnowsYourName 19−7 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) 190RW−02 OVERHAUL 1. (a) REMOVE MAGNETIC SWITCH ASSY Remove the nut and disconnect the lead wire from the magnetic switch. (b) Remove the 2 screws holding the magnetic switch to the starter drive housing. Remove the magnetic switch. Remove the return spring and plunger from starter drive housing. A79718 (c) (d) A79719 2. (a) REMOVE STARTER FIELD FRAME ASSY Remove the 2 through−bolts, and pull out the field frame together with the commutator end frame assy. (b) Remove the field frame from the commutator end frame. A79720 A79721 WhereEverybodyKnowsYourName 19−8 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) 3. (a) REMOVE STARTER AMATURE PLATE Remove the armature plate from the field frame. 4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the commutator end frame cover. A79722 (a) A79723 5. (a) Snap Ring Pliers (b) REMOVE STARTER ARMATURE ASSY Using snap ring pliers, remove the snap ring and plate washer. Remove the armature from the commutator end frame. A82440 6. (a) REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing assy. A81167 7. (a) INSPECT MAGNETIC SWITCH ASSY Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch. A58586 WhereEverybodyKnowsYourName 19−9 STARTING & CHARGING STARTER ASSY (2AZ−FE)(From July, 2003) (b) Check if the pull−in coil has an open circuit. (1) Check the resistance between terminals 50 and C. Standard: Below 1 Ω If the the result is not as specified, replace the magnetic switch. Terminal C Terminal 50 − Below 1 Ω A79725 (c) Check if the hold−in coil has an open circuit. (1) Check the resistance between terminal 50 and the switch body. Standard: Below 2 Ω If the the result is not as specified, replace the magnetic switch. Body Below 2 Ω Terminal 50 A79726 8. (a) INSPECT STARTER ARMATURE ASSY Check if the commutator has an open circuit. (1) Check the resistance between the segments of the commutator. Standard: Below 1 Ω If the result is not as specified, replace the armature assy. Below 1 Ω Segment A58372 (b) 10 kΩ or Higher Commutator Coil Core A58373 Check if the commutator is grounded. (1) Check the resistance between the commutator and armature coil core. Standard: 10 kΩ or higher If the result is not as specified, replace the armature assy. (c) Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No.400) or a lathe. (d) Length Using a vernier caliper, measure the commutator’s length. Specified length: 3.1 to 3.8 mm (0.122 to 0.150 in.) If the length is greater than the maximum, replace the starter armature. A58584 WhereEverybodyKnowsYourName 19−10 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) 9. INSPECT STARTER COMMUTATOR END FRAME COVER (a) Using a vernier caliper, measure the brush length. Specified length: 4.0 to 9.0 mm (0.158 to 0.359 in.) If the length is less than the minimum, replace the end frame assy. Length A76677 (b) Check the brush insulation. (1) Check the resistance between the positive (+) and negative (−) brush. Standard: 10 kΩ or higher If the result is not as specified, repair or replace the end frame assy. 10 kΩ or Higher A79766 10. INSPECT AND ADJUST CLUTCH & BEARING CENTER (a) Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the clutch & bearing center. Lock Free A81655 Apply Grease 11. (a) (b) INSTALL PLANETARY GEAR Apply grease to the planet gears and pin parts of the planetary shaft. Install the 3 planetary gears. A81656 12. (a) (b) Snap Ring Pliers (c) INSTALL STARTER ARMATURE ASSY Apply grease to the plate washer and the armature shaft. Install the starter armature to the starter commutator end frame. Using snap ring pliers, install the plate washer and a new snap ring. A82440 WhereEverybodyKnowsYourName 19−11 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) (d) Using a vernier caliper, measure length of the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace it with a new snap ring. Length A58810 13. (a) INSTALL STARTER COMMUTATOR END FRAME COVER Install the end frame cover to the commutator end frame. A81178 Key keyway 14. (a) (b) INSTALL STARTER AMATURE PLATE Insert the armature plate to the starter field frame. Align the keyway of the starter plate with the key inside the starter field frame, and install the starter plate. 15. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber of the end frame with the cutout of the field frame. Install the end frame to the field frame. A73991 Rubber Cutout (a) (b) A79727 16. (a) Cutout INSTALL STARTER FIELD FRAME ASSY Align the protrusion of the starter field frame with the cut out of the starter drive housing. Protrusion A79728 WhereEverybodyKnowsYourName 19−12 STARTING & CHARGING − STARTER ASSY (2AZ−FE)(From July, 2003) (b) Install the field frame with the 2 through bolts. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 17. (a) (b) INSTALL MAGNETIC SWITCH ASSY Apply grease to the plunger and the hook. Hang the plunger hook of the magnetic switch to the drive lever. Install the plunger and the return spring. A79720 (c) A79729 (d) Install the magnetic switch with the 2 screws. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (e) Connect the lead wire to the magnetic switch with the nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) A79719 A79718 WhereEverybodyKnowsYourName 67−1 AUDIO & VISUAL SYSTEM − AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 671DS−01 LOCATION Instrument Cluster Finish Panel Sub−assy Center Air Conditioner Control Assembly TMMK Made, Separate Type Amplifier: Radio Bracket No.2 Radio Bracket No.1 Radio Receiver Switch Knob Radio Receiver Assy w/ Navigation: Radio Receiver Bracket No.1 Radio Receiver Bracket No.1 Navigation Receiver Assy I31485 WhereEverybodyKnowsYourName 67−2 AUDIO & VISUAL SYSTEM Power Point Socket Cover Front No.2 Speaker Assy − AUDIO & VISUAL SYSTEM Stereo Component Amplifier Assy Cigarette Lighter Assy Power Point Socket Assy Antenna Cord Sub−assy Power Point Socket Assy RR Power Outlet Socket Cover RR Front No.1 Speaker Assy Navigation Antenna Assy Rear Speaker Assy I31484 I40082 WhereEverybodyKnowsYourName 67−3 AUDIO & VISUAL SYSTEM − AUDIO & VISUAL SYSTEM w/ 3 SPOKE STEERING WHEEL ASSY: Steering Pad Switch LH w/ 4 SPOKE STEERING WHEEL ASSY: Steering Pad Switch RH Steering Pad Switch LH I43762 WhereEverybodyKnowsYourName 67−10 AUDIO & VISUAL SYSTEM − REAR SPEAKER ASSY REAR SPEAKER ASSY 671CC−02 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) 2. REMOVE REAR SEAT BACK ASSY RH (See page 72−32) 3. REMOVE REAR SEAT BACK ASSY LH (See page 72−32) 4. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 72−32) 5. REMOVE REAR SIDE SEAT BACK ASSY LH(See page 72−32) 6. REMOVE ROOF SIDE GARNISH INNER RH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 7. REMOVE ROOF SIDE GARNISH INNER LH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 8. REMOVE ROOF SIDE GARNISH INNER RH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 9. REMOVE ROOF SIDE GARNISH INNER LH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 10. REMOVE CENTER STOP LAMP ASSY (See page 65−22) 11. REMOVE REAR SEAT SHOULDER BELT COVER RH (See page 61−13 or 61−16) 12. REMOVE ROOM PARTITION BOARD ASSY (TMMK MADE) (See page 61−16) 13. REMOVE PACKAGE TRAY TRIM PANEL ASSY (TMC MADE) (See page 61−13) 14. REMOVE PACKAGE TRAY TRIM PANEL ASSY (TMMK MADE) (See page 61−16) 15. (a) (b) REMOVE SPEAKER ASSY, RADIO Disconnect the connector. Remove the 4 screws and rear speaker assy. I31487 4 3 1 2 16. INSTALL SPEAKER ASSY, RADIO (a) Install the rear speaker assy with the 4 screws. NOTICE: Install them in the order shown in the illustration. (b) Connect the connector. I31487 WhereEverybodyKnowsYourName 67−11 AUDIO & VISUAL SYSTEM 17. 18. 19. 20. − REAR SPEAKER ASSY INSTALL REAR SIDE SEAT BACK ASSY LH (See page 72−32) INSTALL REAR SIDE SEAT BACK ASSY RH (See page 72−32) INSTALL REAR SEAT BACK ASSY RH (See page 72−32) INSTALL REAR SEAT BACK ASSY LH (See page 72−32) WhereEverybodyKnowsYourName 67−12 AUDIO & VISUAL SYSTEM − ANTENNA CORD SUB−ASSY ANTENNA CORD SUB−ASSY 67097−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page 71−16) 2. REMOVE FRONT DOOR SCUFF PLATE RH (See page 71−16) 3. REMOVE COWL SIDE TRIM SUB−ASSY LH (See page 71−16) 4. REMOVE COWL SIDE TRIM SUB−ASSY RH (See page 71−16) 5. REMOVE INSTRUMENT PANEL COIN BOX SUB−ASSY (See page 71−16) 6. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) 7. REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH (TMMK MADE) (See page 71−16) 8. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71−16) 9. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB−ASSY CENTER (See page 71−16) 10. REMOVE INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) 11. REMOVE GLOVE COMPARTMENT DOOR PAD (See page 71−16) 12. REMOVE INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) 13. REMOVE SHIFT LEVER KNOB SUB−ASSY (M/T TRANSAXLE) (See page 71−16) 14. REMOVE CONSOLE PANEL UPPER REAR (See page 71−16) 15. REMOVE CONSOLE BOX CARPET (See page 71−16) 16. REMOVE RR CONSOLE BOX (See page 71−16) 17. REMOVE INSTRUMENT PANEL CUP HOLDER (W/O ASHTRAY) (See page 71−16) 18. REMOVE FRONT ASH RECEPTACLE ASSY (W/ ASHTRAY) (See page 71−16) 19. REMOVE CONSOLE PANEL SUB−ASSY UPPER (See page 71−16) 20. REMOVE CONSOLE BOX FRONT (See page 71−16) 21. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page 71−16) 22. REMOVE FRONT SEAT TRACK COVER LH REAR OUTER (TMC MADE) (See page 72−15) 23. REMOVE FRONT SEAT TRACK COVER LH REAR INNER (TMC MADE)(See page 72−15) 24. REMOVE FRONT SEAT TRACK COVER RH REAR OUTER (TMC MADE)(See page 72−15) 25. REMOVE FRONT SEAT TRACK COVER RH REAR INNER (TMC MADE)(See page 72−15) 26. REMOVE FRONT SEAT ASSY RH (POWER SEAT) (See page 72−23) 27. REMOVE FRONT SEAT ASSY RH (MANUAL SEAT) (See page 72−15) 28. REMOVE FRONT SEAT ASSY LH (POWER SEAT) (See page 72−23) 29. REMOVE FRONT SEAT ASSY LH (MANUAL SEAT) (See page 72−15) 30. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) 31. REMOVE REAR SEAT BACK ASSY RH (See page 72−32) 32. REMOVE REAR SEAT BACK ASSY LH (See page 72−32) 33. REMOVE REAR SIDE SEAT BACK ASSY RH (TMC MADE) (See page 72−32) 34. REMOVE REAR SIDE SEAT BACK ASSY LH (TMC MADE) (See page 72−32) 35. REMOVE ROOF SIDE GARNISH INNER RH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 36. REMOVE ROOF SIDE GARNISH INNER LH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 37. REMOVE ROOF SIDE GARNISH INNER RH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 38. REMOVE ROOF SIDE GARNISH INNER LH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 39. REMOVE REAR SEAT SHOULDER BELT COVER RH (See page 61−13) 40. REMOVE PACKAGE TRAY TRIM PANEL ASSY (TMC MADE) (See page 67−10) WhereEverybodyKnowsYourName 67−13 AUDIO & VISUAL SYSTEM 41. 42. 43. 44. 45. 46. − ANTENNA CORD SUB−ASSY REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER (TMC MADE) (See page 61−13) REMOVE REAR SEAT INNER W/CENTER BELT ASSY RH (TMC MADE) (See page 61−13) REMOVE REAR SEAT INNER W/CENTER BELT ASSY LH (TMC MADE) (See page 61−13) REMOVE ROOM PARTITION BOARD LH (TMC MADE) (See page 67−10) REMOVE ROOM PARTITION BOARD RH (TMC MADE) (See page 67−10) REMOVE AIR DUCT REAR NO.2 (See page 55−34) 47. (a) (b) (c) REMOVE ANTENNA CORD SUB−ASSY Remove the nut and 2 bolts. Disconnect the connectors. Remove the 12 clamps and antenna cord sub−assy. w/ Diversity 12 Clamps I31483 WhereEverybodyKnowsYourName 67−14 AUDIO & VISUAL SYSTEM 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. − ANTENNA CORD SUB−ASSY INSTALL REAR SEAT INNER W/CENTER BELT ASSY RH (TMC MADE) (See page 61−13) INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER (TMC MADE) (See page 61−13) INSTALL REAR SEAT INNER W/CENTER BELT ASSY LH (TMC MADE) (See page 61−13) INSTALL REAR SIDE SEAT BACK ASSY LH (TMC MADE) (See page 72−32) INSTALL REAR SIDE SEAT BACK ASSY RH (TMC MADE) (See page 72−32) INSTALL REAR SEAT BACK ASSY RH (See page 72−32) INSTALL REAR SEAT BACK ASSY LH (See page 72−32) INSTALL FRONT SEAT ASSY LH (POWER SEAT) (See page 72−23) INSTALL FRONT SEAT ASSY LH (MANUAL SEAT) (See page 72−15) INSTALL FRONT SEAT ASSY RH (POWER SEAT) (See page 72−23) INSTALL FRONT SEAT ASSY RH (MANUAL SEAT) (See page 72−15) WhereEverybodyKnowsYourName 67−15 AUDIO & VISUAL SYSTEM − NAVIGATION ANTENNA ASSY NAVIGATION ANTENNA ASSY 67099−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 2. REMOVE SPARE WHEEL COVER ASSY 3. REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO.1 (See page 76−8) 4. REMOVE REAR FLOOR FINISH PLATE (See page 76−8) 5. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH (See page 76−8) 6. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) 7. REMOVE REAR SEAT BACK ASSY RH (See page 72−32) 8. REMOVE REAR SEAT BACK ASSY LH (See page 72−32) 9. REMOVE REAR SIDE SEAT BACK ASSY RH (TMC MADE) (See page 72−32) 10. REMOVE REAR SIDE SEAT BACK ASSY LH (TMC MADE) (See page 72−32) 11. REMOVE ROOF SIDE GARNISH INNER RH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 12. REMOVE ROOF SIDE GARNISH INNER LH (W/O CURTAIN SHIELD AIR BAG) (See page 76−22) 13. REMOVE ROOF SIDE GARNISH INNER RH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 14. REMOVE ROOF SIDE GARNISH INNER LH (W/ CURTAIN SHIELD AIR BAG) (See page 76−22) 15. REMOVE REAR SEAT SHOULDER BELT COVER RH (See page 61−13 or 61−16) 16. REMOVE PACKAGE TRAY TRIM PANEL ASSY (TMC MADE) (See page 67−10) 17. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER (TMC MADE) (See page 61−13) 18. REMOVE REAR SEAT INNER W/CENTER BELT ASSY RH (TMC MADE) (See page 61−13) 19. REMOVE REAR SEAT INNER W/CENTER BELT ASSY LH (TMC MADE) (See page 61−13) 20. REMOVE ROOM PARTITION BOARD LH (TMC MADE) (See page 67−10) 21. REMOVE ROOM PARTITION BOARD RH (TMC MADE) (See page 67−10) 22. (a) (b) REMOVE NAVIGATION ANTENNA ASSY Disconnect the connector. Tie the string at the tip of the cable of the navigation antenna assy. String I30433 WhereEverybodyKnowsYourName 67−16 AUDIO & VISUAL SYSTEM − NAVIGATION ANTENNA ASSY (c) Remove the screw. (d) Remove the clamp and navigation antenna assy. NOTICE: As the string is used at the time of installation, remain it putting through the luggage room and the room side. Clamp I40997 23. (a) INSTALL NAVIGATION ANTENNA ASSY Detach the string put through the luggage room and the room side from the connector and attach it with a new navigation antenna assy. (b) Using this string put the navigation antenna assy through the luggage room and the room side. NOTICE: To prevent the connector from being damaged, wrap protective tape around the tip of connector of the navigation antenna assy. (c) Install the navigation antenna assy with screw and clamp. (d) Connect the connector. WhereEverybodyKnowsYourName 67−17 AUDIO & VISUAL SYSTEM 24. 25. 26. 27. 28. 29. 30. − NAVIGATION ANTENNA ASSY INSTALL REAR SEAT INNER W/CENTER BELT ASSY RH (TMC MADE) (See page 61−13) INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER (TMC MADE) (See page 61−13) INSTALL REAR SEAT INNER W/CENTER BELT ASSY LH (TMC MADE) (See page 61−13) INSTALL REAR SIDE SEAT BACK ASSY LH (TMC MADE) (See page 72−32) INSTALL REAR SIDE SEAT BACK ASSY RH (TMC MADE) (See page 72−32) INSTALL REAR SEAT BACK ASSY RH (See page 72−32) INSTALL REAR SEAT BACK ASSY LH (See page 72−32) WhereEverybodyKnowsYourName 67−18 AUDIO & VISUAL SYSTEM − STEREO COMPONENT AMPLIFIER ASSY STEREO COMPONENT AMPLIFIER ASSY 67092−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE FRONT DOOR SCUFF PLATE RH (See page 71−16) 2. REMOVE COWL SIDE TRIM SUB−ASSY RH (See page 71−16) 3. REMOVE INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) 4. REMOVE GLOVE COMPARTMENT DOOR PAD (See page 71−16) 5. REMOVE INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) 6. (a) (b) REMOVE STEREO COMPONENT AMPLIFIER ASSY Disconnect the connectors. Remove the 2 nuts and stereo component amplifier assy. I31481 WhereEverybodyKnowsYourName 67−19 AUDIO & VISUAL SYSTEM − STEERING PAD SWITCH LH STEERING PAD SWITCH LH 671DT−01 REPLACEMENT HINT:

COMPONENTS: SEE PAGE 67−1. Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60−1) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60−1) REMOVE STEERING WHEEL COVER LOWER NO.2 TMC MADE (SEE PAGE 50−9) TMMK MADE (SEE PAGE 50−21) REMOVE STEERING WHEEL COVER LOWER NO.3 TMC MADE (SEE PAGE 50−9) TMMK MADE (SEE PAGE 50−21) REMOVE HORN BUTTON ASSY (SEE PAGE 60−25) 1. 2. 3. 4. 5. 6. (a) (b) (c) REMOVE STEERING PAD SWITCH LH (4 SPOKE STEERING WHEEL ASSY) Disconnect the connector. Disconnect the connector of cruise control main switch. Remove the screw. E62430 (d) w/o steering pad switch RH: Release the 2 pins and remove the steering pad switch LH. (e) w/ steering pad switch RH: Remove the clamp. w/ steering pad switch RH: Release the 2 pins and release the steering pad switch LH from steering wheel. E62431 Pin I33301 (f) E62432 Pin Clamp I33302 WhereEverybodyKnowsYourName 67−20 AUDIO & VISUAL SYSTEM − STEERING PAD SWITCH LH (g) w/ steering pad switch RH: Release the tab of steering pad switch cable from steering pad switch LH as shown in the illustration. (h) w/ steering pad switch RH: Disengage the 2 claws as shown in the illustration and open the latch on the top of the connector. (i) w/ steering pad switch RH: Pull out the connector while pinching the latch with fingers and disconnect the steering pad switch cable from the steering pad switch LH. 7. (a) (b) REMOVE STEERING PAD SWITCH LH (3 SPOKE STEERING WHEEL ASSY) Disconnect the connector. Remove the screw. (c) (d) Disengage the 2 claws. Remove the steering pad switch LH. E62433 Claw I36825 I34484 I43947 Claw I43948 WhereEverybodyKnowsYourName 67−21 AUDIO & VISUAL SYSTEM 8. 9. 10. − STEERING PAD SWITCH LH INSTALL HORN BUTTON ASSY (SEE PAGE 60−25) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 60−17) WhereEverybodyKnowsYourName 67−22 AUDIO & VISUAL SYSTEM − STEERING PAD SWITCH RH STEERING PAD SWITCH RH 671DU−01 REPLACEMENT HINT:

1. 2. 3. 4. 5. COMPONENTS: SEE PAGE 67−1. Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60−1) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60−1) REMOVE STEERING WHEEL COVER LOWER NO.2 TMC MADE (SEE PAGE 50−9) TMMK MADE (SEE PAGE 50−21) REMOVE STEERING WHEEL COVER LOWER NO.3 TMC MADE (SEE PAGE 50−9) TMMK MADE (SEE PAGE 50−21) REMOVE HORN BUTTON ASSY (SEE PAGE 60−25) 6. (a) (b) (c) REMOVE STEERING PAD SWITCH RH Remove the screw. Remove the clamp. Disengage the 2 pins and release the steering pad switch RH from the steering wheel. (d) Release the tab of steering pad switch cable from the steering pad switch RH as shown in the illustration. (e) Disengage the 2 claws as shown in the illustration and open the latch on the top of the connector. E62435 Pin Clamp I34738 E62436 Claw I34483 WhereEverybodyKnowsYourName 67−23 AUDIO & VISUAL SYSTEM (f) − STEERING PAD SWITCH RH Pull out the connector while pinching the latch with fingers and disconnect the steering pad switch cable from the steering pad switch RH. I35111 7. 8. 9. INSTALL HORN BUTTON ASSY (SEE PAGE 60−25) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 60−17) WhereEverybodyKnowsYourName 67−24 AUDIO & VISUAL SYSTEM − CIGARETTE LIGHTER ASSY CIGARETTE LIGHTER ASSY 67096−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE FRONT ASH RECEPTACLE ASSY (See page 71−16) 2. (a) (b) Ring Nut REMOVE CIGARETTE LIGHTER ASSY Rotate the ring nut counterclockwise to remove it. Remove the cigarette lighter assy from the instrument panel ash receptacle assy. Socket Cap E57978 3. (a) (b) (c) I31593 INSTALL CIGARETTE LIGHTER ASSY Properly position the socket at the cutout of the instrument panel ash receptacle assy and insert them. Install the socket cap. Rotate the ring nut clockwise from the backside. WhereEverybodyKnowsYourName 67−25 AUDIO & VISUAL SYSTEM − POWER POINT SOCKET ASSY POWER POINT SOCKET ASSY 67098−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE SHIFT LEVER KNOB SUB−ASSY (M/T TRANSAXLE) (See page 71−16) 2. REMOVE CONSOLE PANEL UPPER REAR(See page 71−16) 3. REMOVE INSTRUMENT PANEL CUP HOLDER (W/O ASHTRAY)(See page 71−16) 4. REMOVE FRONT ASH RECEPTACLE ASSY (W/ ASHTRAY)(See page 71−16) 5. REMOVE CONSOLE PANEL SUB−ASSY UPPER(See page 71−16) 6. (a) REMOVE POWER POINT SOCKET ASSY Turn the socket in the circumference direction as shown in the illustration, disengage the claw between the socket and the power pint socket cover, and push out the socket to the room side. (b) Align the socket with the notch on the power point socket cover, remove the power point socket assy to the room side. E03722 Notch Notch I31595 7. (a) INSTALL POWER POINT SOCKET ASSY Align the socket with the notch on the power point socket cover, push the power point socket assy into as hard as possible and install it. WhereEverybodyKnowsYourName 67−26 AUDIO & VISUAL SYSTEM − POWER POINT SOCKET ASSY RR POWER POINT SOCKET ASSY RR 67095−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE SHIFT LEVER KNOB SUB−ASSY (M/T TRANSAXLE) (See page 71−16) 2. REMOVE CONSOLE PANEL UPPER REAR (See page 71−16) 3. REMOVE CONSOLE BOX CARPET (See page 71−16) 4. REMOVE RR CONSOLE BOX (See page 71−16) 5. (a) (b) REMOVE POWER POINT SOCKET ASSY RR Remove the clamp. Turn the socket in the circumference direction as shown in the illustration, disengage the claw between the socket and the power outlet socket cover RR, and push out the socket to the room side. (c) Align the socket with the notch on the power outlet socket cover RR, remove the power point socket assy RR to the room side. E03722 Notch Notch I31596 6. (a) INSTALL POWER POINT SOCKET ASSY RR Align the socket with the notch on the power outlet socket cover RR, push the power point socket assy RR into as hard as possible and install it. WhereEverybodyKnowsYourName 67−27 AUDIO & VISUAL SYSTEM − WINDOW GLASS (ANTENNA WIRE) WINDOW GLASS (ANTENNA WIRE) 67094−02 REPAIR Tester Probe Heat Wire Tin Foil BE4029 1. INSPECT WINDOW GLASS (ANTENNA WIRE) NOTICE: When cleaning the glass, use a soft, dry cloth, and wiper the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown in the illustration. (a) Inspect the continuity, at the center of each antenna wire, as shown in the illustration. 2. (a) REPAIR WINDOW GLASS (ANTENNA WIRE) Clean the broken wire tips with a grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817). E32576 Repair Point (b) Broken Wire (c) Masking Tape BE0150 Fine Tip Brush (d) (e) (f) Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. Repair Point Glass BE0151 WhereEverybodyKnowsYourName 67−4 AUDIO & VISUAL SYSTEM − RADIO RECEIVER ASSY RADIO RECEIVER ASSY 6708W−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71−16) 2. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB−ASSY CENTER (See page 71−16) Radio Bracket 3. (a) REMOVE RADIO RECEIVER ASSY Insert a screwdriver at indicated point and remove the radio receiver assy from instrument cluster finish panel sub−assy center. 4. (a) REMOVE RADIO BRACKET NO.1 Remove the 4 screws and radio bracket No.1. 5. (a) REMOVE RADIO BRACKET NO.2 Remove the 4 screws and radio bracket No.2. Instrument Cluster Finish Panel Sub−assy Center Radio Bracket Instrument Cluster Finish Panel Sub−assy Center I31490 I31475 I31476 WhereEverybodyKnowsYourName 67−5 AUDIO & VISUAL SYSTEM − NAVIGATION RECEIVER ASSY NAVIGATION RECEIVER ASSY 6708X−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71−16) 2. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB−ASSY CENTER (See page 71−16) Radio Bracket 3. (a) REMOVE NAVIGATION RECEIVER ASSY Insert a screwdriver at indicated point and remove the navigation receiver assy from instrument cluster finish panel sub−assy. 4. (a) REMOVE RADIO BRACKET NO.1 Remove the 4 screws and radio receiver bracket No.1. 5. (a) REMOVE RADIO BRACKET NO.2 Remove the 4 screws and radio receiver bracket No.2. Instrument Cluster Finish Panel Sub−assy Center Radio Bracket Instrument Cluster Finish Panel Sub−assy Center I31492 E57974 E57975 WhereEverybodyKnowsYourName 67−6 AUDIO & VISUAL SYSTEM − NAVIGATION ECU NAVIGATION ECU 67090−02 REPLACEMENT HINT: COMPONENTS: See page 67−1 or 76−7 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 2. REMOVE SPARE WHEEL COVER ASSY 3. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB−ASSY RH 4. REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO.1 (See page 76−8) 5. REMOVE REAR FLOOR FINISH PLATE (See page 76−8) 6. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH (See page 76−8) 2 Clamps 7. (a) REMOVE NAVIGATION ECU Disconnect the connectors and remove the 2 clamps. (b) Remove the nut and 2 bolts, then remove the navigation ECU. 8. (a) REMOVE DISC PLAYER BRACKET Remove the 2 screws and disc player bracket. I32054 I31478 I31479 WhereEverybodyKnowsYourName 67−7 AUDIO & VISUAL SYSTEM 9. (a) − NAVIGATION ECU REMOVE DISC PLAYER BRACKET NO.2 Remove the 2 screws and disc player bracket No.2. I31480 WhereEverybodyKnowsYourName 67−8 AUDIO & VISUAL SYSTEM − FRONT NO.1 SPEAKER ASSY FRONT NO.1 SPEAKER ASSY 67093−03 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY (See page 75−8) 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75−8) 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (See page 75−8) 4. REMOVE FRONT DOOR TRIM BOARD SUB−ASSY LH (See page 75−8) 5. (a) (b) REMOVE FRONT NO.1 SPEAKER ASSY Disconnect the connector. Remove the 4 screws and front No.1 speaker assy. I31482 2 3 6. INSTALL FRONT NO.1 SPEAKER ASSY (a) Install the front No.1 speaker assy with the 4 screws. NOTICE: Install them in the order shown in the illustration. (b) Connect the connector. 1 4 I31482 WhereEverybodyKnowsYourName 67−9 AUDIO & VISUAL SYSTEM − FRONT NO.2 SPEAKER ASSY FRONT NO.2 SPEAKER ASSY 6708Y−04 REPLACEMENT HINT: COMPONENTS: See page 67−1 1. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB−ASSY NO.2 (See page 71−16) 2. (a) (b) REMOVE FRONT NO.2 SPEAKER ASSY Remove the 2 bolts. Disconnect the connector and remove the front No.2 speaker assy. E57976 3. (a) (b) INSTALL FRONT NO.2 SPEAKER ASSY Connect the connector. Align a claw with the notch of the instrument panel safety pad with 2 bolts, and install the front No.2 speaker assy. NOTICE: Install them in the order shown in the illustration. Claw 2 1 E57976 WhereEverybodyKnowsYourName 01−1 INTRODUCTION − HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 0108G−07 GENERAL INFORMATION 1. (a) (b) (c) (d) 2. (a) 3. (a) 4. (a) (b) GENERAL DESCRIPTION This manual is written in accordance with SAE J2008. Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection This manual explains the ”Diagnosis” (found in the ”Diagnostics” section) and ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”. ”Final Inspection” is omitted. The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check INDEX An alphabetical INDEX section is provided at the end of the book as a reference to help you find the item to be repaired. PREPARATION Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair situation. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. REPAIR PROCEDURES Component drawing is placed under the title where necessary. Non−reusable parts, grease application areas, precoated parts and tightening torque are specified in the component drawings. Example: Filler Cap Float Clevis Pin
Gasket Reservoir Tank Boot
Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName N17080 01−2 INTRODUCTION − HOW TO USE THIS MANUAL (c) Tightening torque, grease application areas, and non−reusable parts are described as important points in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. (e) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (f) Illustrations of similar models are sometimes used. In those cases, specific details may be different from the actual vehicle. (g) Procedures are presented in a step−by−step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task. It also has information such as specifications and warnings. Example: Illustration: what to do and where The ”< >” marks highlight the part’s name in the Parts Catalog Task heading: what you will be doing INSTALL FRONT AXLE HUB BEARING Detailed text: how to perform task Set part No. Component part No. D31332 HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task headings are easy to read and the text below the task heading provides detailed information. Important specifications and warnings are always written in bold type. 5. (a) SERVICE SPECIFICATIONS SPECIFICATIONS are presented in bold−faced text throughout the text where needed. The specifications are also found in the Service Specifications section for quick reference. 6. TERMS DEFINITION CAUTION NOTICE HINT Possibility of injury to you or other people. Possibility of damage to the components being repaired. Provides additional information to help you perform repairs. WhereEverybodyKnowsYourName 01−3 INTRODUCTION 7. (a) − HOW TO USE THIS MANUAL SI UNIT The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf) WhereEverybodyKnowsYourName 01−19 INTRODUCTION − REPAIR INSTRUCTION 01043−07 VEHICLE LIFT AND SUPPORT LOCATIONS 1. (a) (b) 2. (a) (b) (c) 3. (a) NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded vehicle. When removing heavy equipment such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or shift; or use a mission jack to hold the jacking support. NOTICE FOR USING 4 POST LIFT Follow the safety procedures outlined in its instruction manual. Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. Use wheel chocks to secure the vehicle. NOTICE FOR USING JACK AND SAFETY STAND Work in a flat area using wheel chocks at all times. (b) Rubber Attachment (c) (d) D25082 (f) (g) (e) Use a safety stand with a rubber attachment, as shown in the illustration. Apply the jack and rigid rack to the specified location on the vehicle. When jacking up the front wheels, release the parking brake and place wheel chocks only behind the rear wheels. When jacking up the rear wheels, place wheel chocks only in front of the front wheels. The jack should not be used without the rigid rack. When jacking up only the front wheels or only the rear wheels, place wheel chocks on both sides of the wheels touching the ground. When lowering the vehicle with its front wheels jacked up, release the parking brake and place wheel chocks only in front of the rear wheels. When lowering a vehicle with its rear wheels jacked up, place wheel chocks only behind the front wheels. 470 mm (18.50 in.) : JACK POSITION Front Side Notch : SUPPORT POSITION, PANTOGRAPH JACK POSITION : CENTER OF VEHICLE GRAVITY (unloaded condition) D26604 WhereEverybodyKnowsYourName 01−20 INTRODUCTION 4. (a) (b) (c) (d) (e) (f) 5. (a) (b) (c) − REPAIR INSTRUCTION NOTICE FOR USING SWING ARM TYPE LIFT Follow safety procedures outlined in its instruction manual. Use a swing arm equipped with a rubber attachment, as shown in the illustration. When using the lift, its center should be as close to the vehicle’s center of gravity as possible. Set the vehicle on the lift as level as possible. Then match the groove of the cradle to the rigid rack support location. Be sure to lock the swing arms before lifting and during work (if equipped with arm locks). Lift the vehicle up off the ground. Stand at a safe distance and shake the vehicle to check its stability. NOTICE FOR USING PLATE TYPE LIFT Follow safety procedures outlined in its instruction manual. Use a plate lift attachments (rubber lifting blocks) on top of the plate surface. Refer to the table below to determine how to properly set the vehicle. Right and left set position Place the vehicle over the center of the lift. Front and rear set position Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the front side notch in the vehicle rocker flange. (d) Lift the vehicle up off the ground, and shake it to make sure that it is stable. Swing Arm Type Lift Center of Lift L : CENTER OF VEHICLE GRAVITY (unload condition) Rubber Attachment Plate Type Lift Attachment Dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) B A Attachment C 100 mm (3.94 in.) 200 mm (7.87 in.) D25021 WhereEverybodyKnowsYourName INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−21 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01044−19 GENERAL INFORMATION A large number of ECU controlled systems are used in the CAMRY. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system’s circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. Detailed information and troubleshooting procedures on major ECU controlled systems in this vehicle are outlined below: System 1. SFI System (2AZ−FE) Page 05−1 2. SFI System (2AZ−FE) (PZEV) 05−346 3. SFI System (1MZ−FE/3MZ−FE) 05−491 4. ABS with EBD System (BOSCH made) 05−869 5. ABS with EBD System (DENSO made) 05−928 6. ABS with EBD & BA & TRAC & VSC System 05−980 7. Electronic Controlled Automatic Transmission [ECT] (U250E) 05−1104 8. Electronic Controlled Automatic Transmission [ECT] (U151E) 05−1232 9. Air Conditioning System 05−1360 10.Supplemental Restrant System 05−1443 11.Lighting System 05−1787 12.Audio System 05−1819 13.Navigation System 05−1888 14.Combination Meter 05−1992 15.Power Window Control System 05−2055 16.Power Door Lock Control System 05−2072 17.Wireless Door Lock Control System 05−2088 18.Engine immobiliser System 05−2106 19.Theft Deterrent System 05−2133 20.Multiplex Communication System 05−2148 21.Can Comunication System 05−2161 22.Cruise Control System 05−2206 FOR USING OBD II SCAN TOOL OR HAND−HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If scan tool or tester cannot communicate with the ECU controlled systems when you have connected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a problem on the vehicle side or tester side. (1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Operator’s Manual. WhereEverybodyKnowsYourName 01−22 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01045−11 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. Details in the Diagnostic Section show the most effective methods for each circuit. Confirm the troubleshooting procedures for the relevant circuit before beginning troubleshooting. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. 3 (a) SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK Check the battery positive voltage. Voltage: 11 to 14 V (Engine stopped) Visually check the wire harness, connectors and fuses for open and short, etc. Warm up the engine to the normal operating temperature. Confirm the problem symptoms and conditions, and check for DTCs according to the related chart. (b) (c) (d) OK Go to step 5 NG 4 (a) DTC CHART Check the results obtained in step 3, then confirm the inspection procedures for the system or part using the DTC chart. Go to step 6 5 (a) Check the results obtained in step 3. Confirm the inspection procedures for the system or part using the problem symptoms table. 6 (a) PROBLEM SYMPTOMS CHART CIRCUIT INSPECTION OR PARTS INSPECTION Confirm the circuit in the system or the part that should be checked using the problem symptoms table or the results obtained in step 4. WhereEverybodyKnowsYourName INTRODUCTION 7 (a) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−23 REPAIR Repair the affected system or part according to the instructions in step 6. 8 (a) − CONFIRMATION TEST After completing repairs, confirm that the problem has been solved. If the problem does not recur, perform a confirmation test under the same conditions and in the same environment as when it occurred for the first time. END WhereEverybodyKnowsYourName 01−24 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT:    In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. As much information as possible should be gathered for the reference, even past problems that seem unrelated may help in some cases. In the Diagnostic section, a customer problem analysis table is provided for each system. 5 items are important points in the problem analysis: Important Points with Customer Problem Analysis
What −−−−− Vehicle model, system name
When −−−−− Date, time, occurrence frequency
Where −−−−− Road conditions
Under what conditions? −−−−− Running conditions, driving conditions, weather conditions
How did it happen? −−−−− Problem symptoms (Sample) Supplemental restraint system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet VIN Production Date Customer’s Name / / Licence No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred Weather Temperature Vehicle Operation / Fine Cloudy Rainy Snowy / Other Approx. Starting Driving [ Idling Constant speed Other Acceleration WhereEverybodyKnowsYourName Deceleration ] INTRODUCTION − 01−25 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the CAMRY has various functions.  The first function is the Diagnostic Trouble Code (DTC) check. In a DTC check, a previous malfunction’s DTC can be checked by a technician during troubleshooting. (A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs.)  Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the CAMRY: Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test) SFI System  (with Check Mode)   Electronically Controlled Automatic Transmission [ECT]  (with Check Mode)  System  Engine Immobiliser System  In the DTC check, it is very important to determine whether the problem indicated by the DTC is: 1) still occurring, or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current conditions, as shown in the table below. Never skip the DTC check. Failure to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow the procedures listed above in the correct order. A flow chart showing how to proceed with troubleshooting using the DTC check is shown below. Directions from the flow chart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of the problem symptoms table.  1 DTC CHECK 2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY 3 SYMPTOM CONFIRMATION a a Symptoms exist b No symptoms exist Go to step 5 b WhereEverybodyKnowsYourName 01−26 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4 SIMULATION TEST USING THE SYMPTOM SIMULATION METHODS 5 DTC CHECK a a DTC displayed b No DTC displayed Troubleshooting of problem indicated by DTC b 6 SYMPTOM CONFIRMATION a No symptoms exist b Symptoms exist If a DTC was displayed in the initial DTC check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (see page 01−32). a SYSTEM NORMAL b TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). WhereEverybodyKnowsYourName INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−27 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough customer problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and lead to mistakes or delays. For example: With a problem that only occurs when the engine is cold or occurs as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed−up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. 1. VIBRATION METHOD: When vibration seems to be Vibrate Slightly the major cause. (a) PART AND SENSOR (1) Apply slight vibration with a finger to the part of the sensor considered to be the cause of the problem and check whether or not the malfunction occurs. HINT: Applying strong vibration to relays may open relays. (b) CONNECTORS (1) Slightly shake the connector vertically and horizontally. (c) WIRE HARNESS Shake Slightly (1) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. Vibrate Slightly B71602 2. Malfunction D25084 HEAT METHOD: If the problem seems to occur when the area in question is heated. (a) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE:
Do not heat to more than 60C (140F). Exceeding this temperature may damage components.
Do not apply heat directly to the parts in the ECU. WhereEverybodyKnowsYourName 01−28 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. D25085 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in high−humidity. (a) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE:
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by applying water spray onto the front of the radiator.
Never apply water directly onto the electronic components. HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or shorts. Proceed with caution during water tests. 4. ON (a) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when electrical load is excessive. Turn on all the electrical loads including the heater blower, headlights, rear window defogger, etc., and check if the malfunction occurs. B02389 WhereEverybodyKnowsYourName INTRODUCTION − 01−29 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. The Supplemental Restraint System (SRS) diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedures for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect areas of the problem.
Detection Item Indicates the system or details of the problem. DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). DTC No. (See page) Detection Item
Short in D squib circuit B0100/13 (05−119)
Open in D squib circuit B0101/14 (05−124)
Short in D squib circuit (to ground) B0102/11 (05−128)
Short in D squib circuit (to B+) B0103/12 (05−132) B0105/53 (05−136)
Short in P squib circuit B0106/54
Open in P squib circuit Trouble Area
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness
Front passenger airbag assembly (squib) ON
Airbag sensor assembly
Wire harness
Short in P squib circuit (to Ground) SRS Warning Light
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness WhereEverybodyKnowsYourName ON ON 01−30 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot when, during a DTC check, a ”Normal” code is displayed but the problem is still occurring. Numbers in the table show the inspection order in which the circuits or parts should be checked. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Circuit or Part Name Indicates the circuit or part which needs to be checked.
Problem Symptom PROBLEM SYMPTOMS TABLE HINT: Inspect the ”Fuse” and ”Relay” before confirming the suspected area in the charts below (See page 68−1). Symptom Suspected Area See Page Black screen 1. Power source circuit (multi−display assy) 2. Multi−display 05−1267 67−7 Screen cannot be dimmer in night time 1. SRS warning light circuit (multi−display assy) 2. Multi−display assy 05−1277 67−7 A navigation system cannot be operated 1. Steering pad switch circuit 05−1183 2. AVC−LAN circuit (radio receiver assy−multi− display assy) 05−1303 3. Radio receiver assy 67−5 4. Multi−display assy 67−7 WhereEverybodyKnowsYourName INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−31 CIRCUIT INSPECTION How to read and use each page is shown below.
Circuit Description The major role, operation of the circuit and its component parts are explained.
Diagnostic Trouble Code No. and Detection Item
Indicates the diagnostic trouble codes, diagnostic trouble code settings and suspect areas for a problem.
Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. SFI SFI
Indicates the condition of the connector of the ECU during the check.
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Connector being checked is connected. Connector being checked is disconnected. Connections of tester are indicated by (+), (−) after terminals name. For inspection of connector with body ground, there is nothing about the body ground written down. D25842 WhereEverybodyKnowsYourName 01−32 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01046−09 ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. (a) BASIC INSPECTION RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS (1) Unless stated, all resistance is measured at an ambient temperature of 20
C (68
F). Resistances measured may be outside the specifications if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) WRONG CORRECT D25086 Looseness of Crimping Core Wire Terminal Deformation Pull Lightly D25087 HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting the connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until you hear the lock close with a ”click” sound. (5) If checking the connector with a TOYOTA electrical tester, check it from the backside (harness side) of the connector using a mini test lead. NOTICE:
As a waterproof connector cannot be checked from the backside, check by connecting a sub−harness.
Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when the connector is connected: Squeeze the connector together to confirm that it is fully inserted and locked. (2) Checking when the connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign objects and water; and bent, rusted, overheated, contaminated, and deformed terminals. NOTICE: When testing a gold−plated female terminal, always use a gold−plated male terminal. WhereEverybodyKnowsYourName INTRODUCTION − (3) Same terminal as a male terminal CORRECT WRONG REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any dirt on the terminal, clean the contact point using an air gun or shop rag. Never polish the contact point using a sandpaper as the platings may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold−plated (gold color), use a gold−plated female terminal; if it is silver−plated (silver color), use a silver−plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal will not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) Never make the wire harness come into contact with a high temperature part, rotating, moving, vibrating or sharp−edged parts. Avoid panel edges, screw tips and similar sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or securely repair it with vinyl tape. 2. (a) CHECK OPEN CIRCUIT For an open circuit in the wire harness in Fig. 1, perform a resistance check (step b) or a voltage check (step c). D01557 Fig. 1 ECU Sensor Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for good tension when inserting and after full engagement. (d) WRONG OPEN 1 1 2 2 01−33 D25088 D20024 C HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS B A 1 2 1 2 Z17004 WhereEverybodyKnowsYourName 01−34 INTRODUCTION (b) Fig. 2 ECU Sensor 1 1 2 A 1 2 B 2 C Z17005 Fig. 3 ECU Sensor 1 2 B2 1 2 C 1 1 2 2 A B1 B04722 Fig. 4 5V Sensor 0V 1 5V 1 2 C 1 2 B 2 A Z17007 − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Resistance: Below 1 Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. Fig. 2: Between terminal 1 of connector A and terminal 1 of connector C → 10 kΩ or higher Between terminal 2 of connector A and terminal 2 of connector C → Below 1 Ω If your results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Fig. 3: Between terminal 1 of connector A and terminal 1 of connector B1 → Below 1 Ω Between terminal 1 of connector B2 and terminal 1 of connector C → 10 kΩ or higher If your results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. Fig. 4: With each connector still connected, measure the voltage between the body ground and terminal 1 of connector A at the ECU 5 V output terminal, terminal 1 of connector B and terminal 1 of connector C, in that order. (2) Example results: 5 V: Between terminal 1 of connector A and body ground 5 V: Between terminal 1 of connector B and body ground 0 V: Between terminal 1 of connector C and body ground If your results match the examples above, an open circuit exists in the wire harness between terminal 1 of B and terminal 1 of C. WhereEverybodyKnowsYourName INTRODUCTION Fig. 5 C SHORT 1 2 B 1 2 − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−35 3. (a) CHECK SHORT CIRCUIT If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance between terminals 1 and 2 of connector A and the body ground. Resistance: 10 kΩ or higher A 1 2 Z17008 Fig. 6 ECU Sensor 1 2 1 2 C B 1 2 A Z17009 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. Fig. 6: Between terminal 1 of connector A and body ground → Below 1 Ω Between terminal 2 of connector A and body ground → 10 kΩ or higher If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Fig. 7 ECU Sensor C 1 2 1 2 B2 1 2 B1 1 2 A Z17808 Disconnect connector B and measure the resistance between terminal 1 of connector A and the body ground, and terminal 1 of connector B2 and the body ground. Fig. 7: Between terminal 1 of connector A and body ground → 10 kΩ or higher Between terminal 1 of connector B2 and body ground → Below 1 Ω If your results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. WhereEverybodyKnowsYourName 01−36 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4. CHECK AND REPLACE ECU NOTICE:
Start an inspection of the connector from the backside of the connector at the wire harness side with the connector connected to the ECU.
When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON.
Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Replace the ECU with a normal functioning one and check if the symptoms occur. If the trouble symptoms stop, replace the ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Resistance: Below 1 Ω Example Ground IN0383 (2) ECU Side Ground W/H Side Disconnect the ECU connector. Check the ground terminals (on the ECU side and wire harness side) for evidence of bending, corrosion or foreign material. Lastly check the contact pressure of the female terminals. Ground IN0384 WhereEverybodyKnowsYourName 01−37 INTRODUCTION − TERMS TERMS 01047−09 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti−Lock Brake System A/C Air Conditioner AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air−Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately ASSY Assembly A/T, ATM Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B+ Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi−Level B/S Bore−Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel CKD Complete Knock Down COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve CW Curb Weight DC Direct Current WhereEverybodyKnowsYourName 01−38 INTRODUCTION − TERMS Abbreviations Meaning DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLC Data Link Connector DLI Distributorless Ignition DOHC Double Overhead Camshaft DP Dash Pot DS Dead Soak DSP Digital Signal Processor DTC Diagnostic Trouble Code DVD Digital Versatile Disc EBD Electric Brake Force Distribution ECAM Engine Control And Measurement System ECD Electronically Controlled Diesel ECDY Eddy Current Dynamometer ECT Electronic Control Transmission ECU Electronic Control Unit ED Electro−Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR Exhaust Gas Recirculation EGR−VM EGR−Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ES Easy & Smooth ESA Electronic Spark Advance ETCS−i Electronic Throttle Control System−intelligent EVAP Evaporative Emission Control EVP Evaporator E−VRV Electric Vacuum Regulating Valve EX Exhaust FE Fuel Economy FF Front−Engine Front−Wheel−Drive F/G Fuel Gauge FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front F/W Flywheel FW/D Flywheel Damper FWD Front−Wheel−Drive GAS Gasoline GND Ground GSA Gear Shift Actuator GPS Global Positioning System WhereEverybodyKnowsYourName 01−39 INTRODUCTION − TERMS Abbreviations Meaning HAC High Altitude Compensator H/B Hatchback H−FUSE High Current Fuse HI High HID High Intensity Discharge (Head Lamp) HPU Hydraulic Power Unit HSG Housing HT Hard Top HV Hybrid Vehicle HWS Heated Windshield System IC Integrated Circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension ISC Idle Speed Control J/B Junction Block J/C Junction Connector KD Kick−Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left−Hand LHD Left−Hand Drive L/H/W Length, Height, Width LLC Long−Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX. Maximum MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MG1 Motor Generator No.1 MG2 Motor Generator No.2 MP Multipurpose MPI Multipoint Electronic Injection MPX Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) MT Mount MTG Mounting N Neutral WhereEverybodyKnowsYourName 01−40 INTRODUCTION − TERMS Abbreviations Meaning NA Natural Aspiration No. Number O2S Oxygen Sensor OC Oxidation Catalyst O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option ORVR On−board Refilling Vapor Recovery O/S Oversize PBD Power Back Door P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PROM Programmable Read Only Memory PS Power Steering PSD Power Slide Door PTC Positive Temperature Coefficient PTO Power Take−Off P/W Power Window PZEV Partial Zero Emission Vehicle R&P Rack And Pinion RAM Random Access Memory R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RH Right−Hand RHD Right−Hand Drive RLY Relay ROM Read Only Memory Rr Rear RRS Rigid Rear Suspension RSE Rear Seat Entertainment RWD Rear−Wheel Drive SC Supercharger SCV Swirl Control Valve SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard WhereEverybodyKnowsYourName 01−41 INTRODUCTION − TERMS Abbreviations Meaning STJ Cold−Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer−Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronically Modulated Suspension TFT Toyota Free−Tronic TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge TWC Three−Way Catalyst U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VGRS Variable Gear Ratio Steering VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT−i Variable Valve Timing−intelligent w/ With WGN Wagon W/H Wire Harness w/o Without WU−TWC Warm Up Three−way Catalytic Converter WU−OC Warm Up Oxidation Catalytic Converter 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4 x 2) 3rd Third 4th Fourth 4WD Four Wheel Drive Vehicle (4 x 4) 4WS Four Wheel Steering System 5th Fifth WhereEverybodyKnowsYourName 01−4 INTRODUCTION − IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 01041−10 VEHICLE IDENTIFICATION AND SERIAL NUMBERS A 1. (a) VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label 2. (a) FACTORY OF PRODUCTION World manufacture identifier is used to distinguish between TMC and TMMK made vehicles. The first 3 digits and letters of the vehicle identification number shows the world manufacturer identifier. B D26605 WMI* TMC made JTD TMMK made 4T1 *: World Manufacturer Identifier 3. 3MZ−FE 1MZ−FE (a) ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER The engine serial number is stamped on the cylinder block of the engine, and the transaxle serial number is stamped on the housing, as shown in the illustration. A: Engine Serial Number B: Transaxle Serial Number A 2AZ−FE B D30729 WhereEverybodyKnowsYourName 01−42 INTRODUCTION − TERMS 01048−09 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )−−ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner (A/CL) AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage Battery Voltage (+B) BARO Barometric Pressure High Altitude Compensator (HAC) CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position − CTOX Continuous Trap Oxidizer − CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection Direct Injection (D/INJ) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Communication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode − ECL Engine Coolant Level − ECM Engine Control Module Engine ECU (Electronic Control Unit) 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) EI Electronic Ignition Distributorless Ignition (DLI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control − FEEPROM Flash Electrically Erasable Programmable Read Only Memory − FEPROM Flash Erasable Programmable Read Only Memory − FF Flexible Fuel − FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) − − − WhereEverybodyKnowsYourName 01−43 INTRODUCTION − TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel−Shutoff − ISC Idle Speed Control − KS Knock Sensor Knock Sensor MAF Mass Airflow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature − MVZ Manifold Vacuum Zone − NVRAM Non−Volatile Random Access Memory − O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On−Board Diagnostic On−Board Diagnostic System (OBD) OL O id ti Catalytic Oxidation C t l ti C Converter t Oxidation Catalyst Convert (OC) Catalytic Converter for Oxidation (CCo) OP Open Loop Open Loop PAIR 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) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass Electronic Air Bypass Valve (E−ABV) SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter − SRI Service Reminder Indicator − SRT System Readiness Test − ST Scan Tool − TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger − Indirect Injection (IDL) − − WhereEverybodyKnowsYourName 01−44 INTRODUCTION − TERMS TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three−Way Catalytic Converter Three−Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three−Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU−OC Warm Up Oxidation Catalytic Converter − WU−TWC Warm Up Three−Way Catalytic Converter − 3GR Third Gear − 4GR Fourth Gear − − WhereEverybodyKnowsYourName 01−5 INTRODUCTION − REPAIR INSTRUCTION REPAIR INSTRUCTION 010P4−05 PRECAUTION 1. (a) BASIC REPAIR HINT HINTS ON OPERATIONS 2 1 3 6 5 4 D25016 1 Looks
Always wear a clean uniform.
Hat and safety shoes must be worn. 2 Vehicle protection
Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation
When working with 2 or more persons, be sure to check safety in one another.
When working with the engine running, pay attention to the providing ventilation for exhaust fumes in the workshop.
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement. Removal and installation, disassembly and assembly operations
Diagnose with a thorough understanding of proper procedures and of the reported problem.
Before removing the parts, check the general condition of the assembly and for deformation and damage.
When the assembly is complicated, take notes. For example, note the total number of electrical connectio− ns, bolts, or hoses removed. Add matchmarks to insure re−assembly of components in the original positions. Temporarily mark hoses and their fittings, if needed.
Clean and wash the removed parts if necessary and assemble them after a thorough check. Removed parts
Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.
As for non−reusable parts such as a gasket, an O−ring, and a self−locking nut, replace them with new ones following the instruction of this manual.
Retain the removed parts for customer inspection, if requested. 5 6 WhereEverybodyKnowsYourName 01−6 INTRODUCTION (b) − REPAIR INSTRUCTION JACKING UP AND SUPPORTING VEHICLE (1) 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 01−19). (c) Seal Lock Adhesive Z11554 PRECOATED PARTS (1) Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in anyway, it must be recoated with the specified adhesive. (3) When reusing precoated parts, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to the bolt, nut, or threads. NOTICE: Perform the torque with the lower limit value of the torque tolerance. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock agent to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES Medium Current Fuse and High Current (1) When replacing fuses, be sure that the new fuse Fuse Equal Amperage Rating has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M−FUSE HIGH CURRENT FUSE H−FUSE D27353 V35002 WhereEverybodyKnowsYourName 01−7 INTRODUCTION (g) − REPAIR INSTRUCTION CLIPS (1) The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. Shape (Example) Removal/Installation Clip Pliers Clip Remover Remove clips from front or rear using clip remover or pliers. Protective Tape Screwdriver Remove fasteners with a clip remover or screwdriver. Protective Tape Scraper Remove clips with a wide scraper to prevent panel damage. D25786 WhereEverybodyKnowsYourName 01−8 INTRODUCTION − REPAIR INSTRUCTION Removal/Installation Shape (Example) Removal Installation Screwdriver Push Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell. Removal Installation Screwdriver Push Clip Remover Remove rivet by unscrewing the center pin and prying out the rivet shell. Removal Installation Push Screwdriver Clip Remover Small Clip Remover Remove rivet by prying out the pin and then prying out the rivet shell. V35006 WhereEverybodyKnowsYourName 01−9 INTRODUCTION (h) WRONG − REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. CORRECT D31750 (2) (3) (4) D25064 (i) L1 TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL (1) If SST or an extension tool is combined with the torque wrench to extend its length, do not tighten the torque wrench to the specified torque values in this manual. The actual torque will be excessive. (2) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. (3) Formula: T’=T x L2/(L1 + L2) L2 D02612 L1 L2 When disconnecting vacuum hoses, use tags to identify where they should be reconnected. After completing the job, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step−down adapter for adjustment. Once the hose has been stretched, it may leak air. T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)} T Torque {N⋅m (kgf⋅cm, ft⋅lbf)} L1 Length of SST or extension tool (cm) L2 Length of torque wrench (cm) D01201 WhereEverybodyKnowsYourName 01−10 INTRODUCTION − REPAIR INSTRUCTION 2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER HINT: The CAMRY is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner. Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE (1) Malfunction symptoms of the SRS are difficult to confirm so the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery. (2) To avoid serious injury, servicing the SRS must be started 90 seconds after:
The ignition switch is turned to the LOCK position.
The negative (−) terminal cable is disconnected from the battery. (The SRS is equipped with a back−up power source. If work is started within 90 seconds of disconnecting the negative (−) terminal cable from the battery, the SRS may deploy). Disconnecting the negative (−) terminal cable will erase clock memory and audio system presets. Mark down data as necessary before disconnecting the cable. CAUTION: Never use a back−up power source (battery or other) avoid erasing system memory. The back−up power source may power the SRS, leading to a possible SRS and cause it to deploy. (3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly front seat airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected before further use of the vehicle (See pages 60−27, 60−40, 60−53, 60−47 and 61−7). (4) Never use SRS parts from another vehicle. When replacing parts, use new parts. (5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly front seat airbag assembly, curtain shield airbag assembly or seat belt pretensioner. (7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly or the instrument panel passenger airbag assembly front seat airbag assembly or curtain shield airbag assembly: 1) if damage has occurred from being dropped, or 2) if there are cracks, dents or other defects in the case, bracket or connector. (8) Do not directly expose the airbag sensor assembly, front seat airbag assembly, curtain shield airbag assembly the horn button assembly, the instrument panel passenger airbag assembly or the seat belt pretensioner to hot air or flames. (9) Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits. (10) Information labels are attached to the SRS components. Follow the instructions on the labels. (11) After work on the SRS is completed, check the SRS warning light (see page 05−1456). WhereEverybodyKnowsYourName 01−11 INTRODUCTION (b) Mark − REPAIR INSTRUCTION SPIRAL CABLE (in Combination Switch) (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other problems may occur. Refer to page 60−34 concerning the correct installation of the steering wheel. D30401 (c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it should be placed with the pad surface facing up. See illustration below. Placing the horn button with the pad surface facing down may lead to a serious accident if the airbag accidently inflates. Also, do not place anything on top of the horn button. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the steering wheel pad. (4) Store the horn button assembly where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 yellow pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag or seat belt pretensioner deploying due to currents entering the squib wiring. (6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be inflated using an SST before disposal (see page 60−27). Perform the operation in a safe place away from electrical noise. Example: CORRECT DANGEROUS D25096 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER WhereEverybodyKnowsYourName Z13950 01−12 INTRODUCTION (d) − REPAIR INSTRUCTION INSTRUMENT PANEL PASSENGER AIRBAG ASSY (1) Always place a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kinds should not be applied to the instrument panel passenger airbag assembly. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), has low humidity and away from electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 yellow pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (see page 60−40). Activate in a safe place away from electrical noise. Example: CORRECT DANGEROUS D27522 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (e) Z13951 FRONT SEAT AIRBAG ASSEMBLY (1) Always place a removed or new front seat airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which is very dangerous. (3) Grease should not be applied to the front seat airbag assembly, and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. WhereEverybodyKnowsYourName 01−13 INTRODUCTION (5) (6) − REPAIR INSTRUCTION When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 yellow pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. When disposing of a vehicle or the airbag assembly unit, the airbag should be deployed using SST before disposal (see page 60−53). Activate in a safe place away from electrical noise. Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER D30924 (f) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. NOTICE: Plastic bag is not re−useable. CAUTION: Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which is very dangerous. (3) Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 yellow pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the curtain shield airbag assembly unit, the airbag should be deployed using SST before disposal (see page 05−346). Activate in a safe place away from electrical noise. Example: CORRECT DANGEROUS Clear Plastic Bag D31641 WhereEverybodyKnowsYourName 01−14 INTRODUCTION − REPAIR INSTRUCTION NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (g) D30931 SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner (This may cause the seat belt pretensioner to activate, which is very dangerous). (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner on another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) without high humidity and away from electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 yellow pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the seat belt pretensioner unit, the seat belt pretensioner should be activated before disposal (see page 61−7). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after being activated, so allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat belt pretensioner. (8) Oil or water should not be put on the front seat outer belt, and the front seat outer belt should not be cleaned with detergents of any kind. Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (h) D30370 AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause accidental deployment of the SRS. (3) Work must be started at last 90 seconds after the ignition switch is turned to the LOCK position and the negative (−) terminal cable is disconnected from the battery, even if only loosening the set bolts of the airbag sensor assembly. WhereEverybodyKnowsYourName 01−15 INTRODUCTION (i) − REPAIR INSTRUCTION WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. Negative (−) Terminal 3. (a) ELECTRONIC CONTROL REMOVAL AND INSTALLATION OF BATTERY TERMINAL (1) Before performing electronic work, disconnect the battery negative (−) terminal cable beforehand to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting and installing the terminal cable, turn the ignition switch and lighting switch OFF and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. Remove the battery cable from battery post. (3) Clock settings, radio settings, DTCs and other data are erased when the battery cable is removed. Before removing the battery cable, record any necessary data. (4) When disconnecting the battery’s negative (−) terminal cable, re−initialize the following systems after the completion of the operation. (b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. (2) To disconnect electronic connectors, pull the connector itself, not the wires. (3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced. (4) When cleaning the engine with steam, protect the electronic components, air filter and emission−related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When checking the continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. D25080 WRONG D31751 WhereEverybodyKnowsYourName 01−16 INTRODUCTION 4. (a) (b) − REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Work in a place with good air ventilation and without any ignition sources, such as a welder, grinder, drill, electric motor or stove. (2) Never work in a place such as a pit or near a pit because vaporized fuel will collect in those places. REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting operation. (2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do not spray the area with water. The work surface will become slippery. Do not clean up spills with water as this will spread and gasoline and create a fire hazard. (3) Never use any electric equipment like an electric motor or a working light, as they may create sparks or high temperatures. (4) Never use an iron hammer, as it may create sparks. (5) Dispose of fuel−contaminated shop rags separately using a fire restraint container. 5. (a) (b) D01563 (c) Spring Type Clamp 6. (a) (b) (c) (d) Clamp Track D25081 7. (a) (b) D20025 (c) (d) (e) REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal particle enters the inlet pass, this may damage the engine. When removing and installing the inlet system parts, cover the openings of the removed parts and engine openings. Use clean shop rags, gummed tape, or other suitable materials. When installing the inlet system parts, check that no metal particles have entered the engine or the installed part. HANDLING OF HOSE CLAMPS Before removing the hose, check the clamp position so that you can restore it in the same way. Replace deformed or dented clamps with a new one. When reusing a hose, attach the clamp on the clamp track portion of the hose. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrow marks as shown in the illustration. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details of the ECU and sensors locations, refer to the section on applicable components. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice−versa. Check that the antenna and feeder are correctly adjusted. Do not install any high−powered mobile communication system. WhereEverybodyKnowsYourName 01−17 INTRODUCTION − REPAIR INSTRUCTION 8. TRAC OFF Indicator Light TRAC Cut Switch FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM When using a 2−wheel drum tester such as a speedometer tester, a combination tester of speedometer and brake, chassis dynamometer, or jacking up the front wheels and driving the wheels, always turn the TRAC system off via the TRAC OFF switch before testing. NOTICE: TRAC system OFF condition can be confirmed by the ”TRAC OFF” warning indicator light in the combination meter. (a) Confirm TRAC system is OFF (1) Press the TRAC cut (”TRAC OFF”) switch to turn off the TRAC system. (2) Check if the TRAC OFF indicator light illuminates. HINT: The SLIP indicator light should always operate right after the engine is restarted. (3) Begin testing. B73289 (4) Press the TRAC cut switch to turn on the TRAC system and check that the TRAC OFF indicator light turns off. HINT: The SLIP indicator light blinks when the TRAC system is operating. SLIP Indicator Light B74724 9. DLC3 CG 1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 TS A82779 FOR VEHICLES EQUIPPED WITH VEHICLE SKID CONTROL (VSC) SYSTEM (a) NOTICES WHEN USING DRUM TESTER (1) Before beginning testing, disable the Vehicle Skid Control system (VSC). To disable the VSC, turn the ignition switch OFF and connect SST to terminals TS and CG of DLC3. SST 09843−18040 NOTICE:
Confirm that the VSC warning light blinks.
VSC system will be reset when the engine is restarted.
For safety, secure the vehicle with restraint chains while using a wheel dynamometer. (b) NOTICES OF RELATED OPERATIONS TO VSC (1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts. WhereEverybodyKnowsYourName 01−18 INTRODUCTION (2) − REPAIR INSTRUCTION Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system. 10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheat and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid idling the engine for more than 20 minutes. (c) Avoid a spark jump test. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. WhereEverybodyKnowsYourName SEAT − 72−1 FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 720O1−01 LOCATION Front Power Seat Switch RH Rear Vertical Motor Rear Vertical Motor Reclining Motor Front Vertical Motor Lumbar Support Motor Reclining Motor Slide Motor Power Seat Switch Assy (Lumbar Support) Engine Room R/B
ALT H−fuse Front Power Seat Switch LH Front Vertical Motor Slide Motor B75072 WhereEverybodyKnowsYourName 72−2 SEAT − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) Instrument Panel J/B Assy
PWR SEAT M−fuse B75065 WhereEverybodyKnowsYourName 72−10 SEAT − SEAT HEATER SYSTEM SEAT HEATER SYSTEM 720PQ−01 LOCATION Seat Heater Switch (Driver’s Side) Seat Heater Switch (Passenger’s Side) Front Seat Cushion Heater Assy RH Front Seatback Heater Assy RH Instrument Panel J/B Assy
SEAT HTR Fuse Front Seatback Heater Assy LH Front Seat Cushion Heater Assy LH B75074 WhereEverybodyKnowsYourName 72−11 SEAT − SEAT HEATER SYSTEM 7206V−04 PROBLEM SYMPTOMS TABLE Symptom Seat heaters do not operate Suspected Area 1. 2. 3. 4. 5. 6. 7. SEAT HTR fuse Front seat cushion heater assy LH Front seat cushion heater assy RH Front seatback heater assy LH Front seatback heater assy RH Seat heater switch Wire harness WhereEverybodyKnowsYourName See page 72−10 72−12 72−12 72−12 72−12 72−12 − 72−12 SEAT − SEAT HEATER SYSTEM 7206X−04 INSPECTION HINT:
On the RH side, use in the same procedure as on the LH side. 1. (a) Seat Heat Switch (Driver’s Side) B51466 Seat Heat Switch (Passenger’s Side) B51467 Terminal No. Condition Specified condition Continuity 4⇔6 OFF 3⇔4⇔6 ON Continuity 1⇔2 Illumination Continuity (always) If the continuity is not as specified, replace the seat heater switch. (b) Inspect the seat heater switch (passenger’s side) continuity. Standard: Terminal No. Condition Specified condition 4⇔6 OFF Continuity 3⇔4⇔6 ON Continuity 1⇔2 Illumination Continuity (always) If the continuity is not as specified, replace the seat heater switch. 2. (a) Front Seat Cushion Hater INSPECT SEAT HEATER SWITCH Inspect the seat heater switch (driver’s side) continuity. Standard: INSPECT FRONT SEAT CUSHION HEATER ASSY LH Inspect the seat cushion heater assembly LH continuity. Standard: Terminal No. Condition Specified condition 1⇔2 Constant Continuity If the continuity is not as specified, replace the seat cushion heater assembly. B30883 3. (a) Front Seat back Hater INSPECT FRONT SEAT BACK HEATER ASSY LH Inspect the seat back heater assembly LH continuity. Standard: Terminal No. Condition Specified condition 1⇔2 Constant Continuity If the continuity is not as specified, replace the seat back heater assembly. B51473 WhereEverybodyKnowsYourName 72−13 SEAT (b) − SEAT HEATER SYSTEM Inspect the seat cushion thermostat continuity. (1) Disconnect the seat back heater from the seat cushion heater LH. (2) Heat up the thermostat LH with a heat light. (3) Inspect the seat cushion heater continuity between the terminals. Standard: Terminal No. B51472 1⇔2 4. 5. Condition Specified condition Seat heater temp. below 25 − 35C (77 − 95F) Continuity y Seat heater temp. temp 25 − 35C (77 − 95F) No continuity If the continuity is not as specified, replace the seat heater cushion heater assembly. INSPECT FRONT SEAT CUSHION HEATER ASSY RH INSPECT FRONT SEAT BACK HEATER ASSY RH WhereEverybodyKnowsYourName 72−14 SEAT − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) 720O7−02 COMPONENTS Front Seatback Cover Front Seatback Board Sub−assy LH Front Seat Headrest Assy Front Seatback Pad 5.5 (56, 48 in. lbf) Front Seat Headrest Support Front Seat Cushion Cover
Hog Ring
Hog Ring w/ Seat Heater: Front Seatback Heater Assy LH w/ Seat Heater: Front Seat Cushion Heater Assy LH Front Seat Cushion Shield Lower RH Front Seatback Cover Front Seat Cushion Pad Front Seat Inner Belt Assy LH Front Seat Track Cover LH Rear Inner Reclining Adjuster Inside Cover RH (Lower) Front Seat Cushion Shield Inner LH Front Seatback Cover Sub−assy No.2 Driver’s Seat Only: Lumbar Suppport Adjuster Assy Seat Adjuster Frame Assy 42 (428, 31) Front Seat Track Cover LH Rear Outer Reclining Adjuster Inside Cover LH (Lower) Passenger’s Seat Only: Occupant Classification ECU Driver’s seat only: Seat Position Airbag Sensor Front Seat Cushion Shield Lower LH 37 (375, 27) Reclining Adjuster Inside Cover RH (Upper) Reclining Adjuster Inside Cover LH (Upper) 8.0 (82, 71 in. lbf) 37 (375, 27) Wire Harness Connector Driver’s Seat Only: Power Seat Switch Assy Vertical Adjuster Bush Reclining Adjuster Release Handle LH Clip N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Vertical Seat Adjuster Nob Cap Front Seat Cushion Shield LH Vertical Adjuster Handle LH WhereEverybodyKnowsYourName B75665 72−15 SEAT − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) 720O8−02 OVERHAUL CAUTION:
Wear safety gloves, because the sharp surfaces of the seatback frame and seat adjuster may injure your hand.
Work must be started more than 90 seconds after the ignition switch is turned to the LOCK position and the negative (−) terminal cable is disconnected from the battery. (The SRS is equipped with a back−up power source. If work is started within 90 seconds from disconnecting the negative (−) terminal cable of the battery, the SRS may deploy.) HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
When removing/installing and overhauling the passenger seat, check the passenger occupant classification system and perform the zero point calibration (see page 05−1452).
Use the same procedures for the RH side and LH side.
A bolt without a torque specification is shown in the standard bolt chart (see page 03−2). 1. REMOVE FRONT SEAT TRACK COVER LH REAR OUTER 2. REMOVE FRONT SEAT TRACK COVER LH REAR INNER 3. REMOVE FRONT SEAT ASSY LH HINT: Set the front vertical function to the highest position. (a) Remove the headrest. (b) Disconnect the connectors under the seat. (c) Remove the 4 bolts and seat. NOTICE: Be careful not to damage the body. 4. Passenger ’s seat only: REMOVE OCCUPANT CLASSIFICATION ECU (See page 60−72) 5. (a) REMOVE VERTICAL ADJUSTER HANDLE LH Remove the 2 front seatback cover No. 2 hog rings under the seat. (b) Using a scraper, disengage the 3 claws and remove the vertical seat adjuster nob cap. B73748 Claw Claw HINT: Tape the scraper tip before use. (c) Remove the 2 screws and vertical adjuster handle. B75069 WhereEverybodyKnowsYourName 72−16 SEAT 6. (a) − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) REMOVE RECLINING POWER SEAT SWITCH KNOB Using a screwdriver, pry out the reclining adjuster release handle. HINT: Tape the screwdriver tip before use. B75070 7. (a) (b) Claw Claw REMOVE FRONT SEAT CUSHION SHIELD LH Remove the screw. Using a screwdriver, disengage the 2 claws and clip, and remove the cushion shield. HINT: Tape the screwdriver tip before use. Claw B75253 8. (a) (b) REMOVE FRONT SEAT INNER BELT ASSY LH Disconnect the connectors. Remove the nut and inner belt. 9. (a) (b) REMOVE FRONT SEAT CUSHION SHIELD INNER LH Remove the screw. Using a screwdriver, disengage the claw and clip, and remove the cushion shield. HINT: Tape the screwdriver tip before use. Claw Clip B75254 10. (a) REMOVE FRONT SEAT CUSHION COVER w/ Seat heater: Disconnect the seat connectors. (b) Disengage the hook and remove the seat cushion cover together with the pad. (c) Remove the hog rings and seat cushion cover. 11. w/ Seat heater: REMOVE FRONT SEAT CUSHION HEATER ASSY LH (a) Cut off the tack pins which fasten the seat heater, and then remove the front seat heater from the seat cushion cover. NOTICE: Be careful not to damage the seat cushion cover. WhereEverybodyKnowsYourName 72−17 SEAT 12. (a) (b) (c) (d) − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) REMOVE FRONT SEATBACK COVER Remove the 2 screws and seatback board. Disengage the hook and remove the front seatback cover No. 2. w/ Side airbag: Remove the hog rings, nut and seatback cover bracket. Remove the 2 headrest supports. B74515 (e) (f) Remove the hog rings and seatback cover together with the pad. Remove the hog rings and seatback cover. B60977 13. w/ Seat heater: REMOVE FRONT SEATBACK HEATER ASSY LH (a) Cut off the tack pins which fasten the seat heater, and then remove the front seat heater from the seatback cover. NOTICE: Be careful not to damage the seatback cover. 14. REMOVE FRONT SEAT ADJUSTER SUB−ASSY LH (a) Remove the 2 screws and lumbar support adjuster. (b) Remove the wire harness connector. (c) Remove the screw and reclining adjuster inside covers LH (upper). (d) Remove the screw and reclining adjuster inside covers RH (upper). (e) Remove the screw and reclining adjuster inside covers LH (lower). (f) Remove the screw and reclining adjuster inside covers RH (lower). (g) Remove the screw and front cushion shield lower LH. (h) Remove the screw and front cushion shield lower RH. 15. Driver’s seat only: REMOVE SEAT POSITION AIRBAG SENSOR (a) Disconnect the wire harness connector. (b) Using a torx socket wrench (T30), remove the torx bolt and airbag sensor. 16. Thickness gauge B76909 Driver’s seat only: INSTALL SEAT POSITION AIRBAG SENSOR (a) Temporarily install the seat position airbag sensor. (b) Install a 1 mm thickness gauge between the slide rail and sensor as shown in the illustration. NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the seat position airbag sensor with a new one. WhereEverybodyKnowsYourName 72−18 SEAT
− FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) When installing the seat position airbag sensor, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. HINT: Be sure to maintain a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (c) Push the top of the sensor. While holding the sensor, tighten the sensor using a torx socket wrench (T30). Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Connect the wire harness connector. 17. w/ Seat heater: INSTALL FRONT SEATBACK HEATER ASSY LH (a) Set the seat heater to the seatback cover. (b) Install the front seat heater to the seatback cover with the 8 tack pins. NOTICE: Do not substitute other metal parts for tack pins. a − a: Listing Pocket A Seat Heater Seat Heater Seat Wire C Tack Pin a a Tack Pin Center Tack Pin b a b a b b b b b b b b b b B A: 15 mm (0.59 in.) Seatback Cover B: Install the tack pins under the wire. C: Align the seat heater and the end of listing pocket. b − b: Tack Pin Seat Heater Seatback Cover Tack pins should not be beyond the seat. B57684 WhereEverybodyKnowsYourName 72−19 SEAT − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) 18. (a) (b) Hog Ring Pliers B50126 INSTALL FRONT SEATBACK COVER Install the seatback pad. Cover the top of the seatback pad with the seatback cover. (c) Install the 2 headrest supports. (d) Using hog ring pliers, install the seatback cover completely with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. (e) w/ Side airbag: Install the seatback cover bracket with the nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 48 in⋅lbf) B74515 (f) w/ Side airbag: Install the wire harness and clamp of the side airbag through the seat cushion cover end. NOTICE: Be careful not to damage the cover. Clamp B75071 (g) As shown in the illustration, attach a rubber with new hog rings. (h) Using hog ring pliers, install new hog rings. NOTICE: Be careful not to damage the cover. When installing the hog rings, take care to minimize wrinkles as much as possible. B75242 WhereEverybodyKnowsYourName 72−20 SEAT − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) 19. w/ Seat heater: INSTALL FRONT SEAT CUSHION HEATER ASSY LH (a) Set the seat heater to the seat cushion cover. (b) Install the seat heater to the seat cushion cover with the 24 tack pins. NOTICE: Do not substitute other metal parts for tack pins. Seat Heater A Tack Pin Tack Pin Tack Pin Seat Heater a Seatback Cover a−a c a b−b c−c a − a, c − c: a Tack pins should not be beyond the seat. a b − b: c a b b c ab c b b a c a a a c c c c b ba b c b a c c c c c b a c c c c b b a a a Seat Heater Listing Pocket B Seat Wire c Center Tack Pin C A: Install the tack pins under the wire. B: 15 mm (0.59 in.) C: Align the seat heater and the end of listing pocket. B57686 20. (a) (b) INSTALL FRONT SEAT CUSHION COVER Install the seat cushion pad to the seat cushion cover. Using hog ring pliers, install the seat cushion cover with new hog rings to the seat cushion pad. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring Pliers B50126 21. (a) (b) (c) INSTALL FRONT SEAT INNER BELT ASSY LH Install the inner belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Connect the connectors. Check that the inner seat belt moves smoothly. WhereEverybodyKnowsYourName 72−21 SEAT 22. (a) (b) (c) (d) (e) (f) 23. 24. − FRONT SEAT ASSEMBLY (MANUAL SEAT TYPE) INSTALL FRONT SEAT ASSY LH Place the seat in the cabin. Conect the connectors under the seat. Tighten the 2 bolts on the front side of the seat. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Tighten the 2 bolts on the rear side of the seat. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the 2 seat track covers. Install the headrest. w/ Seat heater: INSPECT SEAT HEATER OPRATION Passenger seat only INITIALIZE FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the zero point calibration or sensitivity check under the conditions listed below.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger’s seat is removed from the vehicle and then reinstalled to the vehicle.
Both the SRS warning light and the passenger airbag ON/OFF indicator light (”OFF”) come on.
The vehicle is brought to the work shop for repair due to an accident or a collision. (a) Zero point calibration procedure. (1) Adjust the seat position according to the conditions below. Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position (2) (3) (4) Connect the hand−held tester to the DLC3. Turn the ignition switch to the ON position. Perform the zero point calibration by following the directions on the tester screen. HINT: Refer to the hand−held tester operator’s manual for further details. (b) Sensitivity check procedure. (1) Connect the hand−held tester to the DLC3. (2) Apply a 30 kg weight (for example, a 30 kg of lead mass) onto the passenger seat. (3) Turn the ignition switch to the ON position. (4) Using the hand−held tester, perform the sensitivity check and confirm that the sensitivity is within the standard value. Standard value: 27 to 33 kg HINT:
When performing the sensitivity check, use a solid weight made from metal. The check result may not be accurate if a weight made from liquid is used.
When the sensitivity deviates from the standard value, retighten the bolts of the passenger seat, taking care not to deform the seat rail. Perform the sensitivity check again. If the sensitivity still does not stay within the standard value, replace the front RH seat assy. NOTICE: Do not place any objects on the seat. Perform the initialization by attaching a mass heavier than 2 kgs in the seatback pocket, seatback table installed by the user, or other appropriate location. WhereEverybodyKnowsYourName 72−22 SEAT − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) FRONT SEAT ASSEMBLY (POWER SEAT TYPE) 720O5−02 COMPONENTS Front Seatback Board Sub−assy Front Seat Headrest Assy Front Seatback Pad 5.5 (56, 48 in. lbf) Front Seat Headrest Support Front Seat Cushion Cover
Hog Ring
Hog Ring w/ Seat Heater: Front Seat Cushion Heater Assy LH Front Seatback Cover Sub−assy No.2 w/ Seat Heater: Front Seatback Heater Assy LH Front Seatback Cover Front Seat Cushion Shield Lower RH Front Seat Cushion Pad Front Seat Inner Belt Assy LH Front Seat Track Cover LH Rear Inner Reclining Adjuster Inside Cover RH (Lower) Front Seat Cushion Shield Inner LH Reclining Adjuster Inside Cover RH (Upper) Driver’s Seat Only: Lumbar Suppport Adjuster Assy Seat Adjuster Frame Assy 42 (428, 31) Front Seat Track Cover LH Rear Outer 37 (375, 27) Passenger’s Seat Only: Occupant Classification ECU Front Seat Cushion Shield Lower LH Power Seat Motor Assy Power Seat Motor 37 (375, 27) Assy Reclining Adjuster Inside Cover LH (Upper) Reclining Adjuster Inside Cover LH (Lower) 8.0 (82, 71 in. lbf) Driver’s Seat Only: Seat Position Airbag Sensor Wire Harness Connector Front Seat Cushion Shield Inner No.1 LH Front Power Seat Switch LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Driver’s seat only: Power Seat Switch Assy Power Seat Switch Knob Front Seat Cushion Shield LH WhereEverybodyKnowsYourName B75066 72−23 SEAT − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) 720O6−02 OVERHAUL CAUTION:
Wear safety gloves, because the sharp surfaces of the seatback frame and seat adjuster may injure your hand.
Work must be started more than 90 seconds after the ignition switch is turned to the LOCK position and the negative (−) terminal cable is disconnected from the battery. (The SRS is equipped with a back−up power source. If work is started within 90 seconds from disconnecting the negative (−) terminal cable of the battery, the SRS may deploy.) HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
When removing/installing and overhauling the passenger seat, check the passenger occupant classification system and perform the zero point calibration (see page 05−1452).
Use the same procedures for the RH side and LH side.
A bolt without a torque specification is shown in the standard bolt chart (see page 03−2). 1. REMOVE FRONT SEAT TRACK COVER LH REAR OUTER 2. REMOVE FRONT SEAT TRACK COVER LH REAR INNER 3. REMOVE FRONT SEAT ASSY LH HINT: Set the power seat front vertical function to the highest position. (a) Remove the headrest. (b) Remove the 4 bolts and seat. (c) Disconnect the connectors under the seat. NOTICE: Be careful not to damage the body. 4. Passenger ’s seat only: REMOVE OCCUPANT CLASSIFICATION ECU (See page 60−72) 5. (a) (b) REMOVE FRONT SEAT CUSHION SHIELD LH Remove the 2 front seatback cover No. 2 hog rings under the seat. Using a screwdriver, remove the 2 reclining power seat switch knobs. HINT: Tape the screwdriver tip before use. B73748 (c) (d) Claw Remove the 5 screws. Using a screwdriver, disengage the claws and remove the cushion shield LH together with the cushion shield inner No.1 LH, and then disconnect the connector. HINT: Tape the screwdriver tip before use. (e) Driver’s seat only: Remove the 2 screws and lumbar support switch. Claw B75241 WhereEverybodyKnowsYourName 72−24 SEAT 6. (a) (b) − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) REMOVE DUMMY’ Remove the screw. Using a screwdriver, disengage the claws and remove the inner from the cushion shield. HINT: Tape the screwdriver tip before use. Claw B75240 7. (a) (b) REMOVE FRONT SEAT INNER BELT ASSY LH Disconnect the connector. Remove the nut and inner belt. 8. (a) (b) Claw Claw REMOVE FRONT SEAT CUSHION SHIELD INNER LH Remove the screw. Using a screwdriver, disengage the 2 claws and clip and remove the cushion shield. HINT: Tape the screwdriver tip before use. Clip B75244 9. (a) (b) 10. (a) REMOVE FRONT POWER SEAT SWITCH LH Disconnect the connector. Remove the 3 screws and power seat switch. REMOVE FRONT SEAT CUSHION COVER w/ Seat heater: Disconnect the seat connectors. (b) Disengage the hook, and remove the seat cushion cover together with the pad. (c) Remove the hog rings and seat cushion cover. 11. w/ Seat heater: REMOVE FRONT SEAT CUSHION HEATER ASSY LH (a) Cut off the tack pins which fasten the seat heater, and then remove the front seat heater from the seat cushion cover. NOTICE: Be careful not to damage the seat cushion cover. 12. (a) (b) (c) REMOVE FRONT SEATBACK COVER Remove the 2 screws and seatback board. Disengage the hook and remove the front seatback cover No. 2. w/ Side airbag: Remove the hog rings, nut and seatback cover bracket. B74515 WhereEverybodyKnowsYourName 72−25 SEAT (d) (e) (f) − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) Remove the 2 headrest supports. Remove the hog rings and seatback cover together with the pad. Remove the hog rings and seatback cover. B60977 13. w/ Seat heater: REMOVE FRONT SEATBACK HEATER ASSY LH (a) Cut off the tack pins which fasten the seat heater, and then remove the front seat heater from the seat back cover. NOTICE: Be careful not to damage the seat back cover. 14. REMOVE FRONT SEAT ADJUSTER SUB−ASSY LH (a) Remove the 2 screws and the lumbar support adjuster. (b) Remove the wire harness connector. (c) Remove the screw and reclining adjuster inside cover LH (upper). (d) Remove the screw and reclining adjuster inside cover RH (upper). (e) Remove the screw and reclining adjuster inside cover LH (lower). (f) Remove the screw and reclining adjuster inside cover RH (lower). (g) Remove the screw and front cushion shield lower LH. (h) Remove the screw and front cushion shield lower RH. 15. REMOVE POWER SEAT MOTOR ASSY (a) Remove the 2 screws each to remove the sliding motor, reclining motor, front vertical motor and rear vertical motor. 16. Driver’s seat only: REMOVE SEAT POSITION AIRBAG SENSOR (a) Disconnect the wire harness connector. (b) Using a torx socket wrench (T30), remove the torx bolt and airbag sensor. 17. Seat Position Airbag Sensor Seat Rail Thickness Gauge B76909 Driver’s seat only): INSTALL SEAT POSITION AIRBAG SENSOR (a) Temporarily install the seat position airbag sensor. (b) Install a 1 mm thickness gauge between the slide rail and sensor as shown in the illustration. NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the seat position airbag sensor with a new one.
When installing the seat position airbag sensor, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. WhereEverybodyKnowsYourName 72−26 SEAT − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) HINT: Be sure to maintain a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (c) Push the top of the sensor. While holding the sensor, tighten the sensor using a torx socket wrench (T30). Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Connect the wire harness connector. 18. (a) (b) w/ Seat heater: INSTALL FRONT SEATBACK HEATER ASSY LH Set the seat heater to the seatback cover. Install the front seat heater to the seatback cover with the 8 tack pins. NOTICE: Do not substitute other metal parts for tack pins. a − a: Listing Pocket A Seat Heater Seat Heater Seat Wire C Tack Pin a a Tack Pin Center Tack Pin b a b a b b b b b b b b b b B A: 15 mm (0.59 in.) Seatback Cover B: Install the tack pins under the wire. C: Align the seat heater and the end of listing pocket. b − b: Tack Pin Seat Heater Seatback Cover Tack pins should not be beyond the seat. B57684 WhereEverybodyKnowsYourName 72−27 SEAT − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) 19. (a) (b) Hog Ring Pliers B50126 INSTALL FRONT SEATBACK COVER Install the seatback pad. Cover the top of the seatback pad with the seatback cover. (c) Install the 2 headrest supports. (d) Using hog ring pliers, install the seatback cover completely with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. (e) w/ Side airbag: Install the seatback cover bracket with the nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 48 in⋅lbf) B74515 (f) w/ Side airbag: Install the wire harness and clamp of the side airbag through the seat cushion cover end. NOTICE:
Be careful not to damage the cover. Clamp B75071 (g) As shown in the illustration, attach a rubber with new hog rings. (h) Using hog ring pliers, install new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. B75242 WhereEverybodyKnowsYourName 72−28 SEAT 20. (a) (b) − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) w/ Seat heater: INSTALL FRONT SEAT CUSHION HEATER ASSY LH Set the seat heater to the seat cushion cover. Install the seat heater to the seat cushion cover with the 24 tack pins. NOTICE: Do not substitute other metal parts for tack pins. Seat Heater A Tack Pin Tack Pin Tack Pin Seat Heater a Seatback Cover a−a c a b−b c−c a − a, c − c: a Tack pins should not be beyond the seat. a b − b: c a b b c ab c b b a c a a a c c c c b ba b c b a c c c c c b a c c c c b b a a a Seat Heater Listing Pocket B Seat Wire c Center Tack Pin C A: Install the tack pins under the wire. B: 15 mm (0.59 in.) C: Align the seat heater and the end of listing pocket. B57686 21. (a) (b) INSTALL FRONT SEAT CUSHION COVER Install the seat cushion pad to the seat cushion cover. Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring Pliers B50126 22. (a) (b) (c) INSTALL FRONT SEAT INNER BELT ASSY LH Install the inner belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Connect the connectors. Check that the inner seat belt moves smoothly. WhereEverybodyKnowsYourName 72−29 SEAT 23. (a) (b) (c) (d) (e) (f) 24. 25. 26. − FRONT SEAT ASSEMBLY (POWER SEAT TYPE) INSTALL FRONT SEAT ASSY LH Place the seat in the cabin. Connect the connectors under the seat. Tighten the 2 bolts on the front side of the seat. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Tighten the 2 bolts on the rear side of the seat. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the 2 seat track covers. Install the headrest. INSPECT POWER SEAT OPERATION (See page 72−4) w/ Seat heater: INSPECT SEAT HEATER OPRATION Passenger ’s seat only: INITIALIZE FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the zero point calibration or sensitivity check under the conditions listed below.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger’s seat is removed from the vehicle and then reinstalled to the vehicle.
Both the SRS warning light and the passenger airbag ON/OFF indicator light (”OFF”) come on.
The vehicle is brought to the work shop for repair due to an accident or a collision. (a) Zero point calibration procedure. (1) Adjust the seat position according to the conditions below. Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position (2) (3) (4) Connect the hand−held tester to the DLC3. Turn the ignition switch to the ON position. Perform the zero point calibration by following the directions on the tester screen. HINT: Refer to the hand−held tester operator’s manual for further details. (b) Sensitivity check procedure. (1) Connect the hand−held tester to the DLC3. (2) Apply a 30 kg weight (for example, a 30 kg of lead mass) onto the passenger seat. (3) Turn the ignition switch to the ON position. (4) Using the hand−held tester, perform the sensitivity check and confirm that the sensitivity is within the standard value. Standard value: 27 to 33 kg HINT:
When performing the sensitivity check, use a solid weight made from metal. The check result may not be accurate if a weight made from liquid is used.
When the sensitivity deviates from the standard value, retighten the bolts of the passenger seat, taking care not to deform the seat rail. Perform the sensitivity check again. If the sensitivity still does not stay within the standard value, replace the front RH seat assy. NOTICE: Do not place any objects on the seat. Perform the initialization by attaching a mass heavier than 2 kgs in the seatback pocket, seatback table installed by the user, or other appropriate location. WhereEverybodyKnowsYourName SEAT − 72−3 FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 720O2−01 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page All power seat functions do not operate 1. P/SEAT M−fuse 2. Front power seat switch 3. Wire harness 72−1 72−6 − Only slide operation function does not operate 1. Front power seat switch 2. Slide motor 3. Wire harness 72−6 72−6 − Only front vertical operation function does not operate 1. Front power seat switch 2. Front vertical motor 3. Wire harness 72−6 72−6 − Only rear vertical operation function does not operate 1. Front power seat switch 2. rear vertical motor 3. Wire harness 72−6 72−6 − Only reclining operation function does not operate 1. Front power seat switch 2. Reclining motor 3. Wire harness 72−6 72−6 − Only lumbar support operation function does not operate (driver’s seat only) 1. Power seat switch assy (Lumbar support) 2. Lumbar support adjuster motor 3. Wire harness 72−6 72−6 − WhereEverybodyKnowsYourName 72−30 SEAT − REAR SEAT ASSEMBLY REAR SEAT ASSEMBLY 720WS−01 COMPONENTS Rear Side Seat Back Assy RH Rear Seat Back Assy RH Rear Seat Back Assy LH 18 (184, 13) Rear Side Seat Back Assy LH 18 (184, 13) 18 (184, 13) 18 (184, 13) Rear Seat Back Hinge Sub−assy RH Rear Seat Back Hinge Sub−assy Center 18 (184, 13) 18 (184, 13) 18 (184, 13) Rear Door Scuff Plate RH 18 (184, 13) Rear Seat Back Hinge Sub−assy LH Rear Seat Cushion Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Rear Door Scuff Plate LH B86850 WhereEverybodyKnowsYourName 72−31 SEAT − REAR SEAT ASSEMBLY Rear Seat Headrest Assy Center Rear Seat Headrest Assy Rear Seat Headrest Support Rear Seat Headrest Support Rear Seat Back Lock Release Button Rear Seat Back Stop Button Grommet Separate Type Rear Seat Back Pad Rear Seat Back Lock Control Bezel Rear Seat Back Lock Release Button Rear Seat Headrest Assy Rear Seat Shoulder Belt Guide Center Rear Seat Headrest Support Separate Type Rear Seat Back Pad
Hog Ring Separate Type Rear Seat Back Cover Rear Seat Back Lock Assy RH Rear Seat Back Frame Sub−assy LH
Hog Ring Separate Type Rear Seat Back Cover Rear Seat Back Lock Assy LH Rear Seat Back Lock Control Bezel 20 (204, 15) 20 (204, 15) Rear Seat Armrest Assy Center
Hog Ring Bench Type Rear Seat Cushion Cover Rear Seat Cushion Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName B86851 72−32 SEAT − REAR SEAT ASSEMBLY 720WT−01 OVERHAUL HINT:



1. 2. COMPONENT: SEE PAGE 72−30. Installation is in the reverse order of removal. Only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03−2). REMOVE REAR DOOR SCUFF PLATE LH (SEE PAGE 76−22) REMOVE REAR DOOR SCUFF PLATE RH (SEE PAGE 76−22) 3. (a) REMOVE REAR SEAT CUSHION ASSY Pull up the 2 portions of the rear seat cushion assy as shown in the illustration and remove it. A: 100 mm (3.94 in.) or less NOTICE: In this case, hold the base of the clip up to prevent the cushion frame from being distorted. 100 mm (3.94 in.) Clip B86852 4. (a) REMOVE REAR SEAT BACK ASSY LH Remove the rear seat belt from the rear seat shoulder belt guide center. (b) Fold the rear seat assy LH forward and open the separate type rear seat back cover. Remove the 2 bolts and the rear seat back assy LH. B86853 (c) B86854 5. REMOVE REAR SEAT BACK ASSY RH HINT: Use the same procedures for the RH side and LH side. WhereEverybodyKnowsYourName 72−33 SEAT 6. (a) Claw − REAR SEAT ASSEMBLY REMOVE REAR SIDE SEAT BACK ASSY LH Remove the bolt and the rear side seat back assy LH as shown in the illustration. B86855 7. REMOVE REAR SIDE SEAT BACK ASSY RH HINT: Use the same procedures for the RH side and LH side. 8. (a) REMOVE REAR SEAT BACK HINGE SUB−ASSY LH Remove the bolt and the rear seat back hinge sub−assy LH. B86856 9. REMOVE REAR SEAT BACK HINGE SUB−ASSY RH HINT: Use the same procedures for the RH side and LH side. 10. (a) REMOVE REAR SEAT BACK HINGE SUB−ASSY CENTER Remove the 2 bolts and the rear seat back hinge sub− assy center. B86857 WhereEverybodyKnowsYourName 72−34 SEAT 11. (a) − REAR SEAT ASSEMBLY REMOVE BENCH TYPE REAR SEAT CUSHION COVER Remove the 56 hog rings and the bench type rear seat cushion cover. Hog ring B86858 Hog ring B86859 12. 13. REMOVE REAR SEAT HEADREST ASSY REMOVE REAR SEAT HEADREST ASSY CENTER 14. (a) REMOVE REAR SEAT BACK LOCK RELEASE BUTTON Remove the rear seat back lock release button as shown in the illustration. HINT: Use the same procedures for the RH side and LH side. B86860 WhereEverybodyKnowsYourName 72−35 SEAT 15. (a) − REAR SEAT ASSEMBLY REMOVE REAR SEAT SHOULDER BELT GUIDE CENTER Remove the 2 screws and the rear seat shoulder belt guide center. HINT: Use the same procedures for the RH side and LH side. B86861 16. (a) REMOVE REAR SEAT BACK LOCK CONTROL BEZEL Remove the screw and the rear seat back lock control bezel. HINT: Use the same procedures for the RH side and LH side. B86864 17. (a) REMOVE REAR SEAT BACK HINGE COVER Remove the rear seat back hinge cover. 18. (a) REMOVE REAR SEAT ARMREST ASSY CENTER Remove the bolt and the rear seat armrest assy center. 19. REMOVE REAR SEAT BACK STOP BUTTON GROMMET Remove the rear seat back stop button grommet. B86862 B86863 (a) B86868 WhereEverybodyKnowsYourName 72−36 SEAT − REAR SEAT ASSEMBLY 20. (a) REMOVE REAR SEAT HEADREST SUPPORT Disengage the separate type rear seat back cover and turn back the sides of the cover. (b) Turn back the separate type rear seat back cover and remove the 13 hog rings. B86865 Hog ring B86866 (c) Disengage the 6 claws and remove the 3 rear seat headrest supports. Claw B86867 21. REMOVE REAR SEAT HEADREST SUPPORT HINT: Use the same procedures for the RH side and LH side. WhereEverybodyKnowsYourName 72−37 SEAT 22. (a) Hog ring (a) Hog ring REAR SEAT ASSEMBLY REMOVE SEPARATE TYPE REAR SEAT BACK COVER Remove the 5 hog rings and the separate type rear seat back cover. B86869 23. Hog ring − REMOVE SEPARATE TYPE REAR SEAT BACK COVER Remove the 12 hog rings and the separate type rear seat back cover. B86870 B86871 24. (a) REMOVE REAR SEAT BACK LOCK ASSY LH Remove the 3 bolts and the rear seat back lock assy LH. B86872 25. REMOVE REAR SEAT BACK LOCK ASSY RH HINT: Use the same procedures for the RH side and LH side. WhereEverybodyKnowsYourName 72−38 SEAT 26. (a) − REAR SEAT ASSEMBLY INSTALL REAR SEAT BACK LOCK ASSY LH Install the rear seat back lock assy LH with the 3 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) B86872 27. INSTALL REAR SEAT BACK LOCK ASSY RH Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) HINT: Use the same procedures for the RH side and LH side. 28. INSTALL SEPARATE TYPE REAR SEAT BACK COVER (a) Using hog ring pliers, install the separate type rear seat back cover with 12 new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. Hog ring B86870 Hog ring B86871 Hog Ring Pliers B50126 WhereEverybodyKnowsYourName 72−39 SEAT − REAR SEAT ASSEMBLY 29. INSTALL SEPARATE TYPE REAR SEAT BACK COVER (a) Using hog ring pliers, install the separate type rear seat back cover with 5 new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. Hog ring B86869 Hog Ring Pliers B50126 WhereEverybodyKnowsYourName 72−40 SEAT − REAR SEAT ASSEMBLY 30. INSTALL BENCH TYPE REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the bench type rear seat cushion cover with 56 new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring Pliers B50126 Hog ring B86858 Hog ring B86859 WhereEverybodyKnowsYourName 72−41 SEAT 31. (a) − REAR SEAT ASSEMBLY INSTALL REAR SEAT BACK HINGE SUB−ASSY CENTER Install the rear seat back hinge sub−assy center with the 2 bolts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) B86857 32. (a) INSTALL REAR SEAT BACK HINGE SUB−ASSY LH Install the rear seat back hinge sub−assy LH with the bolt. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) B86856 33. INSTALL REAR SEAT BACK HINGE SUB−ASSY RH Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) HINT: Use the same procedures for the RH side and LH side. 34. (a) Claw 35. INSTALL REAR SIDE SEAT BACK ASSY LH Install the rear side seat back assy LH with the bolt. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) B86855 INSTALL REAR SIDE SEAT BACK ASSY RH Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) HINT: Use the same procedures for the RH side and LH side. 36. (a) (b) INSTALL REAR SEAT BACK ASSY LH Install the rear seat back assy LH with the 2 bolts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) Close the separate type rear seat back cover and put back the rear seat back assy LH. B88170 WhereEverybodyKnowsYourName 72−42 SEAT (c) − REAR SEAT ASSEMBLY Install the rear seat belt to the rear seat shoulder belt guide center. B86853 37. INSTALL REAR SEAT BACK ASSY RH Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) HINT: Use the same procedures for the RH side and LH side. WhereEverybodyKnowsYourName 72−4 SEAT − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 720O4−01 ON−VEHICLE INSPECTION Lumbar Support Function (driver’s seat only) 1. (a) Reclining Function Rear Vertical Function CHECK POWER SEAT FUNCTION Check the basic functions. (1) Operate the power seat switches and check to make sure each seat function works:
Sliding
Front vertical
Rear vertical
Reclining
Lumbar support (driver’s seat only) Sliding Function Front Vertical Function 2. B66896 CHECK POWER SEAT MOTOR ASSY (SLIDING, FRONT VERTICAL, REAR VERTICAL AND RECLINING FUNCTIONS) Check the PTC operation inside the power seat motor. (a) HINT: The PTC thermistor’s resistance increases when the power seat switch is held down even after the power seat has been moved to the maximum in one direction. after the resistance increases, current is shut off to prevent a short circuit. NOTICE: Perform steps (1) to (4) for the full range of motion for each power seat function. (1) Choose a power seat function. Operate the power seat switch and move the seat to the maximum in one direction. Keep the seat in that position for approximately 60 seconds. (2) Operate the power seat switch again and continue to try to move the seat in the same direction as in step (1). Measure the amount of time elapsed before the electrical current is automatically cut. Check if electrical current has shut off by making sure the sound of the motor has stopped. Standard: 4 to 90 seconds (3) After the current has stopped, release the power seat switch and wait for approximately 60 seconds. (4) Operate the same power seat switch and move the seat to the opposite extreme of the direction in step (1). Check that the motor operates. (5) Repeat steps (1) to (4) for the remaining power seat functions. WhereEverybodyKnowsYourName SEAT − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 3. 72−5 Driver’s seat only: CHECK LUMBAR SUPPORT ADJUSTER ASSY LH (a) Check the PTC operation inside the power seat motor. NOTICE: The inspection should be performed with the seat installed in the vehicle. (1) Operate the lumbar support switch and move the lumbar support to either the foremost or rearmost position. Keep the seat in that position for approximately 60 seconds. (2) Operate the lumbar support switch again and continue to try to move the lumbar support in the same direction as in step (1). Measure the amount of time elapsed before the electrical current is automatically cut. Check if electrical current has shut off by making sure the sound of the motor has stopped. Standard: 4 to 90 seconds (3) After the current has stopped, release the lumbar support switch and wait for approximately 60 seconds. (4) Operate the lumbar support switch and move the seat to the opposite extreme of the direction in step (1). Check that the motor operates. WhereEverybodyKnowsYourName 72−6 SEAT − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 720O3−01 INSPECTION 1. Driver’s Seat: Front Power Seat Switch (a) Front Vertical Switch Reclining Switch Slide Switch Rear Vertical Switch Driver’s seat: INSPECT FRONT POWER SEAT SWITCH Check the resistance between the terminals when each switch is operated. Standard: Slide switch Tester Connection Switch Condition Specified Condition 1−9 FRONT Below 1 Ω 4−6 FRONT Below 1 Ω 4−6 OFF Below 1 Ω 4−9 OFF Below 1 Ω 1−6 REAR Below 1 Ω 4−9 REAR Below 1 Ω Tester Connection Switch Condition Specified Condition 1 − 10 UP Below 1 Ω 4−5 UP Below 1 Ω 4−5 OFF Below 1 Ω 4 − 10 OFF Below 1 Ω 1−5 DOWN Below 1 Ω 4 − 10 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1−7 UP Below 1 Ω 4−8 UP Below 1 Ω 4−7 OFF Below 1 Ω 4−8 OFF Below 1 Ω 1−8 DOWN Below 1 Ω 4−7 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1−3 FRONT Below 1 Ω 2−4 FRONT Below 1 Ω 2−4 OFF Below 1 Ω 3−4 OFF Below 1 Ω 1−2 REAR Below 1 Ω 3−4 REAR Below 1 Ω Front vertical switch B60011 Rear vertical switch Reclining switch If the result is not as specified, replace the switch. WhereEverybodyKnowsYourName SEAT Passenger’s Seat: Front Power Seat Switch Front Vertical Switch Reclining Switch Rear Vertical Switch Slide Switch 2. (a) − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 72−7 Passenger ’s seat: INSPECT FRONT POWER SEAT SWITCH Check the resistance between the terminals when each switch is operated. Standard: Slide switch Tester Connection Switch Condition Specified Condition 1−9 FRONT Below 1 Ω 4−6 FRONT Below 1 Ω 4−6 OFF Below 1 Ω 4−9 OFF Below 1 Ω 1−6 REAR Below 1 Ω 4−9 REAR Below 1 Ω Tester Connection Switch Condition Specified Condition Front vertical switch B75243 1−5 UP Below 1 Ω 4 − 10 UP Below 1 Ω 4−5 OFF Below 1 Ω 4 − 10 OFF Below 1 Ω 1 − 10 DOWN Below 1 Ω 4−5 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 4−7 UP Below 1 Ω 1−8 UP Below 1 Ω 4−7 OFF Below 1 Ω 4−8 OFF Below 1 Ω 4−8 DOWN Below 1 Ω 1−7 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1−3 FRONT Below 1 Ω 2−4 FRONT Below 1 Ω 2−4 OFF Below 1 Ω 3−4 OFF Below 1 Ω 1 −2 REAR Below 1 Ω 3−4 REAR Below 1 Ω Rear vertical switch Reclining switch If the result is not as specified, replace the switch. WhereEverybodyKnowsYourName 72−8 SEAT 3. Power Seat Switch Assy (Lumbar Support) (a) HOLD RELEASE − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) INSPECT POWER SEAT SWITCH ASSY(LUMBAR SUPPORT) Driver’s seat only: Check the resistance between the terminals when the switch is operated. Standard: Tester Connection Switch Condition Specified Condition 1−2 HOLD Below 1 Ω 3−4 HOLD Below 1 Ω 1−2 OFF Below 1 Ω 4−5 OFF Below 1 Ω 1−3 RELEASE Below 1 Ω 4−5 RELEASE Below 1 Ω If the result is not as specified, replace the switch assy. B68208 4. (a) Slide Motor Counter− clockwise Clockwise Driving Axis B73550 INSPECT FRONT SEAT ADJUSTER ASSY Check operation of the slide motor. (1) Check if the motor rotates smoothly when the battery is connected to the slide motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (−) → 1 Clockwise Battery positive (+) → 1 Battery negative (−) → 2 Counterclockwise If the result is not as specified, replace the slide motor. Front Vertical Motor (b) Clockwise Counter− clockwise Driving Axis B73550 Check operation of the vertical motor. (1) Check if the motor rotates smoothly when the battery is connected to the vertical motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (−) → 1 Clockwise Battery positive (+) → 1 Battery negative (−) → 2 Counterclockwise If the result is not as specified, replace the vertical motor. WhereEverybodyKnowsYourName SEAT (c) Rear Vertical Motor Clockwise Counter− clockwise Driving Axis B73550 − FRONT POWER SEAT CONTROL SYSTEM (From July, 2003) 72−9 Check operation of the rear vertical motor. (1) Check if the motor rotates smoothly when the battery is connected to the rear vertical motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (−) → 1 Clockwise Battery positive (+) → 1 Battery negative (−) → 2 Counterclockwise If the result is not as specified, replace the rear vertical motor. (d) Reclining Motor Counter− clockwise Clockwise Driving Axis B73550 Check operation of the reclining motor. (1) Check if the motor rotates smoothly when the battery is connected to the reclining motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (−) → 1 Clockwise Battery positive (+) → 1 Battery negative (−) → 2 Counterclockwise If the result is not as specified, replace the lifter motor. 5. (a) Lumbar Support Adjuster Motor Counter− clockwise Clockwise Driving Axis B68209 INSPECT LUMBAR SUPPORT ADJUSTER ASSY LH Driver’seat only: Check operation of the lumbar support adjuster motor. (1) Check if the motor rotates smoothly when the battery is connected to the lumbar support adjuster motor connector terminals. Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (−) → 2 Clockwise Battery positive (+) → 2 Battery negative (−) → 1 Counterclockwise If the result is not as specified, replace the adjuster motor. WhereEverybodyKnowsYourName 73−1 THEFT DETERRENT & DOOR LOCK − POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM 73083−02 ON−VEHICLE INSPECTION 1. (a) DOOR LOCK FAIL−SAFE When a malfunction in the door control switch (manual switch, interlocked operation with key) has been detected, door LOCK/UNLOCK operations become disabled. 2. CHECK ELECTRICAL DOOR LOCK OPERATION (a) Check the basic function. (1) Check that all doors lock when the door control switch (for manual operation) is turned to LOCK and all doors unlock when turned to UNLOCK. (2) Check that all doors lock when the driver side door lock key cylinder is turned to LOCK and all doors unlock when turned to UNLOCK from outside the vehicle. (b) Check the key confinement prevention function. NOTICE: In order to prevent the key from being locked−in, the inspection should be made with the driver side door glass open. (1) Insert the key into the ignition key cylinder. (2) With the driver side door open, check that all doors unlock immediately after the door lock knob for the driver side door is turned to LOCK. (3) With the driver side door open, check that all doors unlock immediately after the door control switch (for manual operation) is turned to LOCK. (4) With the driver side door open, turn the driver side door lock knob to LOCK and hold it for 2 seconds or more, and then close the driver side door. Then, check that all doors unlock. (c) Check the security function. (1) Close all doors with the driver side door glass open so that the door control switch can be operated from outside the vehicle. (2) Pull out the key, open the driver side door, and close and lock the door without using the key. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (3) Pull out the key, close and lock the driver side door by key operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (4) Pull out the key, close the driver side door and lock the door by wireless door lock operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. HINT: Check that the security function is canceled under the conditions below:
The ignition switch is turned ON.
The driver side door is unlocked using the key.
The door control switch (for manual operation) is turned to UNLOCK after the door control knob is turned to UNLOCK manually.
The doors are unlocked by wireless operation. WhereEverybodyKnowsYourName 73−2 THEFT DETERRENT & DOOR LOCK (d) − POWER DOOR LOCK CONTROL SYSTEM Check the illumination function. (1) Set the room light switch in the DOOR position. (2) With all doors locked, check that all doors unlock when the driver side door lock cylinder is turned to UNLOCK using the key. At the same time, the room light comes on. (3) The room light goes off in approximately 15 seconds if doors have not been opened for a while. WhereEverybodyKnowsYourName 73−11 THEFT DETERRENT & DOOR LOCK − KEY UNLOCK WARNING SYSTEM KEY UNLOCK WARNING SYSTEM 7307W−04 PROBLEM SYMPTOMS TABLE Symptom Key reminder buzzer does not sound Suspected Area 1. 2. 3. 4. 5. Unlock warning switch Front door courtesy lamp switch Instrument panel J/B (Body ECU) Combination meter Wire harness WhereEverybodyKnowsYourName See page 73−15 73−15 73−13 − − 73−12 THEFT DETERRENT & DOOR LOCK − KEY UNLOCK WARNING SYSTEM 7307U−04 LOCATION Unlock Warning Switch Assy Combination Meter (Warning Buzzer) Instrument Panel J/B (Body ECU) Front Door Courtesy Lamp Switch B56177 WhereEverybodyKnowsYourName 73−13 THEFT DETERRENT & DOOR LOCK − KEY UNLOCK WARNING SYSTEM 7307V−03 ON−VEHICLE INSPECTION 1. (a) (b) 2. (a) (b) FUNCTION CHECK Check that the key reminder warning buzzer sounds. (1) With the driver side door closed, insert the key into the ignition key cylinder, and then turn the key to LOCK or ACC. (2) Then, check that the buzzer sounds intermittently after the driver side door is opened. Check that the key reminder warning buzzer stops. (1) Check that the buzzer stops when any of the following operations is performed while the buzzer is sounding.
Close the driver side door (front door courtesy lamp switch is OFF).
Turn the ignition switch ON.
Pull out the key from the ignition key cylinder. CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSY (BODY ECU) (LEFT SIDE) Disconnect the B6 body ECU connector. Check the continuity of the connector terminal. B6 B6 B7 B8 B8 B7 B56678 B58627 Standard: Symbols (Terminal No.) Wiring color KSW (B6−19) ⇔ Body ground L⇔ − Condition No key in ignition key cylinder → Key inserted Specified condition No continuity→Continuity If the continuity is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the connector. (d) Check the voltage of the connector terminal. Standard: Symbols (Terminal No.) Wiring color DCTY (B8−1) ⇔ Body ground R−G ⇔ − Condition Driver side door fully closed → Opened If the value is not as specified, the instrument panel J/B may malfunction. WhereEverybodyKnowsYourName Specified condition 10 − 14 V → 0 V 73−14 THEFT DETERRENT & DOOR LOCK 3. (a) (b) − KEY UNLOCK WARNING SYSTEM CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSY (BODY ECU) (REAR SIDE) Disconnect the 2F and 2G connectors. Check the voltage or continuity between the connector terminals. 2R 2B 2A 2C 2D 2B 2A 2C 2D 2E 2F 2G From Instrument Panel Wire 2K 2J 2H 2G 2F 2E 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 2J 2H 2K B58626 Standard: Symbols (Terminals No.) Wiring color Condition Specified condition B (2F−7) ⇔ Body ground R⇔− Constant 10 − 14 V BDR1 (2G−14) ⇔ Body ground L−W ⇔ − Constant 10 − 14 V GND (2R−8) ⇔ Body ground W−B ⇔ − Constant Continuity If the result is not as specified, there may be a malfunction on the wire harness side. WhereEverybodyKnowsYourName 73−15 THEFT DETERRENT & DOOR LOCK − KEY UNLOCK WARNING SYSTEM 7307X−03 INSPECTION 1. (a) OFF INSPECT UN−LOCK WARNING SWITCH ASSY Check the switch continuity. Standard: Terminals No. ON 1⇔2 Condition Specification Switch pressed in Continuity Switch not pressed in No continuity If the continuity is not as specified, replace the switch. B51903 2. (a) INSPECT FRONT DOOR COURTESY LAMP SWITCH ASSY Check the switch continuity. Standard: Terminals No. 1 1 ⇔ Switch body Condition Specification FREE Continuity PUSH No continuity If the continuity is not as specified, replace the switch. B32309 WhereEverybodyKnowsYourName 73−16 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) ENGINE IMMOBILISER SYSTEM (2AZ−FE(PZEV)) 730EO−07 REGISTRATION 1. (a) (b) DESCRIPTION OF CODE REGISTRATION When adding master keys and sub−keys (Additional registration). (1) Register the key code (immobiliser code) in the transponder key ECU. See step Transponder key ECU 3. When replacing the transponder key ECU (New registration). (1) Register the key code (immobiliser code) in the transponder key ECU. (2) (c) Target ECU Target ECU See step Transponder key ECU 2. Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See step ECM 5. When replacing the ECM. (1) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See step Transponder key ECU 5. WhereEverybodyKnowsYourName 73−17 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) 2. KEY REGISTRATION IN AUTOMATIC REGISTRATION (New Registration) (a) The new registration of the key codes (immobiliser codes) is made automatically. HINT:
When you install a new transponder key ECU, the key codes (immobiliser codes) must be registered.
A new transponder key ECU starts in the automatic key code registration mode. In this mode, a maximum of 4 key codes for 3 master keys and 1 sub−key can be registered. Since the transponder key ECU can distinguish types of keys, the registration order is not specified. Automatic Key Code Registration (New Registration): Security Indicator START BLINKING (Until the first key is inserted.) Insert the key in the ignition key cylinder. OFF (Approx. 1 sec.) Registration begins (The registration is completed approx. 1 sec. after the key is inserted). Remove the key. ON (When the maximum number of key codes are registered, the security indicator re- Yes mains OFF until the Register another key? last key registered is removed. After it is removed, the security indicator starts No END WhereEverybodyKnowsYourName blinking.) 73−18 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) HINT:
When no key is inserted in the ignition key cylinder in the automatic key code registration mode, the security indicator remains on.
When the immobiliser system is operates normally and the key is pulled out, the security indicator blinks. NOTICE: If the key code registration has failed in the automatic key code registration mode, code 2−1 will be output from the security indicator. Trying to re−register an already registered key will cause code 2−2 to be output when the key is inserted. The output details are shown below. Security Indicator: 0.2 sec. ON Normal (Immobiliser system is operating normally.) OFF 1.8 sec. 0.25 sec. 1 sec. ON Code 2−1 OFF 0.25 sec. 0.5 sec. 0.25 sec. 1 sec. ON Code 2−2 OFF 0.25 sec. 0.5 sec. (b) Finish the automatic key code registration mode. The automatic key code registration mode can be forced to end when at least 1 key code (immobiliser code) for the master key has been registered. (1) Turn the ignition switch ON/OFF alternately 5 times within 10 seconds using the already registered master key. WhereEverybodyKnowsYourName 73−19 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) 3. REGISTRATION OF ADDITIONAL KEY (Additional Registration) HINT:
A maximum of 5 master key codes and 3 sub−key codes can be registered.
Registration mode will end if each step is not completed within the specified time.
When the ignition cylinder or the key cylinder set is replaced, remove the transmitter module from the original master key in which a transmitter is built. Then install this transmitter module to a new key and use it as master key. If necessary, use this master key to register other keys. WhereEverybodyKnowsYourName 73−20 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) Additional Registration: Security Indicator START BLINKING (Until the first key is inserted.) Insert the already registered master key in the ignition key cylinder and turn the ignition switch ON. OFF Hand−held tester operation: 1. Select ”CAMRY” from the menu. 2. Select ”IMMOBILISER”. 3. Select ”ID UTILITY”. 4. Select ”TRANSP CODE REG”. After the above operation, proceed to the next step according to the prompts on the tester screen. ON Within 120 sec. Within 20 sec. after the tester instruction Remove the master key. Within 10 sec. Insert the key to be registered in the ignition key cylinder. BLINKING After 60 sec. the key is registered (The security indicator goes off). OFF END HINT:
A brief outline of procedures for key code registration is shown on this page. For detailed information, please refer to the prompts on the screen of the hand−held tester.
When the immobiliser system is operating normally and the key is pulled out, the security indicator blinks. NOTICE: If the key code registration has failed in the automatic key code registration mode, code 2−1 will be output from the security indicator. Trying to re−register an already registered key will cause code 2−2 to be output when the key is inserted. The output details are shown in step 2 (New Registration). WhereEverybodyKnowsYourName 73−21 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) 4. ERASURE OF KEY CODE HINT:
All key codes are erased except for the master key which is used for erasure operation. In order to use a key for which the code has been erased, it is necessary to register the key code again.
Registration operation will be cancelled if each step is not completed within the specified time. Erasing Key Code: Security Indicator START BLINKING (Until the first key is inserted.) Insert the already registered master key in the ignition key cylinder and turn the ignition switch ON. OFF Hand−held tester operation: 1. Select ”CAMRY” from the menu. 2. Select ”IMMOBILISER”. 3. Select ”ID UTILITY”. 4. Select ”TRANSP CODE ERS”. After the above operation, proceed to the next step in accordance with the prompts on the tester screen. ON for 1 sec. then OFF Within 120 sec. Within 10 sec. after the tester indicates Remove the master key. BLINKING END HINT:

A brief outline of procedures for key code registration is shown on this page. For detailed information, please refer to the prompts on the screen of the hand−held tester. When the immobiliser system is operating normally and the key is pulled out, the security indicator blinks. WhereEverybodyKnowsYourName 73−22 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (2AZ−FE(PZEV)) 5. ECU COMMUNICATION ID REGISTRATION NOTICE:
The ECU communication ID should be registered when the transponder key ECU and/or the ECM is replaced, in order to match these ECM COMMUNICATION ID.
The engine cannot be started unless the ECM COMMUNICATION ID matches. (a) Register the ECU communication ID. (1) After the transponder key ECU and/or the ECM is replaced, turn the ignition switch ON (the engine is not running). (2) Short the Tc and CG terminals of the DLC3 and leave it as is for 30 minutes. (3) Check that the engine starts. WhereEverybodyKnowsYourName THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) 73−23 ENGINE IMMOBILISER SYSTEM (Except 2AZ−FE(PZEV)) 73086−03 REGISTRATION 1. (a) KEY REGISTRATION IN AUTOMATIC REGISTRATION Registration of a new transponder key.
This must be done when you install a new ECM.
The new ECM is in the automatic key code registration mode. The number of key codes for this ECM is already fixed, and so it can be registered. On this type of vehicle, up to 3 key codes can be registered.
In the automatic registration mode, the key registered last becomes the sub−key. START Security indicator continues blinking until the first key is inserted. The indicator lights up after the key registration. Insert the key in the key cylinder. Security indicator ON Under registration Security indicator OFF Registration completion Remove the key. Yes Will you register the next key? No Security indicator light is ON (After the last key (sub−key) has been registered, the indicator remains OFF until removing the key. And after removing the key, the indicator blinks.) END WhereEverybodyKnowsYourName 73−24 THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) HINT:
When no key is inserted in the key cylinder in the automatic registration mode, the security indicator always lights on. When the immobiliser system operates normally and the key is pull out, the security indicator blinks. When key code registration could not be performed in the automatic registration mode, code 2−1 is output from the security indicator. And when inserting the already registered key, code 2−2 is output.

Blinks 1.2 Sec. 0.8 Sec. (b) Code 2−1 0.25 Sec. 1 Sec. 0.25 Sec. 0.5 Sec. Code 2−2 0.25 Sec. 1 Sec. 0.25 Sec.0.5 Sec. Automatic registration mode completion If finishing the mode forcibly after registering more than 1 key codes in the automatic registration mode, perform the following procedures. After 1 more key code has been registered with the master key, perform step (1) or (2) without pulling the key out or inserting the already registered key. (1) Depress and release the brake pedal 5 times or more within 15 seconds. (2) With the hand−held tester, require the automatic registration mode completion. WhereEverybodyKnowsYourName THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) 73−25 2. REGISTRATION OF ADDITIONAL KEY There are 2 ways for registration of additional master key; one way is depressing the brake pedal and acceleration pedal and the other way is using the hand−held tester. HINT:
It is possible to register up to 7 master key codes including the already registered key code.
When any operation time described below is over, registration mode will be stopped forcibly.
When the next procedure is started while the timer is working, the timer stops working, then the next timer starts.
When replacing ”Ignition Cylinder Key Set” or ”Lock Cylinder Set” and register according to the following procedure using the original master key. However, after the registration of the additional master key, the original master key and the original sub−key are not necessary any more, and there fore registration of those key codes should be deleted. (1) Depressing the brake pedal and acceleration pedal: Insert the already registered master key in the key cylinder Depress and release the acceleration pedal 5 times. Depress and release the brake pedal 6 times, and remove the master key. Within 15 sec. Within 20 sec. Within 10 sec. Insert a key to be registered in key cylinder. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 sec. After 60 sec. additional master key is registration is complete. (Security indicator is OFF) Yes Will you register the next key? No The registration mode is complete when pulling out the key and depressing and releasing the brake pedal once or more within 10 secs. after indicator has been off or 10 sec. have passed. WhereEverybodyKnowsYourName Within 10 sec. 73−26 (2) THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) Using the hand−held tester: Insert the already registered master key in the key cylinder and turn the ignition switch ON. Using the hand−held tester, select the master key registration. Within 20 sec. Remove the master key. Within 10 sec. Insert a key to be registered in the key cylinder. (Security indicator blinks) After 60 sec., additional master key registration is complete. (Security indicator OFF) The registration mode is complete when pulling out the key and depressing and releasing the brake pedal once or more within 10 sec. after indicator has been off or 10 sec. have passed. HINT: Follow the screen of the hand−held tester for more detailed procedure. WhereEverybodyKnowsYourName THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) 73−27 3. ERASURE OF KEY CODE There are 2 ways for erasure of transponder key codes; one way is depressing the brake pedal and acceleration pedal and the other way is using hand−held tester. HINT:
Delete all the other master and sub−key codes than a master key code to use the erasing operation. When using the key which was used for deletion, it is necessary to register the code again.
When any operation time described below is over, registration mode will be stopped forcibly.
When the next procedure is started while the timer is working, the timer stops working, then the next timer starts. (1) Depressing the brake pedal and acceleration pedal: 1. Insert the already registered master key in the key cylinder. Within 15 sec. 2. Depress and release the acceleration pedal 6 times. Within 20 sec. 3. Depress and release the brake pedal 7 times. Within 10 sec. 4. Remove the master key. END (Key code erased) HINT: When the key cannot be pulled out in step 4, key code deletion is canceled. WhereEverybodyKnowsYourName 73−28 (2) THEFT DETERRENT & DOOR LOCK − ENGINE IMMOBILIZER SYSTEM (Except 2AZ−FE(PZEV)) Using the hand−held tester: 1. Insert the already registered master key in the key cylinder and turn the ignition switch ON. 2. Require the key code deletion on the hand−held tester. (Security indicator blinks) Within 10 sec. 3. Remove the master key. END (Key code erased) HINT:
When the key cannot be pulled out in step 3, key code deletion is canceled. (Security indicator is OFF.)
Follow the screen of the hand−held tester for more detailed procedure. WhereEverybodyKnowsYourName 73−29 THEFT DETERRENT & DOOR LOCK − THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM 7307L−02 ON−VEHICLE INSPECTION 1. (a) (b) (c) OUTLINE OF THEFT DETERRENT SYSTEM When the theft deterrent system detects that the vehicle is being tampered with, the system sets off the alarm, causing the horns to sound and the lights to light up or blink in order to alert people around the vehicle to the theft. The theft deterrent system has 2 modes; one is active arming mode and the other is passive arming mode. Passive arming mode can be switched ON/OFF by the specified method (See step 6). Each mode has 4 states; disarmed state, arming preparation state, armed state, alarm sounding state. (1) Disarmed state:  The alarm function is not operating.  The theft deterrent system is not operating. (2) Arming preparation state:  The time until the system goes into the armed state.  The theft deterrent system is not operating. (3) Armed state:  The theft deterrent system is operating. HINT: If the vehicle remains in a condition that sets off the alarm (any door remains open, engine hood remains open, luggage compartment door remains open, ignition switch remains directly connected) after the alarm ends, the alarm will be set off repeatedly a maximum of 10 times for every one of the above specified conditions. Alarm time: (60 sec.
5 sec.) x 10 WhereEverybodyKnowsYourName 73−30 THEFT DETERRENT & DOOR LOCK (4) − THEFT DETERRENT SYSTEM Alarm sounding state: When the theft deterrent system detects that the vehicle is being tampered with while in the armed state, the system causes the horns to sound and the lights to light up or blink in order to alert people around the vehicle to the theft. Refer to the table below for the alarm method and time: Alarm Method Alarm Time Headlight Blinking (cycle of 0.4 sec.) Taillight Blinking (cycle of 0.4 sec.) Hazard Warning Light Blinking (cycle of flasher relay) Room Light Illuminating Vehicle Horn Sounding (cycle of 0.4 sec.) Theft Deterrent Horn Sounding (cycle of 0.4 sec.) 60 sec.
5 sec. (maximum 10 times) HINT: If either of the doors is unlocked and there is also no key in the ignition key cylinder during the armed state, a forced door lock signal will be output (See step 4). WhereEverybodyKnowsYourName 73−31 THEFT DETERRENT & DOOR LOCK 2. − THEFT DETERRENT SYSTEM ACTIVE ARMING MODE Disarmed state (No key inserted in ignition cylinder.) Performing any of the following will cause the system to go into arming preparation state:
With all doors and engine hood closed, lock all doors by key operation.
With all doors and engine hood closed, lock all doors by wireless operation.
With all doors and engine hood closed, open and close any door and the engine hood then close and lock all doors and engine hood. Arming preparation state Performing any of the following will cause the system to return to disarmed state:
Open any door and the engine hood.
Unlock any door.
Insert key into ignition key cylinder.
Reconnect battery. Performing the following will cause the system to go into armed state:
With all doors and engine food closed, lock all doors. Allow 30 (
1.5) sec. to elapse Armed state Performing any of the following will cause the system to return to disarmed state:
Unlock any door by wireless operation.
Unlock any door by key operation.
Insert key into ignition key cylinder and turn ignition switch ON. Performing any of the following will cause the system to go into alarm sounding state:
Open engine hood.
Reconnect battery.
Open any door.
Unlock any door without key or wireless operation.
Turn ignition switch ON. Alarm sounding state When the system detects tampering, horns sound and lights illuminate or blink in order to alert people around the vehicle to the theft. After 60 (
5) sec., alarm stops and system returns to armed state. Performing any of the following will cause the system to return to disarmed state:
Unlock any door by wireless operation.
Unlock any door by key operation.
Insert key into ignition key cylinder and turn ignition switch from OFF to ON. WhereEverybodyKnowsYourName 73−32 THEFT DETERRENT & DOOR LOCK 3.         − THEFT DETERRENT SYSTEM PASSIVE ARMING MODE Passive arming mode can be switched ON/OFF by the specified method (See step 6). The mode set initially (shipped from factory) is active arming mode (not passive arming mode). During passive arming mode, the theft deterrent system goes into the armed state even if the doors are not locked. Passive arming mode starts the alarm control after the key is removed from the ignition key cylinder and the doors are closed. Detecting that the doors are unlocked does not set off the alarm during passive arming mode. A forced door lock signal is not output during passive arming mode (See step 4). When the theft deterrent system detects that the doors are opened during passive arming mode, the alarm is not set off immediately because an entry delay time is set. If either of the following conditions is fulfilled during passive arming mode, the theft deterrent system will switch to active arming mode.  With all doors and engine hood closed, lock all doors by key operation.  With all doors and engine hood closed, lock all doors by wireless operation.  With all doors and engine hood closed, open and close any door and the engine hood then close and lock all doors and engine hood. WhereEverybodyKnowsYourName 73−33 THEFT DETERRENT & DOOR LOCK − THEFT DETERRENT SYSTEM Disarmed state (A) Performing the following will cause the system to go into disarmed state (B):
Remove key from ignition key cylinder, close driver side door, then turn ignition switch OFF. Disarmed state (B) Performing any of the following will cause the system to return to disarmed state (A):
Unlock all doors by wireless operation.
Unlock all doors by key operation.
Insert key in ignition key cylinder.
Reconnect battery.
Turn ignition switch from OFF to ON. Performing the following will cause the system to go into arming preparation state:
Close all doors. Arming preparation state Performing the following will cause the system to return to disarmed state (B):
Open any door and the engine hood. Performing any of the following will cause the system to return to disarmed state (A):
Unlock all doors by wireless operation.
Insert key into ignition key cylinder.
Reconnect battery
Turn ignition switch from OFF to ON.
Unlock all doors by key operation. Performing the following will cause the system to go into armed state:
With all doors and engine hood closed, lock all doors. Allow 30 (
1.5) sec. to elapse. Armed state Performing any of the following will cause the system to return to disarmed state (A):
Unlock all doors by wireless operation
Unlock all doors by key operation.
Insert key into ignition key cylinder and turn ignition switch from OFF to ON Performing any of the following will cause the system to go into alarm sounding state:
Open any door and allow entry delay time to pass.
Open engine hood.
Open luggage compartment door without key and wireless operation.
Reconnect battery. Continued from next page Continued on next page WhereEverybodyKnowsYourName 73−34 THEFT DETERRENT & DOOR LOCK Continued on previous page − THEFT DETERRENT SYSTEM Continued from previous page Alarm sounding When the system detects tampering, horns sound and lights illuminate or blink in order to alert people around the vehicle to the theft. After 60 (
5) sec., alarm stops and system returns to armed state. Performing any of the following will cause the system to return to disarmed state (A):
Unlock all doors by wireless operation.
Unlock all doors by key operation.
Insert key into ignition key cylinder and turn ignition switch from OFF to ON *3: When any door is opened while all the doors are closed during the armed state in passive arming mode, the entry delay time starts. If the switch condition (armed state → disarmed state) is fulfilled during the entry delay time, the theft deterrent system will return to the disarmed state. However, if the switch condition to the disarmed state is not fulfilled, the theft deterrent system will recognize it as a theft and go into alarm sounding state. Entry delay time of 0, 14 or 30 sec. can be selected by the customizing function. WhereEverybodyKnowsYourName 73−35 THEFT DETERRENT & DOOR LOCK − THEFT DETERRENT SYSTEM 4. (a) FORCED DOOR LOCK CONTROL The forced door lock control prevents the vehicle from being tampered with. Immediately after a door is unlocked (alarm starts), the door is forced to lock by a forced door lock signal. (1) Conditions that force the doors to lock: When no key is in the ignition key cylinder and 0.4 second has elapsed after the previous output of a forced door lock signal, the doors will be forced to lock if any of the following conditions is fulfilled.  The theft deterrent system is in the armed state of active arming mode.  All the doors are locked. → Any door is unlocked.  Any door is unlocked state. 5. (a) SECURITY INDICATOR LIGHT OUTPUT The theft deterrent ECU outputs a signal to light up the security indicator light, according to the state of the theft deterrent system. However, some of the actual lighting conditions of the security indicator light are different from the outputs of the theft deterrent ECU. Security indicator light State of theft deterrent system*1 Output signals from the theft deterrent ECU Actual lighting condition OFF (Immobiliser system unset) BLINKING (Immobiliser system set) Disarmed state OFF Arming preparation state ON ON Armed state OFF BLINKING Alarm sounding state ON ON *1: Common to active arming mode and passive arming mode Blinking cycle: Time Security indicator light 0.2 sec. ON 1.8 sec. OFF HINT: When the immobiliser system is set, the security indicator light blinks during the disarmed state and the armed state, due to the output signals from the immobiliser system. WhereEverybodyKnowsYourName 73−36 THEFT DETERRENT & DOOR LOCK 6. − THEFT DETERRENT SYSTEM CHANGING METHOD OF PASSIVE MODE (ON or OFF) Remove the ignition key from key cylinder. All the doors and luggage compartment door except engine hood are closed and unlocked. Any of doors is locked and unlocked by turns 3 times by the key or remote control. Input to the vehicle Output from the vehicle Within 30 sec. Driver’s side door is opened. Driver’s side knob for door lock is locked and unlocked 3 times. Within 2 sec. The system starts force lock at once after 2 sec. Driver’s side knob for door lock is unlocked. Within 20 sec. Driver’s side door is closed and opened 2 times Driver’s side door is closed and opened 3 to 5 times 3 times Driver’s side knob for door lock is locked and unlocked. The system starts force lock at once after 2 secs. 5 times Driver’s side knob for door lock is locked and unlocked. * 0 sec. Within 2 sec. 4 times * 14 sec. * 30 sec. The system starts force lock at once after 2 sec. PASSIVE MODE OFF (ACTIVE MODE ON) PASSIVE MODE ON HINT:
Initial mode is PASSIVE MODE OFF.
If the ignition switch is turned ON, changing operation will be canceled. *: Entry delay time WhereEverybodyKnowsYourName 73−3 THEFT DETERRENT & DOOR LOCK − POWER DOOR LOCK CONTROL SYSTEM 73082−02 INSPECTION 1. (a) INSPECT FRONT DOOR W/MOTOR LOCK ASSY RH Inspect operation of the door lock motor. Standard: Measurement condition Operation Battery positive − Terminal 4 Battery negative − Terminal 1 Lock Battery positive − Terminal 1 Battery negative − Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Standard: Unlock Terminals No. Lock 7⇔8 Door lock position Specification Lock No continuity Unlock Continuity If the continuity is not as specified, replace the door lock assembly. B56102 2. (a) Lock Unlock INSPECT FRONT DOOR W/MOTOR LOCK ASSY LH Inspect the door lock assembly continuity. Standard: Terminals No. Switch position Specified condition 9−7 Lock Continuity − OFF No continuity 10 − 7 Unlock Continuity If the continuity is not as specified, replace the door lock assembly. B56797 WhereEverybodyKnowsYourName 73−4 THEFT DETERRENT & DOOR LOCK (b) − POWER DOOR LOCK CONTROL SYSTEM Inspect operation of the door lock motor. Standard: Measurement condition Operation Battery positive − Terminal 4 Battery negative − Terminal 1 Lock Battery positive − Terminal 1 Battery negative − Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (c) Inspect the position switch continuity. Standard: Terminals No. Unlock Door lock position Specification Lock No continuity Unlock Continuity 7⇔8 Lock If the continuity is not as specified, replace the door lock assembly. B56798 3. (a) INSPECT REAR DOOR W/MOTOR LOCK ASSY RH Inspect operation of the door lock motor. Standard: Measurement condition Operation Battery positive − Terminal 4 Battery negative − Terminal 1 Lock Battery positive − Terminal 1 Battery negative − Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Standard: Terminals No. Unlock Lock 6⇔9 Door lock position Specification Lock No continuity Unlock Continuity If the continuity is not as specified, replace the door lock assembly. B56799 WhereEverybodyKnowsYourName 73−5 THEFT DETERRENT & DOOR LOCK 4. (a) − POWER DOOR LOCK CONTROL SYSTEM INSPECT REAR DOOR W/MOTOR LOCK ASSY LH Inspect operation of the door lock motor. Standard: Measurement condition Operation Battery positive − Terminal 4 Battery negative − Terminal 1 Lock Battery positive − Terminal 1 Battery negative − Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Standard: Terminals No. Lock Unlock Door lock position Specification Lock No continuity Unlock Continuity 6⇔9 If the continuity is not as specified, replace the door lock assembly. B56800 5. (a) INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSY Inspect operation of the door lock motor. Standard: Measurement condition Operation Battery positive − Terminal 1 Battery negative − Lock body Open If operation is not as specified, replace the door lock assembly. Open B56801 WhereEverybodyKnowsYourName 73−6 THEFT DETERRENT & DOOR LOCK − WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM 73085−02 ON−VEHICLE INSPECTION 1. CHECK WIRELESS DOOR LOCK CONTROL FUNCTION HINT: The switch described in this text is a switch for transmitting signals (LOCK switch and UNLOCK switch), built in the door control transmitter. (a) Vehicle initial condition (conditions that allow the wireless control function to be operated)
No key in the ignition key cylinder
All doors closed (door open indicator off)
All doors locked (b) Check the basic function. (1) Check whether the LED lights up 3 times when each switch is pressed 3 times. HINT: In case that the LED does not light up when the switch has been pressed 3 times or more, it may have a dead battery. (2) In the remote control operational area, check that all the doors lock or unlock when the switch has been pressed for approximately 1 second. However, this will not happen when the key is in the ignition key cylinder or any of the doors is open. HINT: The UNLOCK function operates even when any of the doors is open. (3) Check that the luggage compartment door opens when the trunk switch has been pressed for 1 second (this function operates even when a door is open). (c) Check the automatic locking function. (1) Check that all doors lock automatically as long as none of the doors have been opened or all doors have not been locked within approximately 30 seconds after all doors are unlocked by pressing the switch. (2) Under the above condition, check that the automatic locking function does not operate when any of the doors has been opened or all doors have been locked within approximately 30 seconds after all doors are unlocked by pressing the switch. (d) Check the switch operation fail−safe function. (1) Check that doors can not be locked or unlocked by the switch while the key is in the ignition key cylinder. However, this does not apply when the system is in the recognition code registration mode. (e) Check the chattering prevention function. (1) Check that the corresponding operation occurs only once, and not repeated continuously while the switch is kept pressed. However, when the switch is operated repeatedly at one second intervals, check that the corresponding operation is carried out. (f) Check the repeat function. (1) Check that all doors attempt to automatically lock once again, 1 second after the lock switch has been pressed while the movement of the driver side door control knob, which is in the unlocked state, is being restricted. (g) Check the operation stop function when a door is open or not completely closed. (1) Check that doors are not locked or unlocked by the switch while the doors are open or not completely closed. WhereEverybodyKnowsYourName 73−7 THEFT DETERRENT & DOOR LOCK (h) − WIRELESS DOOR LOCK CONTROL SYSTEM Check the hazard flashing and buzzer sounding function (answer−back). (1) Check that the hazard lights flash and also the buzzer sounds once (when locked) or twice (when unlocked) simultaneously with locking or unlocking operation of all doors, when the switch is pressed. 2. CHECK WIRELESS CONTROL RECEIVER (a) Disconnect the D5 receiver connector, and check the voltD5 age or continuity of each terminal of the wire harness side connector B58961 B59140 Standard : Symbols (Terminals No.) Wiring color Condition Specification GND (D5−1) ⇔ Body ground W−B ⇔ − Constant Continuity +B (D5−5) ⇔ Body ground R⇔− Constant 10 − 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (b) Using an oscilloscope, connect the receiver connector and check the voltage. Standard : Symbols (Terminal No.) RDA (D5−2) ⇔ Body ground Wiring color L−W ⇔ − Condition All doors are closed → Door control transmitter ON Specification Below 1 V → 6 − 7 V → Below 1 V If the result is not as specified, there may be a malfunction on the wire harness side. WhereEverybodyKnowsYourName 73−8 THEFT DETERRENT & DOOR LOCK − DOOR CONTROL TRANSMITTER DOOR CONTROL TRANSMITTER 73084−02 REPLACEMENT 1. REGISTRATION OF RECOGINITION CODE HINT:
The add mode is used to register a new recognition codes while still retaining codes already registered. This mode is used to add a new transmitter. If the number of registered codes exceeds 4, the previously registered codes will be erased in order, starting from the first registered code.
The rewrite mode is used to erase all the previously registered codes in order to register all new recognition codes. This mode is used to exchange the transmitter or the door control receiver for a new one.
The prohibition mode is used to erase all the registered codes and disables the wireless door lock function. Use this mode when the transmitter is lost.
The confirmation mode is used to confirm how many recognition codes have already been registered before an additional registration of the recognition codes. (a) Make sure that the vehicle fulfills the following conditions. (1) No key is inserted in the ignition key cylinder. (2) The driver side door is opened (The other doors are closed). (3) The driver side door is unlocked. (b) Select a mode. (1) Insert the key into the ignition key cylinder, then pull it out (Perform this operation once again within 5 seconds). (2) Close and open the driver side door twice. (3) Insert the key into the ignition key cylinder, then pull it out. (4) Close and open the driver side door twice. (5) Insert the key into the ignition key cylinder, then close the driver side door. (6) To select a mode, turn the ignition switch from ON to LOCK at approximately 1 second intervals according to the number of times shown below. Then remove the key from the ignition key cylinder. Add Mode ON−LOCK change 1 time Confirmation Mode 1 sec. 1 sec. 1 sec. ON ON LOCK LOCK Rewrite Mode ON−LOCK change 2 times Prohibition Mode ON−LOCK change 5 times 1 sec.1 sec. ON LOCK ON−LOCK change 3 times 1 sec.1 sec. ON LOCK B50826 NOTICE:
If the number of ON−LOCK operations of the ignition switch is 4 or more than 5, the registration will end without any signs. WhereEverybodyKnowsYourName 73−9 THEFT DETERRENT & DOOR LOCK (7) − DOOR CONTROL TRANSMITTER Within 3 seconds after a mode has been selected, the theft warning ECU automatically performs LOCK−UNLOCK operation to inform the operator which mode has been selected. HINT:

When the confirmation mode has been selected and 0 codes are registered, LOCK−UNLOCK operation is automatically performed 5 times. When the confirmation mode has been selected and LOCK−UNLOCK operation has been performed twice as shown in the illustration below, the number of the registered recognition codes is 2. Confirmation Mode Add Mode 1st time 1 sec. 2nd time 2sec. 2 sec. LOCK LOCK UNLOCK UNLOCK Rewrite Mode Prohibition Mode 1sec. 1 sec 1 sec.1 sec. LOCK LOCK UNLOCK UNLOCK B50827 HINT: When the prohibition mode or the confirmation mode is selected, the registration mode ends. WhereEverybodyKnowsYourName 73−10 THEFT DETERRENT & DOOR LOCK − DOOR CONTROL TRANSMITTER (c) Register the transmitter. (1) Within 40 seconds after the add mode or the rewrite mode has been selected, simultaneously press the LOCK and UNLOCK switches twice. NOTICE: Press and hold both switches for 1 second or more during each press. However, the time between the 1st press and the 2nd press must be under 3 seconds. (2) LOCK−UNLOCK operation is automatically performed once within 3 seconds after above operation (step 1), when the recognition code of the transmitter has been registered correctly. If the LOCK−UNLOCK operation is performed twice, the registration of the recognition code has failed. In this case, register the recognition code from the beginning of the registration procedures once again. LOCK−UNLOCK occurs once LOCK−UNLOCK occurs twice Registration has been completed Approx. 1 sec. Registration has failed Approx. Approx. 1 sec.1 sec. LOCK LOCK UNLOCK UNLOCK B50828 (3) In order to continue in registration mode, start the next registration within 40 seconds after the previous one. HINT: The maximum number of the recognition codes that can be registered is 4. (d) If even one of the following conditions is satisfied, the registration mode will end. (1) 40 seconds have elapsed under the condition that the registration mode is ready. (2) The driver side door is opened (3) The key is inserted in the ignition key cylinder. (4) 4 recognition codes are registered at once. WhereEverybodyKnowsYourName 69−1 COMMUNICATION SYSTEM − HORN SYSTEM HORN SYSTEM 6902L−06 PROBLEM SYMPTOMS TABLE Symptom Horn does not sound. Suspected Area 1. 2. 3. 4. 5. Horn button switch High pitched horn Low pitched horn HORN relay Wire harness WhereEverybodyKnowsYourName See Page − − − 69−3 − 69−2 COMMUNICATION SYSTEM − HORN SYSTEM 6902K−05 LOCATION Steering Wheel Pad
Horn Button Switch Low Pitched Horn Assy Engine Room J/B
HORN Relay High Pitched Horn Assy B74619 WhereEverybodyKnowsYourName 69−3 COMMUNICATION SYSTEM − HORN SYSTEM 6902M−05 INSPECTION 3 5 1 2 5 1 2 3 B60778 1. (a) (b) INSPECT RELAY (HORN) Remove the HORN relay from the engine room R/B. Check the HORN relay resistance. Standard: Tester Connection Specified Condition 3−5 1 kΩ or higher 3−5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. WhereEverybodyKnowsYourName 69−4 COMMUNICATION SYSTEM − HORN ASSY HORN ASSY 69090−01 REPLACEMENT 1. (a) (b) 2. (a) (b) 3. (a) (b) 4. (a) (b) REMOVE HIGH PITCHED HORN ASSY Disconnect the connector. Remove the bolt and horn. REMOVE LOW PITCHED HORN ASSY Disconnect the connector. Remove the bolt and horn. INSTALL HIGH PITCHED HORN ASSY Place the stay onto the baffle part in the radiator support upper. Then install the horn with the bolt. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Connect the connector. INSTALL LOW PITCHED HORN ASSY Place the stay onto the baffle part in the radiator support upper. Then install the horn with the bolt. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Connect the connector. WhereEverybodyKnowsYourName 69−5 COMMUNICATION SYSTEM − GARAGE DOOR OPENER SYSTEM GARAGE DOOR OPENER SYSTEM 69059−01 REGISTRATION 1. NEW CODE REGISTRATION HINT:
The garage door opener is built in the map lamp assy. When transmitter codes for garage door, gate, entry gate, door lock, home lighting system or security system are registered with the garage door opener, be sure to register them again whenever replacing the map lamp assy.
After the map lamp assy has been replaced, register transmitter codes with the garage door opener (Registration mode). NOTICE:
While the transmitter code for a system (garage, door, gate, etc.) is being registered, the system may operate. During code registration and while the system is in operation, be sure that no people or objects are in the way.
Be sure to stop the engine and remove the key from the ignition switch before transmitter code registration.
The garage door opener does not apply to systems manufactured before April 1, 1982 and systems that do not comply with the Federal Safety Standards.
Garage doors without a jam protection function do not meet the Federal Safety Standards. HINT:
Every one of the garage door opener switches can have only one transmitter code; total 3 transmitter codes can be registered with the garage door opener.
Even if the battery is disconnected, transmitter codes registered with the garage door opener will not be erased.
Even if you attempt to rewrite the transmitter code registered with the garage door opener and the attempt has failed, the registered transmitter code will not be erased. (a) Garage Door Opener Switch (b) LED B56159 Select a switch of the garage door opener for transmitter code registration. Press and hold the selected switch for 20 seconds. Then, the garage door opener enters registration mode. HINT: When the garage door opener is in registration mode, the LED changes from ON to flashing at a cycle of 1 Hz. (In the case of the ”rolling code” type, the LED will flash at a cycle of 8.8 Hz for 1.6 seconds at first and then change the flash cycle to 1 Hz after the garage door opener has entered registration mode.) WhereEverybodyKnowsYourName 69−6 COMMUNICATION SYSTEM (c) Garage Door Opener Original Transmitter Press (d) B56160 − GARAGE DOOR OPENER SYSTEM After the garage door opener has entered registration mode, bring the original transmitter of the system within 1−inch of the garage door opener while pressing the switch of the garage door opener. Under this condition, press the original transmitter. When the transmitter code registration has been completed correctly, the LED of the garage door opener flashes at a cycle of 5.6 Hz. When this happens, release both the switch and the original transmitter. HINT:

If the code registration has failed, the battery of the original transmitter may be weak or the system may not meet the garage door opener. In this case, press the original transmitter repeatedly. Some transmitters may need 1 to 2 seconds to stop transmitting signals. If the transmitter code registration has not been completed in 90 seconds after the garage door opener has entered registration mode, the garage door opener will enter low power mode (See step c). Timing Chart of Registration Mode: PRESSED Garage Door Opener Switch RELEASED Registrat ion ENTER Mode EXIT LED Operation Original Transmitter 20 sec. ON OFF LED flashes at a cycle of 1 Hz ON LED flashes at a cycle of 5.6 Hz OFF I03487 WhereEverybodyKnowsYourName 69−7 COMMUNICATION SYSTEM Garage Door Opener Switch LED B56159 − GARAGE DOOR OPENER SYSTEM 2. Erase the transmitter codes (Clear mode). HINT:
All the transmitter codes registered in the garage door opener are erased at the same time (maximum 3 codes).
If the switches are released within 10 seconds after the transmitter codes have been erased, the garage door opener will enter registration mode.
If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to all the 3 switches of the garage door opener. With this default code, you can check operation of the garage door opener using a tester. (a) Press and hold the 2 switches at both ends of the garage door opener simultaneously for 20 seconds. Then, the LED starts flashing at a cycle of 5.6 Hz. Releasing the switches will end clear mode. Timing Chart of Clear Mode: Garage Door Opener Switches (at both ends) PRESSED RELEASED Enter clear mode to erase all 3 codes Load Default Code ON 20 sec. Clear Mode/Default Mode 10 sec. OFF ON LED Operation OFF LED flashes at a cycle of 5.6 Hz A53171 3. (a) Low power mode: If the switch of the garage door opener is held for 100 seconds or more, the garage door opener will enter low power mode to economize the power consumption. When the garage door opener has entered low power mode, the LED goes off. WhereEverybodyKnowsYourName 69−8 COMMUNICATION SYSTEM − GARAGE DOOR OPENER SYSTEM 6902T−03 INSPECTION Garage Door Opener Switch 1. (a) INSPECT GARAGE DOOR OPENER Press the switch and check that each LED (red) lights up. Even if only one switch is found not to light up, replace it. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING LED B56159 Garage Door Opener Original Transmitter Press B56160 HINT: Use the home link tester made by KENT MORE for this test. As it is necessary to register the transmitter code of the home link tester, erase the customer’s code. When the inspection completes, please register the customer’s code again. (a) Register the transmitter code of the home link tester for inspection (See page 69−5 for further details). HINT: If the transmitter code can not be registered, replace the garage door opener. (b) Garage Door Opener Press the switch in which an inspection code has been registered and check that the LED (green) of the home link tester lights up. HINT: If the LED (green) does not light up, replace the garage door opener. Press Home Link Tester B56158 WhereEverybodyKnowsYourName 14−1 ENGINE MECHANICAL − ENGINE (2AZ−FE)(From July, 2003) ENGINE (2AZ−FE)(From July, 2003) 141I6−03 INSPECTION 1. 2. 3. 4. 5. INSPECT INSPECT INSPECT INSPECT INSPECT ENGINE COOLANT (See page 16−1) ENGINE OIL (See page 17−1) BATTERY (See page 19−14) AIR CLEANER FILTER ELEMENT SUB−ASSY (See page 99−5) SPARK PLUG (See page 18−3) WRONG CORRECT A87787 6. INSPECT V−RIBBED BELT HINT:
After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley.
”New belt” is a belt which has been used less than 5 minutes on a running engine.
”Used belt” is a belt which has been used on a running engine for 5 minutes or more.
After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. 7. INSPECT IGNITION TIMING (a) Warm up the engine. (b) Hand−held Tester When using the hand−held tester: Check the ignition timing. (1) Connect the hand−held tester to the DLC3. (2) Enter DATA LIST MODE on the hand−held tester. Ignition timing: 8 to 12 BTDC @ idle HINT: Please refer to the hand−held tester operator’s manual for help on selecting the DATA LIST. DLC3 A59675 (c) CG DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TC A82779 When not using the hand−held tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843−18040 NOTICE:
Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
Turn off all electrical systems before connecting the terminals.
Perform this inspection after the cooling fan motor is turned off. WhereEverybodyKnowsYourName 14−2 ENGINE MECHANICAL − (2) (3) A52004 Remove the cylinder head cover No. 2. Pull out the wire harness as shown in the illustration. Connect the clip of the timing light to the engine. NOTICE:
Use a timing light which can detect the first signal.
After checking, be sure to tape the wire harness. (4) Check the ignition timing at idle. Ignition timing: 8 to 12 BTDC @ idle NOTICE: When checking the ignition timing, the transmission should be in the neutral position. HINT: After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds, check that it returns to idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (6) Check the ignition timing at idle. Ignition timing: 5 to 15 BTDC @ idle (7) Confirm that ignition timing moves to the advanced angle side when the engine rpm is increased. (8) Remove the timing light. 8. INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) Hand−held Tester ENGINE (2AZ−FE)(From July, 2003) When using the hand−held tester: Check the idle speed. (1) Connect the hand−held tester to the DLC3. HINT: Please refer to the hand−held tester operator’s manual for further details. (2) Enter DATA LIST MODE on the hand−held tester. Idle speed: DLC3 A59675 Item Specified Condition M/T 650 to 750 rpm A/T 610 to 710 rpm NOTICE:
When checking the idle speed, the tranmission should be in the neutral position.
Check idle speed with the cooling fan off.
Switch off all accessories and air conditioning before connecting the hand−held tester. WhereEverybodyKnowsYourName 14−3 ENGINE MECHANICAL (c) DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TAC A82779 A01037 − ENGINE (2AZ−FE)(From July, 2003) When not using the hand−held tester: Check the idle speed. (1) Using SST, connect tachometer tester probe to terminal 9 (TAC) of the DLC3. SST 09843−18030 (2) Check the idle speed. Idle speed: Item Specified Condition M/T 650 to 750 rpm A/T 610 to 710 rpm 9. (a) (b) (c) (d) INSPECT COMPRESSION Warm up and stop the engine. Disconnect the injector connectors. Remove the ignition coils. Remove the spark plugs. (e) Check the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression pressure: Item Specified Condition PZEV 1,300 kPa (13.3 kg/cm2, 189 psi) Except PZEV 1,360 kPa (13.9 kg/cm2, 198 psi) Minimum pressure: Item Specified Condition PZEV 1,000 kPa (10.2 kg/cm2, 145 psi) Except PZEV 980 kPa (10.0 kg/cm2, 142 psi) Difference between each cylinder: Item Specified Condition PZEV 29 kPa (0.3 kg/cm2, 4.3 psi) Except PZEV 100 kPa (1.0 kg/cm2, 14 psi) NOTICE:
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Check other cylinder’s compression pressure in the same way.
This measurement must be done as quickly as possible. (4) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. WhereEverybodyKnowsYourName 14−4 ENGINE MECHANICAL − ENGINE (2AZ−FE)(From July, 2003) HINT:

If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. 10. INSPECT CO/HC (a) Start the engine. (b) Rev the engine at 2,500 rpm for approximately 180 seconds. (c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Immediately check CO/HC concentration at idle and/or 2,500 rpm. HINT:
Complete the measuring within 3 minutes.
Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check A/F sensor operation (see page 05−288). (2) See the table below for possible causes, and then inspect and repair. CO Normal Low High HC High High High Problems Causes Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system:
Faulty pressure regulator
Defective ECT
Defective MAF meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor WhereEverybodyKnowsYourName ENGINE MECHANICAL − TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ−FE)(From July, 2003) 14−101 TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ−FE)(From July, 2003) 141J0−01 REPLACEMENT 1. 2. 3. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB−ASSY NO.1 4. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and control rod. A59888 5. 6. 7. REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE MOUNTING BRACKET NO.2 RH REMOVE FAN AND GENERATOR V BELT (See page14−5) 8. (a) REMOVE CRANKSHAFT PULLEY TMC made: Remove the crankshaft pulley. (1) Using SST, loosen the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 SST A52485 (2) Using SST, remove the pulley bolt and pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) SST A36685 WhereEverybodyKnowsYourName 14−102 ENGINE MECHANICAL (b) − TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ−FE)(From July, 2003) TMMK made: Remove the crankshaft pulley. (1) Using SST, loosen the pulley bolt. SST 09960−10010 (09962−01000, 09963−01000) SST A62057 (2) Using SST, remove the crankshaft pulley. SST 09950−40011 (09951−04010, 09952−04010, 09953−04030, 09954−04010, 09955−04041, 09957−04010, 91111−51014) Hooking Point SST A62058 9. (a) SST REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using SST, remove the oil seal. SST 09308−10010, 09950−60010 (09951−00200) SST A87778 10. SST A32663 SST A52486 INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−22010 NOTICE: Wipe off extra grease from the crankshaft. 11. INSTALL CRANKSHAFT PULLEY (a) TMC made: Install the crankshaft pulley. (1) Align the pulley set key with the key groove of the pulley. (2) Using SST, install the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021, 09960−10010 (09962−01000, 09963−01000) Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft⋅lbf) WhereEverybodyKnowsYourName ENGINE MECHANICAL (b) − TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ−FE)(From July, 2003) 14−103 TMMK made: Install the crankshaft pulley. (1) Align the pulley set key with the key groove of the pulley. (2) Using SST, install the pulley bolt. SST 09960−10010 (09962−01000, 09963−01000) Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft⋅lbf) SST A62057 12. 13. 14. INSTALL FAN AND GENERATOR V BELT (See page 14−5) INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 15. INSTALL ENGINE MOVING CONTROL W/BRACKET (a) Install the control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A59888 16. 17. INSTALL FRONT WHEEL RH CHECK FOR ENGINE OIL LEAKS WhereEverybodyKnowsYourName ROD 14−104 ENGINE MECHANICAL − ENGINE REAR OIL SEAL (2AZ−FE)(From July, 2003) ENGINE REAR OIL SEAL (2AZ−FE)(From July, 2003) 141IZ−02 REPLACEMENT 1. SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T) (See page 40−18) HINT: Remove the transaxle after removing the engine assy w/ transaxle. 2. SEPARATE MANUAL TRANSAXLE ASSY (M/T) (See page 41−11) HINT: Remove the transaxle after removing the engine assy w/ transaxle. 3. (a) REMOVE DRIVE PLATE & RING GEAR SUB−ASSY TMC made: Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) TMMK made: Using SST, fix the crankshaft. SST 09960−10010 (09962−01000, 09963−01000) (c) Remove the 8 bolts, rear spacer, drive plate and front spacer. SST A32665 SST A62061 A91018 4. 5. REMOVE CLUTCH COVER ASSY (M/T) (See page 42−15) REMOVE CLUTCH DISC ASSY (M/T) (See page 42−15) WhereEverybodyKnowsYourName 14−105 ENGINE MECHANICAL − ENGINE REAR OIL SEAL (2AZ−FE)(From July, 2003) 6. (a) REMOVE FLYWHEEL SUB−ASSY (M/T) Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Remove the 8 bolts and flywheel. SST A32665 A91020 Cut Position 7. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut through the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400−grit sandpaper. . A53052 SST A32658 8. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−15030, 09950−70010 (09951−07100) NOTICE: Wipe off extra grease from the crankshaft. 9. (a) INSTALL DRIVE PLATE & RING GEAR SUB−ASSY (A/T) TMC made: Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 SST A32665 WhereEverybodyKnowsYourName 14−106 ENGINE MECHANICAL SST TMMK made: Using SST, fix the crankshaft. SST 09960−10010 (09962−01000, 09963−01000) (c) (d) Clean the bolt and the bolt hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND or equivalent Install the front spacer, drive plate and rear spacer with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 98 N⋅m (1,000 kgf⋅cm, 72 ft⋅lbf) A62061 33 8 8 44 7 2 ENGINE REAR OIL SEAL (2AZ−FE)(From July, 2003) (b) 11 66 − (e) 7 55 A61988 10. (a) INSTALL FLYWHEEL SUB−ASSY Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) (c) Clean the bolt and the bolt hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND or equivalent Install the flywheel with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 130 N⋅m (1,330 kgf⋅cm, 96 ft⋅lbf) SST A32665 6 1 3 (d) 7 8 5 4 2 A91020 11. 12. 13. 14. INSTALL CLUTCH DISC ASSY (M/T) (See page 42−15) INSTALL CLUTCH COVER ASSY (M/T) (See page 42−15) INSTALL AUTOMATIC TRANSAXLE ASSY (A/T) (SeePage 40−18) INSTALL MANUAL TRANSAXLE ASSY (M/T) (See page 41−11) WhereEverybodyKnowsYourName 14−107 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 141ID−02 COMPONENTS Valve Lifter
Valve Retainer Lock Retainer Inner Compression Spring Intake Valve Guide Bush
Valve Stem Oil Seal Valve Spring Seat Exhaust Valve Guide Bush Stud Bolt Ring w/ Head Pin Cylinder Head Assy Exhaust Valve Intake Valve
Non−reusable part A77366 WhereEverybodyKnowsYourName 14−108 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 141IE−02 OVERHAUL 1. REMOVE VALVE LIFTER HINT: Arrange the valve lifters in the correct order. 2. (a) SST REMOVE INTAKE VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202−70020 (09202−00010) Remove the retainer, valve spring and valve. (b) HINT: Arrange the removed parts in the correct order. Wooden Blocks A52444 3. (a) SST REMOVE EXHAUST VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202−70020 (09202−00010) Remove the retainer, valve spring and valve. (b) HINT: Arrange the removed parts in the correct order. Wooden Blocks A52472 4. (a) REMOVE VALVE STEM OIL O SEAL OR RING Using needle−nose pliers, remove the oil seals. A13356 5. 6. REMOVE VALVE SPRING SEAT REMOVE STUD BOLT WhereEverybodyKnowsYourName 14−109 ENGINE MECHANICAL 7. (a) Cylinder Block Side − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Item Specified Condition Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.) If the warpage is greater than the maximum, replace the cylinder head. Intake Manifold Side Exhaust Manifold Side A52445 8. (a) INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head. A13365 9. (a) (b) (c) Width EM0183 A52446 INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve seat according to the following procedure. (1) If blue appears 360
around the valve face, the valve face is concentric. If not, replace the valve. (2) If blue appears 360
around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.). WhereEverybodyKnowsYourName 14−110 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 10. REPAIR VALVE SEATS NOTICE: Keep the lip free from foreign matter. (a) If the seating is too high on the valve face, use 30
and 45
cutters to correct the seat. (b) If the seating is too low on the valve face, use 75
and 45
cutters to correct the seat. Hand−lap the valve and valve seat with an abrasive compound. Check the valve seating position. 45
30
1.0−1.4mm 1.0 to1.4 mm A53031 75
45
(c) (d) 1.0−1.4mm 1.0 to 1.4 mm A53032 11. (a) (b) A36626 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Specified thrust clearance: Item Specified Condition Intake 0.040 to 0.110 mm (0.0016 to 0.0043 in.) Exhaust 0.080 to 0.150 mm (0.0032 to 0.0059 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. 12. (a) (b) (c) INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft journal. A36627 WhereEverybodyKnowsYourName 14−111 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) (d) Install the bearing caps. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for No. 1 bearing cap 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for No. 2 bearing cap 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for No. 3 bearing cap NOTICE: Do not turn the camshaft. A32645 (e) A36628 Remove the bearing cap, and measure the plastigage at its widest point. Specified oil clearance: Item Specified Condition Intake No. 1 journal bearing mark 1 0.007 to 0.070 mm (0.0003 to 0.0028 in.) Intake No. 1 journal bearing mark 2 0.008 to 0.070 mm (0.0003 to 0.0028 in.) Intake No. 1 journal bearing mark 3 0.008 to 0.070 mm (0.0003 to 0.0028 in.) Other journals 0.025 to 0.100 mm (0.0010 to 0.0039 in.) Exhaust No. 1 journal 0.040 to 0.100 mm (0.0016 to 0.0039 in.) Other journals 0.025 to 0.100 mm (0.0010 to 0.0039 in.) NOTICE: Completely remove the plastigage after the inspection. If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head. If the oil clearance on the No.1 journal is greater than the maximum, choose a new bearing and install it. HINT: Cylinder head journal bore diameter Number Mark Mark 1 40.000 to 40.009 mm (1.5748 to 1.5752 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.017 to 40.025 mm (1.5755 to 1.5758 in.) Standard bearing center wall thickness Number Mark A13530 Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789 in.) Mark 2 2.004 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.008 to 2.012 mm (0.0791 to 0.0792 in.) Camshaft journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) WhereEverybodyKnowsYourName 14−112 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 13. (a) INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) If the free length is not as specified, replace the valve spring. EM0801 (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) If the deviation is greater than the maximum, replace the valve spring. Deviation EM0988 14. (a) INSPECT INTAKE VALVE Using a vernier caliper, measure the valve overall length. Specified overall length: 101.21 to 101.71 mm (3.9846 to 4.0043 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) A32770 (c) Using a vernier caliper, measure the valve head margin thickness. Specified margin thickness: 0.50 to 1.45 mm (0.0197 to 0.0571 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 WhereEverybodyKnowsYourName 14−113 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 15. (a) INSPECT EXHAUST VALVE Using a vernier caliper, measure the valve overall length. Specified overall length: 100.70 to 101.15 mm (3.9646 to 3.9823 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Z00052 (c) Using a vernier caliper, measure the valve head margin thickness. Specified margin thickness: 0.50 to 1.60 mm (0.0197 to 0.0630 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 16. (a) A13367 INSPECT INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bush. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Specified oil clearance: 0.025 to 0.080 mm (0.0010 to 0.0031 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see steps 18 and 20). WhereEverybodyKnowsYourName 14−114 ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 17. (a) A13367 INSPECT EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bush. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Specified oil clearance: 0.030 to 0.100 mm (0.0012 to 0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see steps 19 and 21). 18. (a) SST REMOVE INTAKE VALVE GUIDE BUSH Using SST and a hammer, tap out the guide bush. SST 09201−10000 (09201−01050), 09950−70010 (09951−07100) A36632 19. (a) SST A36633 REMOVE EXHAUST VALVE GUIDE BUSH Using SST and a hammer, tap out the guide bush. SST 09201−10000 (09201−01050), 09950−70010 (09951−07100) 20. INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Install the STD bush if the diameter is within the specified diameter. Specified diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) (a) SST Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) SST 09201−10000 (09201−01050), 09950−70010 (09951−07100) A36634 WhereEverybodyKnowsYourName 14−115 ENGINE MECHANICAL (b) 21. (a) (b) (c) SST (d) A36635 22. (a) − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Install the STD bush if the diameter is within the specified diameter. Specified diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. SST 09201−10000 (09201−01050), 09950−70010 (09951−07100) Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P16860 (b) A13374 Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Specified oil clearance: 0.033 to 0.070 mm (0.0013 to 0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. WhereEverybodyKnowsYourName 14−116 ENGINE MECHANICAL Upper Side 11mm (0.43 in.) 8 mm (0.31 in.) 3 mm (0.12 in.) A92403 − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) 23. (a) INSTALL RING W/HEAD PIN Using a plastic−faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 24. INSTALL STUD BOLT Torque: 5 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for bolt A 5 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for bolt B 10 N⋅m (97 kgf⋅cm, 7 ft⋅lbf) for bolt C 10 N⋅m (97 kgf⋅cm, 7 ft⋅lbf) for bolt D Front Side Upper Side A Intake Side C Exhaust Side B D 12 mm (0.47 in.) 14 mm (0.55 in.) (M6) 9 mm (0.35 in.) 49.5 mm (1.95 in.) 46.5 mm (1.83 in.) 31.5 mm (1.24 in.) 12 mm (0.47 in.) (M6) 18 mm (0.71 in.) 18 mm (0.71 in.) 38.7 mm (1.52 in.) 13 mm (0.51 in.) (M8) (M8) 13 mm (0.51 in.) A90852 WhereEverybodyKnowsYourName 14−117 ENGINE MECHANICAL 25. − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) INSTALL VALVE SPRING SEAT Intake Side Exhaust Side Gray Black A52449 26. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil on a new oil seal. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. (b) Using SST, push in the oil seal. SST 09201−41020 SST A36639 27. (a) (b) SST Wooden Blocks A52444 (c) Using a plastic−faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the valve stem tip. Vinyl Tape Valve Stem INSTALL INTAKE VALVE Install the valve, spring and retainer to the cylinder head. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202−70020 (09202−00010) A13888 WhereEverybodyKnowsYourName 14−118 ENGINE MECHANICAL 28. (a) (b) SST − CYLINDER HEAD ASSY (2AZ−FE)(From July, 2003) INSTALL EXHAUST VALVE Install the valve, spring and retainer to the cylinder head. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202−70020 (09202−00010) Wooden Blocks A52472 (c) Using a plastic−faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the valve stem tip. Vinyl Tape Valve Stem A13888 29. INSTALL VALVE LIFTER (a) Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTICE: Install the valve lifters in their original places. WhereEverybodyKnowsYourName 14−119 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 141IF−02 COMPONENTS Piston Ring Set Piston  Snap Ring  Snap Ring Piston Pin Connecting Rod Connecting Rod Bearing Cylinder Block Assy Crankshaft Thrust Washer Crankshaft Bearing Crankshaft Connecting Rod Bearing Connecting Rod Cap Connecting Rod Bearing See page 14−120 1st: 25 (250, 18) 2nd: Turn 90
Crankshaft Bearing Connecting Rod Cap Crankshaft Bearing Cap Bolt See page 14−120 1st: 20 (204, 15) 2nd: Turn 90
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A88217 14−120 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 141IG−03 OVERHAUL 1. (a) INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Specified thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. A36642 A13397 2. INSPECT CONNECTING ROD OIL CLEARANCE HINT: The connecting rod cap bolts are tightened in 2 progressive steps. (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. (b) Remove the 2 connecting rod cap bolts. (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. (f) Lay a strip of Plastigage on the crank pin. A13400 WhereEverybodyKnowsYourName 14−121 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) (g) Check that the front mark of the connecting rod cap is facing in the correct direction. (h) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (i) Install the connecting cap (see step 37). NOTICE: Do not turn the crankshaft. (j) Remove the 2 bolts and connecting rod cap. Front Mark A52515 (k) Measure the Plastigage at its widest point. Specified oil clearance: 0.024 to 0.080 mm (0.0009 to 0.0031 in.) If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. A36644 Mark 1, 2 or 3 Mark 1, 2 or 3 A13840 HINT: If replacing a bearing, replace it with one that has the same number as the connecting rod. There are 3 sizes of standard bearings: 1, 2 and 3. Standard bearing center wall thickness: Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.) Mark 2 1.488 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 1.491 to 1.494 mm (0.0587 to 0.0588 in.) (l) Completely remove the Plastigage. 3. (a) REMOVE PISTON SUB−ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. (b) HINT:

A13469 4. Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. REMOVE CONNECTING ROD BEARING WhereEverybodyKnowsYourName 14−122 ENGINE MECHANICAL 5. (a) − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) (b) REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. 6. (a) REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings. 7. (a) REMOVE PISTON Gradually heat the piston to approxinately 80 to 90C (176 to 194F). (b) Using a plastic−faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. A36647 A13478 A01178 HINT:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A01179 8. (a) A36645 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Specified thrust clearance: 0.040 to 0.300 mm (0.0016 to 0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness: 1.930 to 1.980 mm (0.0760 to 0.0780 in.) WhereEverybodyKnowsYourName 14−123 ENGINE MECHANICAL 2 6 10 8 4 1 5 9 7 3 9. (a) − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 10 main bearing cap bolts, in the sequence shown in the illustration. A87780 (b) A87781 Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings. NOTICE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps in correct order. (c) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each journal. (h) Install the main bearing caps (see step 36). HINT: Do not turn the crankshaft. (i) Remove the main bearing cap (see steps (a) and (b) above). Plastigage A87782 (j) Measure the Plastigage at its widest point. Standard oil clearance: 0.008 to 0.024 mm (0.00031 to 0.00094 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. A87783 WhereEverybodyKnowsYourName 14−124 ENGINE MECHANICAL (k) Number Mark No. 3 No. 4 CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then selecting the bearing according to the chart below. There are 4 sizes of standard bearings: 1, 2, 3, and 4. Cylinder block (A) + Crankshaft (B) 0 to 2 3 to 5 6 to 8 9 to 11 Use bearing 1 2 3 4 HINT: EXAMPLE Cylinder block 4 (A) + Crankshaft 3 (B) = Total number 7 (Use bearing 3) No. 1 No. 2 − No. 5 Number Mark A87784 Item Reference: Mark Specified Condition Cylinder block main journal bore diameter (A) 0 1 2 3 4 5 6 59.000 to 59.002 mm (2.3228 to 2.3229 in.) 59.002 to 59.004 mm (2.3229 to 2.3230 in.) 59.004 to 59.006 mm (2.3230 to 2.3231 in.) 59.006 to 59.009 mm (2.3231 to 2.3232 in.) 59.009 to 59.011 mm (2.3232 to 2.3233 in.) 59.011 to 59.013 mm (2.3233 to 2.3234 in.) 59.013 to 59.016 mm (2.3234 to 2.3235 in.) Crankshaft main journal diameter (B) 0 1 2 3 4 5 54.998 to 55.000 mm (2.1653 to 2.1654 in.) 54.996 to 54.998 mm (2.1652 to 2.1653 in.) 54.994 to 54.996 mm (2.1651 to 2.1652 in.) 54.992 to 54.994 mm (2.1650 to 2.1651 in.) 54.990 to 54.992 mm (2.1650 to 2.1650 in.) 54.988 to 54.990 mm (2.1649 to 2.1650 in.) Standard bearing center wall thickness 1 2 3 4 1.993 to 1.996 mm (0.0785 to 0.0786 in.) 1.996 to 1.999 mm (0.0786 to 0.0787 in.) 1.999 to 2.002 mm (0.0787 to 0.0788 in.) 2.002 to 2.005 mm (0.0788 to 0.0789 in.) (l) Completely remove the Plastigage. 10. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in the correct order. 11. REMOVE CRANKSHAFT THRUST WASHER UPPER 12. REMOVE CRANKSHAFT BEARING HINT: Arrange the bearings in the correct order. 13. REMOVE CRANKSHAFT BEARING NO.2 HINT: Arrange the bearings in the correct order. 14. REMOVE STUD BOLT WhereEverybodyKnowsYourName 14−125 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 15. CLEAN CYLINDER BLOCK SUB−ASSY NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45C (113F) or less. 16. (a) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. A36648 17. (a) INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 88.500 to 88.633 mm (3.4843 to 3.4894 in.) If the average of the measured diameters is greater than the maximum, replace the cylinder block. Thrust Direction Front Axial Direction A 10 mm B A88899 WhereEverybodyKnowsYourName 14−126 ENGINE MECHANICAL 18. (a) − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) INSPECT PISTON DIAMETER Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.3 mm (1.193 in.) from the piston head. Piston diameter: 88.439 to 88.449 mm (3.4818 to 3.4822 in.) 30.3 mm (1.193 in.) A13486 19. (a) INSPECT PISTON CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Specified oil clearance: 0.051 to 0.100 mm (0.0020 to 0.0039 in.) If the clearance is greater than the maximum, replace all the 4 pistons. If necessary, replace the cylinder block. 20. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Ring groove clearance: 0.030 to 0.070 mm (0.0012 to 0.0028 in.) If the clearance is not as specified, replace the piston. A36650 21. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (b) Using a feeler gauge, measure the end gap. Specified end gap: 110 mm Piston Ring A53017 EM2552 Item Specified Condition No. 1 0.22 to 0.892 mm (0.0087 to 0.0350 in.) No. 2 0.50 to 1.35 mm (0.0197 to 0.0531 in.) Oil (side rail) 0.10 to 0.73 mm (0.0039 to 0.0287 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block. WhereEverybodyKnowsYourName 14−127 ENGINE MECHANICAL 22. (a) A13490 (b) EM0227 (c) A01185 (d) − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the pin hole bush diameter of the piston. Pin hole diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Pin hole diameter (Reference): Mark mm (in.) A 22.001 to 22.004 (0.8662 to 0.8663) B 22.004 to 22.007 (0.8663 to 0.8664) C 22.007 to 22.010 (0.8664 to 0.8665) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.009 mm (0.8660 to 0.8665 in.) Piston pin diameter (Reference): Mark mm (in.) A 21.997 to 22.000 (0.8660 to 0.8661) B 22.000 to 22.003 (0.8661 to 0.8663) C 22.003 to 22.006 (0.8663 to 0.8664) D 22.006 to 22.009 (0.8664 to 0.8665) Using a caliper gauge, measure the inside diameter of the connecting rod bush. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Bushing inside diameter: Mark mm (in.) A 22.005 to 22.008 (0.8663 to 0.8665) B 22.008 to 22.011 (0.8665 to 0.8666) C 22.011 to 22.014 (0.8666 to 0.8667) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement. Specified oil clearance: 0.001 to 0.010 mm (0.00004 to 0.00039 in.) WhereEverybodyKnowsYourName 14−128 ENGINE MECHANICAL Piston Bushing Inside Diameter Mark Front Mark − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. (e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Specified oil clearance: 0.005 to 0.100 mm (0.0002 to 0.0020 in.) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set. Front Mark Connecting Rod Bushing Inside Diameter Mark A62247 23. (a) INSPECT CONNECTING ROD SUB−ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for out−of−alignment. Maximum out−of−alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the out−of−alignment is greater than the maximum, replace the connecting rod assembly. Z00064 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z00065 24. (a) INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Specified diameter: 7.0 to 7.3 mm (0.276 to 0.287 in.) If the diameter is less than the minimum, replace the bolt. A01470 WhereEverybodyKnowsYourName 14−129 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 25. (a) INSPECT CRANKSHAFT Using a dial indicator and V−blocks, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the crankshaft. A13491 (b) Using a micrometer, measure the diameter of each main journal. Diameter: 54.988 to 55.000 (2.1648 to 2.06535 in.) If the diameter is not as specified, check the oil clearance (see step 9). If necessary, replace the crankshaft. (c) Check each main journal for taper and out−of−round as shown in the illustration. Maximum taper and out−of−round: 0.003 mm (0.0001 in.) If the taper and out−of−round is greater than the maximum, replace the crankshaft. Diameter (Reference): A36653 Mark Specified Condition 0 54.998 to 55.000 mm (2.1653 to 2.1654 in.) 1 54.996 to 54.998 mm (2.1652 to 2.1653 in.) 2 54.994 to 54.996 mm (2.1651 to 2.1652 in.) 3 54.992 to 54.994 mm (2.1650 to 2.1651 in.) 4 54.990 to 54.992 mm (2.1650 to 2.1650 in.) 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) (d) ZF6928 Using a micrometer, measure the diameter of each crank pin. Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.) If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft. (e) Check each crank pin for taper and out−of−round as shown in the illustration. Maximum taper and out−of−round: 0.003 mm (0.0001 in.) If the taper and out−of−round is greater than the maximum, replace the crankshaft. WhereEverybodyKnowsYourName 14−130 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 26. (a) INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Specified diameter: 7.2 to 7.6 mm (0.283 to 0.299 in.) If the diameter is less than the minimum, replace the bolt. EM6347 A15065 27. (a) INSTALL RING PIN Using a plastic−faced hammer, tap into the ring pin. Bottom Side Upper Side A A A 14 mm (0.55 in.) A 13 mm (0.51 in.) B B 12 mm (0.47 in.) 6 mm (0.24 in.) for Ring Pin A 5 mm (0.20 in.) for Ring Pin B 12 mm (0.47 in.) A92404 WhereEverybodyKnowsYourName 14−131 ENGINE MECHANICAL 28. (a) (b) − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) INSTALL TIGHT PLUG Apply adhesive around the tight plugs. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent. Using SST, install new tight plugs as shown in the illustration. SST 09950−60010 (09951−00200), 09950−70010 (09951−07100) Standard depth: Engine front 1.7 to 2.7 mm (0.067 to 0.106 in.) Engine rear 2.2 to 3.2 mm (0.087 to 0.126 in.) A62239 29. (a) INSTALL STUD BOLT Install the stud bolts as shown in the illustration. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for stud bolt A 10 N⋅m (97 kgf⋅cm, 7 ft⋅lbf) for stud bolt B 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for stud bolt C C Front Side Exhaust Side A 16 mm (0.63 in.) B 18 mm (0.71 in.) A (M16) 14 mm (0.55 in.) 84 mm (3.31 in.) 31.5 mm (1.24 in.) 9 mm (0.35 in.) A 27.5 mm (1.08 in.) 20 mm (0.79 in.) B (M10) C (M16) 9 mm (0.35 in.) A92405 WhereEverybodyKnowsYourName 14−132 ENGINE MECHANICAL 30. (a) Rear Side − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) INSTALL STRAIGHT PIN Using a plastic−faced hammer, tap into the straight pin. Bottom Side Front Side A A B A B A 10 mm (0.39 in.) 8 mm (0.31 in.) 22 mm (0.87 in.) 15 mm (0.59 in.) A 7.5 mm (0.30 in.) for Pin A 12 mm (0.47 in.) for Pin B B A92406 31. (a) (b) INSTALL PISTON Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually heat the piston to approxinately 80 to 90C (176 to 194F). A32958 P12418 (c) (d) Front Mark Align the front marks of the piston and connecting rod, and push in the piston with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. Front Mark A13497 WhereEverybodyKnowsYourName 14−133 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 32. (a) (b) INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the painted mark as shown in the illustration. NOTICE: Install the compression ring No. 2 with the code mark (2N) facing upward. Upward No. 1 Painted Mark No. 2 Code Mark (2N) A52526 No. 1 and Expander (c) Side Rail Lower Position the piston rings so that the ring ends are as shown in the illustration. Front Side Rail Upper No. 2 Compression A52527 33. (a) INSTALL CRANKSHAFT BEARING Install the upper bearing with an oil groove on the cylinder block. NOTICE: Clean the backside of the bearing and the bearing surface of the cylinder block and let not stick the oils and fats. A53029 34. INSTALL CRANKSHAFT BEARING NO.2 (a) Install the lower bearing on bearing cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils. A33379 WhereEverybodyKnowsYourName 14−134 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 35. (a) INSTALL CRANKSHAFT THRUST WASHER UPPER Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. 36. (a) INSTALL CRANKSHAFT Apply engine oil to upper bearing and install the crankshaft on the cylinder block. Apply engine oil to the lower bearing. A13501 (b) (c) (d) Examine the front marks and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the bearing cap bolts. A13502 7 3 1 5 9 8 4 2 6 10 90 (e) Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) (f) (g) Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts by 90 in the numerical order shown in the illustration. Check that the painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. A36657 Paint Mark Engine Front (h) (i) A50671 WhereEverybodyKnowsYourName 14−135 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FE)(From July, 2003) 37. (a) Claw A50672 INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oil. 38. INSTALL PISTON NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps. (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. Front Mark Front A52528 (d) Front Mark (g) Check that the protrusion of the connecting rod cap is facing in the correct direction. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using a 12 mm socket wrench, uniformly tighten the 2 bolts. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) Mark the front of the connecting cap bolts with paint. (h) (i) Retighten the cap bolts by 90 as shown in the illustration. Check that the crankshaft turns smoothly. (e) (f) A52515 90 Paint Mark Engine Front A50671 WhereEverybodyKnowsYourName 14−136 ENGINE MECHANICAL − ENGINE (1MZ−FE/3MZ−FE) ENGINE (1MZ−FE/3MZ−FE) 1404Q−09 INSPECTION 1. 2. 3. 4. 5. INSPECT INSPECT INSPECT INSPECT INSPECT ENGINE COOLANT (See page 16−21) ENGINE OIL (See page 17−23) BATTERY (See page 19−39) AIR CLEANER FILTER ELEMENT SUB−ASSY (See page 99−5) SPARK PLUG (See page 18−9) 6. (a) A87786 INSPECT V−RIBBED BELT Using a belt tension gauge, check the belt tension. Belt tension gauge: DENSO BTG−20 (95506−00020) Borroughs No. BT−33−73F Drive belt tension: Item Specified Condition Cooler compressor to crankshaft pulley New belt 139 to 192 lbf Cooler compressor to crankshaft pulley Used belt 66 to 110 lbf Vane pump New belt 154 to 176 lbf Vane pump Used belt 77 to 110 lbf HINT:
CORRECT
WRONG
A87787
7. (a) (b) Hand−held Tester After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crankshaft pulley. ”New belt” is a belt which has been used less than 5 minutes on a running engine. ”Used belt” is a belt which has been used on a running engine for 5 minutes or more. After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. INSPECT IGNITION TIMING Warm up the engine. When using the hand−held tester: Check the ignition timing. (1) Connect the hand−held tester to the DLC3. (2) Enter DATA LIST MODE on the hand−held tester. Ignition timing : 8 to 12 BTDC @ idle HINT: Please refer to the hand−held tester operator’s manual for help on selecting the DATA LIST. DLC3 A59675 WhereEverybodyKnowsYourName 14−137 ENGINE MECHANICAL − ENGINE (1MZ−FE/3MZ−FE) (c) CG DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TC A82779 When not using the hand−held tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. NOTICE:
Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
Turn off all electrical systems before connecting the terminals.
Perform this inspection after the cooling fan motor is turned off. (2) Remove the V−bank cover. (3) (4) Tester Terminal Black Lead Wire A82935 NOTICE: Use a timing light which detects the first signal. (5) Check the ignition timing at idle. Ignition timing : 8 to 12 BTDC @ idle NOTICE: When checking the ignition timing, the transmission should be in the neutral position. HINT: Run the engine at 1,000 to 1,300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. (6) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (7) Check the ignition timing at idle. Ignition timing : 7 to 24 BTDC @ idle (8) Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased. (9) Remove the timing light. 8. INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) Hand−held Tester DLC3 Pull out the black lead wire harness as shown in the illustration. Connect the tester terminal of the timing light to the engine. When using the hand−held tester: Check the idle speed. (1) Connect the hand−held tester to the DLC3. (2) Enter DATA LIST MODE on the hand−held tester. Idle speed: Item Specified Condition 1MZ−FE 550 to 650 rpm 3MZ−FE 630 to 730 rpm A59675 WhereEverybodyKnowsYourName 14−138 ENGINE MECHANICAL − ENGINE (1MZ−FE/3MZ−FE) NOTICE:
When checking the idle speed, the transmission should be in the neutral position.
Check the idle speed with the cooling fan off.
Switch off all accessories and air conditioning before connecting the hand−held tester. HINT: Please refer to the hand−held tester operator’s manual for further details. (c) DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TAC A82779 9. (a) (b) (c) (d) (e) When not using the hand−held tester: Check the idle speed. (1) Using SST, connect tachometer test probe to terminal 9 (TAC) of the DLC3. SST 09843−18030 (2) Check the idle speed. Idle speed: Item Specified Condition 1MZ−FE 550 to 650 rpm 3MZ−FE 630 to 730 rpm INSPECT COMPRESSION Warm up and stop the engine. Disconnect the injector connectors. Remove the intake air surge tank (see page 14−142). Remove the 6 ignition coils. Remove the 6 spark plugs. (f) P19471 Check the cylinder compression pressure. SST 09992−00500 (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression pressure:1.5 MPa (15.3 kgf/cm2, 218 psi) Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) NOTICE:
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Check other cylinder’s compression pressure in the same way.
This measurement must be done as quickly as possible. WhereEverybodyKnowsYourName 14−139 ENGINE MECHANICAL − (4) ENGINE (1MZ−FE/3MZ−FE) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT:

If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. 10. INSPECT CO/HC (a) Start the engine. (b) Rev the engine at 2,500 rpm for approximately 180 seconds. (c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Check CO/HC concentration at idle and/or 2,500 rpm. HINT: Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check A/F sensor operation (see page 05−791). (2) See the table below for possible causes, and then inspect and repair. CO Normal Low High HC High High High Problems Causes Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system:
Faulty fuel pressure regulator
Defective ECT sensor
Defective MAF meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor WhereEverybodyKnowsYourName 14−140 ENGINE MECHANICAL − DRIVE BELT (1MZ−FE/3MZ−FE) DRIVE BELT (1MZ−FE/3MZ−FE) 1405G−08 REPLACEMENT 1. 2. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH 3. (a) (b) REMOVE V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Loosen bolts A and B. Loosen adjusting bolt C and remove the belt. 4. (a) REMOVE VANE PUMP V BELT Loosen bolts A and B, and remove the belt. 5. (a) (b) INSTALL VANE PUMP V BELT Install the belt on each pulley. Using a bar, adjust the belt tension and tighten bolt B. Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) Tighten bolt A. Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) A C TO B A62387 A B A62382 A (c) B A62382 6. A C B (a) (b) (c) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Install the belt on each pulley. Tighten adjusting bolt C, and adjust the belt tension. First tighten bolt A, then B. Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) for bolt A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B A62387 WhereEverybodyKnowsYourName 14−141 ENGINE MECHANICAL 7. 8. − DRIVE BELT (1MZ−FE/3MZ−FE) INSPECT DRIVE BELT TENSION (See page 14−140) INSTALL FRONT WHEEL RH WhereEverybodyKnowsYourName 14−142 ENGINE MECHANICAL − VALVE CLEARANCE (1MZ−FE/3MZ−FE) VALVE CLEARANCE (1MZ−FE/3MZ−FE) 141IH−03 ADJUSTMENT 1. 2. DRAIN ENGINE COOLANT (See page 16−27) REMOVE FRONT FENDER APRON SEAL RH 3. (a) (b) REMOVE V−BANK COVER SUB−ASSY Using a socket hexagon wrench 5, remove the 3 nuts. Remove the V−bank cover. A81195 4. 5. 6. REMOVE RADIATOR HOSE INLET REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) REMOVE AIR CLEANER ASSEMBLY WITH HOSE (a) 7. (a) (b) REMOVE EMISSION CONTROL VALVE SET Disconnect the 2 VSV connectors. Remove the wire harness clamp. (c) (d) (e) (f) (g) Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Disconnect the 2 vacuum hoses. Remove the clamp. Remove the 2 nuts and the emission control valve set. (b) (a) A79751 (d) (e) (e) (f) (c) A82428 WhereEverybodyKnowsYourName 14−143 ENGINE MECHANICAL (d) (a) (c) − VALVE CLEARANCE (1MZ−FE/3MZ−FE) 8. (a) (b) (c) (d) REMOVE INTAKE AIR SURGE TANK Disconnect the throttle motor connector. Disconnect the water by−pass hose No. 3. Disconnect the water by−pass hose No. 2. Disconnect the union to check valve hose. (e) Disconnect the ventilation hose. (f) Remove the 3 nuts and disconnect the pressure feed tube. (g) (h) (i) Remove the 2 bolts and engine hanger No. 1. Remove the 2 bolts and surge tank stay No. 1. Remove the 2 bolts and surge tank stay No. 2. (j) (k) Using a socket hexagon wrench 8, remove the 4 bolts. Remove the 2 nuts, emission control valve bracket and intake air surge tank. Remove the gasket from the intake air surge tank. (b) A81623 (e) A79706 (f) A81678 (h) (g) (i) A81674 (l) A82427 WhereEverybodyKnowsYourName 14−144 ENGINE MECHANICAL 9. − VALVE CLEARANCE (1MZ−FE/3MZ−FE) REMOVE IGNITION COIL ASSY 10. (a) (b) (c) REMOVE CYLINDER HEAD COVER SUB−ASSY Remove the 2 engine wire harness clamps. Remove the 3 nuts and disconnect the engine wire harness. Remove the 9 bolts and cylinder head cover. A78541 11. (a) (b) REMOVE CYLINDER HEAD COVER SUB−ASSY LH Using an E6 torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector. Remove the 9 bolts and cylinder head cover. A36719 12. (a) INSPECT VALVE CLEARANCE Turn the crankshaft pulley, and align the timing notch with timing mark 0 of the No. 1 timing belt cover. (b) Check that the valve lifters on the No. 1 timing belt cover (IN and EX) are both loose. If not, turn the crankshaft 1 revolution (360) and align the mark as above. P18805 WhereEverybodyKnowsYourName 14−145 ENGINE MECHANICAL (c) RH Bank 3 3 EX IN − Check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) 1 1 Front LH Bank VALVE CLEARANCE (1MZ−FE/3MZ−FE) 6 6 Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 2 2 A78666 (d) RH Bank 5 5 EX IN 3 3 LH Bank Turn the crankshaft 2/3 of a revolution (240), and check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Front 2 2 Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 4 4 A78667 WhereEverybodyKnowsYourName 14−146 ENGINE MECHANICAL (e) RH Bank 1 1 EX IN Front 4 4 VALVE CLEARANCE (1MZ−FE/3MZ−FE) Turn the crankshaft 2/3 of a revolution (240), and check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) 5 5 LH Bank − Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 6 6 A78668 Upward 13. (a) (b) ADJUST VALVE CLEARANCE Turn the camshaft so that the cam lobe faces upward. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. (c) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248−55040 (09248−05410, 09248−05420) Notch A78669 Front of No. 1 and No. 2 Cylinders SST (A) HINT:
SST (B)
7 Apply SST (B) at a slight angle on the side marked with ”9” or ”7” at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle. Others SST (A) SST (B) 9 A78670 WhereEverybodyKnowsYourName 14−147 ENGINE MECHANICAL − VALVE CLEARANCE (1MZ−FE/3MZ−FE) (d) Using a small screwdriver and magnetic finger, remove the adjusting shim. (e) Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. SST (B) Magnetic Finger A78671 (f) EM0494 (g) A Thickness of new shim B Thickness of used shim C Measured valve clearance Specified value (Cold): Intake A = B + (C − 0.20 mm (0.0079 in.)) Exhaust A = B + (C − 0.30 mm (0.0118 in.)) Select a new shim with a thickness as close as possible to the calculated values. EXAMPLE (Intake): Measured valve clearance = 0.45 mm (0.0177 in.) 0.45 mm (0.0177 in.) − 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.) (Measured − Specification = Excess clearance) Used shim measurement = 2.80 mm (0.1102 in.) 0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.) (Excess clearance + Used shim = Ideal new shim) Closest new shim = 3.05 mm (0.1201 in.) Select No. 12 shim HINT:

Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). Refer to adjusting shim selection chart on the following 2 pages. WhereEverybodyKnowsYourName 14−148 Adjusting Shim Selection Chart (Intake) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL − Shim No. V00719 Intake valve clearance (Cold): 0.15 to 0.25 mm (0.006 to 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim. WhereEverybodyKnowsYourName Thickness Shim No. mm (in.) Thickness HINT: A shim’s thickness is written on its face in millimeters. VALVE CLEARANCE (1MZ−FE/3MZ−FE) New shim thickness Adjusting Shim Selection Chart (Exhaust) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL − Shim No. WhereEverybodyKnowsYourName Shim No. Thickness HINT: A shim’s thickness is written on its face in millimeters. 14−149 V00720 Exhaust valve clearance (Cold): 0.25 to 0.35 mm (0.010 to 0.014 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 10 shim. Thickness mm (in.) VALVE CLEARANCE (1MZ−FE/3MZ−FE) New shim thickness 14−150 ENGINE MECHANICAL SST (A) (h) (i) SST (B) (j) − VALVE CLEARANCE (1MZ−FE/3MZ−FE) Place a new adjusting shim on the valve lifter with the imprinted number facing down. Press down the valve lifter with SST (A), and remove SST (B). SST 09248−55040 (09248−05410, 09248−05420) Recheck the valve clearance. A78672 14. (a) : Seal Packing Front A78673 : Seal Packing Front A78674 16. 17. (a) (b) (c) (d) INSTALL CYLINDER HEAD COVER SUB−ASSY Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover. (b) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) (c) Install the engine wire harness with the 3 nuts. Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf) 15. INSTALL CYLINDER HEAD COVER SUB−ASSY LH (a) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover. (b) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) (c) Using an E6 torx socket wrench, install the engine wire harness protector with the 2 bolts. INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) INSTALL INTAKE AIR SURGE TANK Install a new gasket to the intake air surge tank. Install the intake air surge tank and emission control valve bracket with the 2 nuts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Using a socket hexagon wrench 8, tighten the 4 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Install the surge tank stay No. 2 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) WhereEverybodyKnowsYourName 14−151 ENGINE MECHANICAL (e) (f) (g) (h) (i) (j) (k) (l) − VALVE CLEARANCE (1MZ−FE/3MZ−FE) Install the surge tank stay No. 1 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) Install the engine hanger No. 1 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) Install the pressure feed tube with the 3 nuts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) Connect the ventilation hose. Connect the union to check valve hose. Connect the water by−pass hose No. 2. Connect the water by−pass hose No. 3. Connect the throttle motor connector. (d) (c) (c) (b) 18. (a) (b) (c) (d) (e) INSTALL EMISSION CONTROL VALVE SET Install the valve set with the 2 nuts. Install the clamp. Connect the 2 vacuum hoses. Connect the fuel vapor feed hose No. 2. Connect the fuel vapor feed hose No. 1. (f) (g) Install the wire harness clamp. Connect the 2 VSV connectors. (e) A82428 (b) (b) (a) A79751 19. 20. 21. 22. (a) (b) 23. 24. 25. INSTALL AIR CLEANER ASSEMBLY WITH HOSE INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N⋅m (816 kgf⋅cm, 59 ft.⋅lbf) INSTALL RADIATOR HOSE INLET INSTALL V−BANK COVER SUB−ASSY Fit the 2 retainers and install the V−bank cover. Using a socket hexagon wrench 5, tighten the 3 nuts. Torque: 7.9 N⋅m (81 kgf⋅cm, 70 in.⋅lbf) INSTALL FRONT FENDER APRON SEAL RH ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) WhereEverybodyKnowsYourName 14−152 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 141IT−02 COMPONENTS Front Fender Apron Seal RH 7.9 (81, 70 in.·lbf) V−Bank Cover Radiator Hose Intlet V Belt No. 1 Oil Reservoir to Pump Hose No. 1 Vane Pump V Belt Heater Inlet Water Hose Heater Outlet Water Hose Steering Gear Outlet Return Tube Fuel Pipe Clamp Oil Cooler Outlet Hose Oil Cooler Inlet Hose Fuel Pipe No. 1 7.5 (77, 66 in.·lbf) Air Cleaner Assy W/Hose Radiator Hose Outlet Air Cleaner Inlet 9.0 (92, 80 in.⋅lbf) Air Cleaner Bracket 5.0 (51, 44 in.·lbf) Air Cleaner Inlet No. 1 Battery Intake Air Resonator Engine Unde Cover RH Engine Under Cover LH N·m (kgf·cm, ft·lbf) : Specified torque WhereEverybodyKnowsYourName A90191 14−153 ENGINE MECHANICAL Generator Bracket No. 2 − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 64 (653, 47) Engine Moving Control Rod 28 (286, 21) 9.8 (100, 87 in.⋅lbf) 23 (235, 17) 56 (571, 41) 8.0 (82, 71 in.·lbf) Condenser Engine Mounting Stay No. 2 RH 18 (184, 13) 43 (438, 32) Generator Assy 18 (184, 13) Generator Belt Adjusting Bar 35 (357, 26) Steering Intermediate Shaft Sub−Assy Front Stabilizer Link Assy LH Tie Rod Assy LH Floor Shift Transmission Control Cable Assy 74 (755, 55) 49 (500, 36) 15 (150, 11) Compressor and Magnetic Clutch 8.0 (82, 71 in.·lbf) Speed Sensor Front LH 26 (260, 19)  294 (2,998, 217) Front Axle Hub LH Nut 127 (1,295, 94) 25 (250, 18) Frame Side Rail Plate RH Front Suspension Member Brace Rear RH Exhaust Pipe Gasket Front Suspension Member Brace Rear LH Exhaust Pipe Assy Front 62 (633, 46)  62 (633, 46)  Frame Side Rail Plate LH 32 (326, 24) 85 (867, 63) 32 (326, 24) Exhaust Pipe Gasket 85 (867, 63) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName 56 (571, 41) Front Exhaust Pipe No. 1 Support Bracket  33 (337, 24) A62388 14−154 ENGINE MECHANICAL Vane Pump Assy − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 7.8 (80, 69 in.·lbf) 43 (439, 32) Drive Shaft Bearing Bracket 95 (969, 70) 64 (653, 47) 32 (330, 24) 87 (887, 64) 95 (969, 70) Front Frame Assy N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A60467 WhereEverybodyKnowsYourName 14−155 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Front Drive Shaft Assy RH Hole Snap Ring 46 (469, 34) 7.8 (80, 69 in.·lbf) 64 (653, 47) 37 (379, 27) Flywheel Housing Under Cover Exhaust Pipe Support Bracket No. 1 21 (214, 15) Automatic Transaxle Assy  Snap Ring Starter Assy 9.8 (100, 72) Front Drive Shaft Assy LH 42 (429, 31) A60468 N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A91473 WhereEverybodyKnowsYourName 14−156 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 8.0 (82, 71 in.⋅lbf) Emission Control Valve Set 20 (204 15) 20 (204, 15) Emission Control Valve Bracket 20 (204, 15) 28 (286, 21) Surge Tank Stay No. 2 Intake Air Surge Tank Surge Tank Stay No. 1 Engine Hanger No. 1 28 (286, 21) 15 (153, 11)  Gasket 8.4 (86, 74 in.⋅lbf) 15 (153, 11) x2 15 (153, 11) 15 (153, 11) x4 x5 15 (153, 11) Intake Manifold Water Outlet 8.0 (80, 71 in.⋅lbf)  Gasket  Gasket Ignition Coil Assy 83 (846, 61) x8 Drive Plate Spacer Front N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName Drive Plate Spacer Rear Drive Plate & Ring Gear Sub−assy A86169 14−157 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 1MZ−FE Knock Sensor 8.5 (87, 75 in.⋅lbf) 39 (398, 29) x3 Exhaust Manifold Heat Insulator No. 1 Exhaust Manifold Sub−assy RH x6  Gasket 49 (500, 36) Knock Sensor 20 (204, 15) 8.0 (82, 71 in.⋅lbf)  O−ring x3 Water Inlet 32 (326, 24) x3 20 (204, 15)  O−ring Thermostat Pump Bracket 8.5 (87, 75 in.⋅lbf) Water Inlet Pipe Engine Oil Pressure Switch Assy 15 (153, 11)  Gasket Exhaust Manifold Heat Insulator No. 2 54 (551, 40) Engine Mounting Bracket RH 49 (500, 36) Manifold Stay No. 2 58 (591, 43) x6 49 (500, 36) Generator Bracket No. 1 8.5 (87, 75 in.⋅lbf) 49 (500, 36) 25 (250, 18) Compressor Mounting Bracket No. 1 Exhaust Manifold Converter Sub−assy No. 2 N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part Manifold Converter Insulator No. 3 A92942 WhereEverybodyKnowsYourName 14−158 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Oil Filler Cap Sub−assy Spark Plug Ventilation Valve Sub−assy 25 (250, 18) 19 (193, 14) 8.0 (80, 71 in.⋅lbf) 8.0 (80, 71 in.⋅lbf) Cylinder Head Cover Sub−assy Oil Filler Cap Gasket Camshaft Timing Oil Control Valve Assy Cylinder Head Cover Gasket Cylinder Head Cover Sub−assy LH  Spark Plug Tube Gasket Cylinder Head Cover Gasket No. 2 VVT Sensor  O−Ring 8.0 (82, 71 in.⋅lbf)  Spark Plug Tube Gasket 8.0 (82, 71 in.⋅lbf) Camshaft Timing Oil Control Valve Assy  O−Ring Oil Level Gage Guide Oil Level Gage Sub−assy  O−ring N·m (kgf·cm, ft·lbf) : Specified torque 8.0 (82, 71 in.⋅lbf)  Non−reusable part A78304 WhereEverybodyKnowsYourName 14−159 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Timing Belt 8.5 (87, 75 in.⋅lbf) Timing Belt No. 2 Cover Timing Belt Guide No. 2 Engine Mounting Bracket RH 28 (286, 21) Timing Belt No. 1 Cover 8.5 (87, 75 in.⋅lbf) 220 (2,250, 162) Crankshaft Pulley 27 (280, 20) Timing Belt Tensioner Assy N·m (kgf·cm, ft·lbf) : Specified torque A78305 WhereEverybodyKnowsYourName 14−160 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Timing Belt No. 3 Cover Gasket 28 (286, 21) Collar 8.5 (87, 76 in.⋅lbf) Timing Belt Idler Bracket Bushing x6 Camshaft Timing Pulley 43 (438, 32) 125 (1,275, 92) Timing Belt Idler Sub−assy No. 2 Water Pump Assy  Water Pump Gasket 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Timing Belt Idler Sub−assy No. 1 34 (347, 25) Crankshaft Timing Pulley 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part Crankshaft Position Sensor 8.0 (80, 71 in.⋅lbf) Timing Belt Plate A78306 WhereEverybodyKnowsYourName 14−161 ENGINE MECHANICAL RH Bank − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Camshaft Bearing Cap No. 4 Camshaft Bearing Cap No. 2 16 (163, 12) Camshaft Timing Gear Bolt Washer Camshaft Sub Gear Camshaft Sub Gear Wave Washer x 10 Camshaft Sub Gear Shaft Snap Ring Camshaft Bearing Cap No. 1 Camshaft Bearing Cap No. 5 Camshaft Bearing Cap No. 2 No. 2 Camshaft Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 6 x 10 16 (163, 12) 150 (1,530, 111) Camshaft Bearing Cap No. 2 Camshaft Timing Gear Assy Camshaft  Gasket 10 (102, 7) 19 (189, 14) See page 14−47 1st: 54 (550, 40) 2st: Turn 90
x4 Cylinder Head Sub−assy Cylinder Head Cover Rear 45 (459, 33)  Gasket Oil Control Valve Filter  Camshaft Setting Oil Seal  Cylinder Head Gasket N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A78307 WhereEverybodyKnowsYourName 14−162 ENGINE MECHANICAL Camshaft Bearing Cap No. 5 LH Bank − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Camshaft Bearing Cap No. 2 Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 6 Camshaft Timing Gear Assy 16 (163, 12) 150 (1,530, 11) Camshaft Bearing Cap No. 2 Camshaft Sub Gear Shaft Snap Ring Camshaft Sub Gear Camshaft Bearing Cap No. 4 No 3 Camshaft Sub−assy Camshaft Bearing Cap No. 2 16 (163, 12) Camshaft Bearing Cap No. 1 Camshaft Sub Gear Wave Washer No 4 Camshaft Sub−assy Camshaft Timing Gear Bolt Washer Oil Control Valve Filter  Gasket See page 14−47 45 (459, 33) 10 (102, 7) 1st: 54 (550, 40) 2st: Turn 90
x4 19 (189, 14) Cylinder Head LH Cylinder Head Cover Rear  Camshaft Setting Oil Seal  Gasket Engine Hanger No. 2  Cylinder Head Gasket No. 2 20 (199, 14) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A78308 14−163 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 8.0 (82, 71 in.⋅lbf) Water Inlet Housing Engine Rear Oil Seal Retainer Cylinder Block Sub−assy  Engine RearOil Seal Oil Pump Assy 20 (199, 14) 43 (439, 32) x6 8.0 (82, 71 in.⋅lbf) 30 (306, 22)  O−Ring 8.0 (82, 71 in.⋅lbf)  Oil Filter Sub−assy Oil Pan Baffle Plate 8.0 (82, 71 in.⋅lbf)  Oil Pump Seal 20 (199, 14) 8.0 (82, 71 in.⋅lbf) Oil Pan Sub−assy 20 (199, 14) 8.0 (82, 71 in.⋅lbf) 20 (199, 14)  Gasket Oil Strainer Sub−assy 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf)  Gasket Oil Pan Sub−assy No. 2 Drain Plug 45 (459, 33) 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A78309 WhereEverybodyKnowsYourName 14−16 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 141I8−02 COMPONENTS Engine Moving Control Rod w/ Bracket 64 (653, 47) Engine Cover Sub−assy No. 1 52 (531, 38) Engine Mounting Bracket No. 2 RH 64 (653, 47) Engine Mounting Stay No. 2 RH Fan and Generator V Belt Heater Inlet Water Hose 52 (531, 38) 21 (214, 15) Generator Assy 25 (250, 18) Radiator Hose Inlet Compressor and Magnetic Clutch ABS R/B Radiator Hose Outlet Heater Outlet Water Hose 9 (82, 80 in.⋅lbf) Engine Under Cover RH Air Cleaner Inlet Assy Air Cleaner Assy Air Cleaner Bracket Battery Battery Tray Engine Under Cover LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName A91109 14−17 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) M/T Floor Shift Cable Transmission Control Shift Front Fender Apron Seal LH Clutch Release Cylinder Steering Intermediate Shaft Sub−assy 35 (357, 26) Oil Reservoir Hose Return Tube Floor Shift Cable Transmission Control Shift (A/T) Tie Rod Assy LH 15 (150, 11) 49 (500, 36) Drive shaft 8 (82, 71 in.⋅lbf) Speed Sensor Front LH  294 (3,000, 217) Front Axle Hub LH Nut Oil Cooler Hose Front Suspension Arm Sub−assy Lower No.1 LH 127 (1,295, 94) Exhaust Pipe Assy Front 56 (571, 41)  Gasket  Gasket  Rear Exhaust Pipe No. 1 Support Bracket 62 (633, 46) Front Exhaust Pipe No. 1 Support Bracket 33 (337, 24)  N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part 33 (337, 24) WhereEverybodyKnowsYourName A92885 14−18 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) A/T 43 (439, 32) 54 (551, 40) 95 (969, 70) Vane Pump Assy Transverse Engine Engine Mounting Bracket 95 (969, 70) 87 (888, 64) Front Frame Assy Frame Side Rail Plate Sub−assy RH Frame Side Rail Plate Sub−assy LH 32 (326, 24) Frame Suspension Member Brace Rear RH 85 (867, 63) Frame Suspension Member Brace Rear LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName 32 (326, 24) 85 (867, 63) A60070 14−19 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) M/T 43 (439, 32) 89 (910, 66) Engine Mounting Bracket Rear No. 2 54 (551, 40) 64 (653, 47) 95 (969, 70) Vane Pump Assy Transverse Engine Engine Mounting Bracket 87 (888, 64) 143 (1,459, 105) Front Frame Assy Frame Side Rail Plate Sub−assy RH Frame Side Rail Plate Sub−assy LH Frame Suspension Member Brace Rear LH 85 (867, 63) 32 (326, 24) Frame Suspension Member Brace Rear LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName 32 (326, 24) 85 (867, 63) A59886 14−20 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) A/T Front Drive Shaft Assy RH 64 (653, 47) Drive Shaft Bearing Bracket Flywheel Housing Under Cover Front Spacer 44 (450, 32) Drive Plate and Ring Gear Sub−assy Engine Wire 98 (1,000, 72) 41 (418, 30) 64 (650, 47) Automatic Transaxle Assy Rear Spacer 46 (470, 34) Starter Assy 39 (398, 29) N⋅m (kgf⋅cm, ft⋅lbf) Front Drive Shaft Assy LH : Specified torque WhereEverybodyKnowsYourName A60075 14−21 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) M/T Front Drive Shaft Assy RH 64 (653, 47) Engine Mounting Bracket Rear 44 (450, 32) Engine Wire 130 (1,330, 96) 19 (195, 14) 64 (560, 47) Flywheel Sub−assy Clutch Disc Assy 46 (470, 34) Clutch Cover Assy 64 (650, 47) 46 (470, 34) Manual Transaxle Assy Front Drive Shaft Assy LH Starter Assy 39 (398, 29) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName A60074 14−22 ENGINE MECHANICAL − PZEV PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 9 (92, 80 in.⋅lbf) 30 (306, 22) Intake Manifold Ignition Coil Assy  Gasket Intake Manifold Runner Valve Assy  Gasket 30 (306, 22) Intake Manifold Insulator No. 1 Ventilation Hose Ventilation Hose No. 2 V−ribbed Belt Tensioner Assy 59.5 (607, 44)  Gasket 37 (378, 27) Exhaust Manifold Converter Sub−assy Manifold Stay 44 (449, 32) 44 (449, 32) Manifold Stay No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A77375 14−23 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Except PZEV 9.0 (92, 80 in.⋅lbf) Ignition Coil Assy Intake Manifold 30 (306, 22)  Gasket Intake Manifold Insulator No. 1 Ventilation Hose Manifold Converter Insulator No. 1 Ventilation Hose No. 2 V−Ribbed Belt Tensioner Assy 12 (122, 9) 37 (378, 27)  Gasket 59.5 (607, 44) Exhaust Manifold Converter Sub−assy 44 (449, 32) 44 (449, 32) Manifold Stay No. 2 Manifold Stay A89789 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A92012 14−24 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 20 (204, 15) Fuel Delivery Pipe w/ Injector Knock Sensor Engine Oil Pressure Switch Assy 20 (204, 15) 15 (153, 11) ECT Sensor 20 (208, 15) Water By−pass Pipe No. 1 Oil Level Gage 9 (92, 80 in.⋅lbf) 9 (92, 80 in.⋅lbf)  Gasket 9 (92, 80 in.⋅lbf) Oil Level Gage Guide TMMK made  O−ring Oil Level Gage 9 (92, 80 in.⋅lbf) Thermostat 9 (92, 80 in.⋅lbf) Water Inlet 9 (92, 80 in.⋅lbf) 9 (92, 80 in.⋅lbf)  Gasket  Water Housing Gasket No. 1 Oil Level Gage Guide  O−ring N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A80062 14−25 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 11 (110, 8) Ventilation Valve Sub−assy 19 (194, 14) Cylinder Head Cover Sub−assy Camshaft Position Sensor Cylinder Head Cover Gasket Spark Plug 19 (194, 14) 9.0 (92, 80 in.⋅lbf) Water Pump Assy Water Pump Pulley 9.0 (92, 80 in.⋅lbf) Crankshaft Position Sensor Oil Filter Union 9.0 (92, 80 in.⋅lbf) 30 (306, 22) 9.0 (92, 80 in.⋅lbf) 26 (265, 19) Oil Filter Sub−assy 170 (1,733, 125) Crankshaft Pulley  Gasket Oil Pan Sub−assy Oil Pan Drain Plug x8 25 (255, 18) 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque x2  Non−reusable part A88218 WhereEverybodyKnowsYourName 14−26 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Chain Sub−assy Chain Vibration Damper No. 1 Crankshaft Timing Sproket Chain Tensioner Slipper No. 2 Chain Sub−assy 19 (194, 14) Spring Oil Pump Drive Sprocket Chain Tensioner Crankshaft Position Sensor Plate No. 1 30 (301, 22) 9.0 (92, 80 in.⋅lbf) Oil Pump Driven Sprocket  Gasket 12 (122, 9.0) Timing Chain Guide Oil Pump Assy 19 (194, 14) 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) Chain Tensioner Assy No. 1  Gasket V−Ribbed Belt Tensioner Assy 43 (438, 32) x4 59.5 (607, 44) 9.0 (92, 80 in.⋅lbf)  Timing Chain Case Oil Seal x8 Timing Chain or Belt Cover Sub−assy 21 (214, 15) N·m (kgf·cm, ft·lbf) : Specified torque A88219  Non−reusable part A91016 WhereEverybodyKnowsYourName 14−27 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) x 16 9.0 (92, 80 in.⋅lbf) 30 (301, 22) x4 No. 1 Bearing Cap Camshaft Bearing No. 1 No. 3 Bearing Cap No. 2 Bearing Cap Camshaft Camshaft Timing Gear Assy No. 2 Camshaft Cylinder Head Bolt 54 (551, 39) See page 14−47 54 (551, 39) 1st: 79 (806, 58) 2nd: Turn 90
Camshaft Timing Sprocket Camshaft Bearing No. 2 9.0 (92, 80 in.⋅lbf) Oil control valve  O−Ring Cylinder Head Sub−assy  Cylinder Head Gasket N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A92010 WhereEverybodyKnowsYourName 14−28 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003)  Engine Rear Oil Seal  Gasket Plug 30 (306, 22) Oil Control Valve Filter for Camshaft timing  O−ring Stiffening Crankcase Assy 33 (337, 24) x5 x6 33 (337, 24) No. 2 Balanceshaft No. 1 Balanceshaft Bearing Balance Shaft Housing See page 14−47 x8 1st: 22 (224, 16) 2nd: Turn 90
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part WhereEverybodyKnowsYourName A91573 14−164 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 141IX−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−26) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL DRAIN ENGINE COOLANT (See page 16−27) DRAIN AUTOMATIC TRANSAXLE FLUID REMOVE BATTERY REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) 12. (a) REMOVE ENGINE MOVING CONTROL ROD Remove the 4 bolts and control rod. 13. (a) REMOVE ENGINE MOUNTING STAY NO.2 RH Remove the bolt, mounting stay No. 2 RH and mounting bracket No. 2 RH. A90268 A52344 14. (a) REMOVE UNION TO CHECK VALVE HOSE Remove the vacuum hose for the brake booster. 15. (a) (b) REMOVE V−BANK COVER SUB−ASSY Using a 5 mm hexagon wrench, remove the 3 nuts. Disconnect the 2 clips, and remove the cover. A81195 WhereEverybodyKnowsYourName 14−165 ENGINE MECHANICAL 16. 17. 18. 19. 20. − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE AIR CLEANER INLET ASSY REMOVE AIR CLEANER ASSEMBLY WITH HOSE REMOVE AIR CLEANER BRACKET REMOVE AIR CLEANER INLET NO.1 REMOVE INTAKE AIR RESONATOR SUB−ASSY 21. SEPARATE FUEL PIPE SUB−ASSY NO.1 (a) Remove the fuel pipe clamp. Fuel Pipe Clamp No.1 A60083 (b) A A B12941 22. 23. 24. 25. 26. 27. 28. Disconnect the connector from the tube while pinching part A with fingers as shown in the illustration. NOTICE:
Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
Disconnect the connector with your hands.
Do not bend, fold or rotate the nylon tube.
If the pipe and connector are stuck together, push and pull the connector until it comes free.
Put the pipe and connector ends in vinyl bags to prevent damage and contamination. REMOVE RADIATOR HOSE INLET REMOVE RADIATOR HOSE OUTLET DISCONNECT OIL COOLER INLET HOSE DISCONNECT OIL COOLER OUTLET HOSE DISCONNECT HEATER INLET WATER HOSE DISCONNECT HEATER OUTLET WATER HOSE REMOVE GLOVE COMPARTMENT DOOR ASSY 29. DISCONNECT ENGINE WIRE (a) Disconnect the engine wire from the ECM and J/B. (b) (1) (2) Disconnect the engine wire from the engine room J/B. (1) Remove the nut and separate the wire harness. (2) Using a screwdriver, unlock the engine room junction block. Disconnect the engine wire by pulling it upward. A59893 WhereEverybodyKnowsYourName 14−166 ENGINE MECHANICAL (c) (d) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (3) Disconnect the connector. Pull out the engine wire. Remove the body ground. A59894 30. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (See page 40−65) 31. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 32. DISCONNECT STEERING GEAR OUTLET RETURN TUBE A60072 A60073 33. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET 34. REMOVE EXHAUST PIPE ASSY FRONT 35. DISCONNECT FRONT STABILIZER LINK ASSY LH (a) Using a 6 mm socket hexagon wrench, hold the ball stud. (b) Remove the nut and disconnect the stabilizer link. 36. DISCONNECT FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. WhereEverybodyKnowsYourName 14−167 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 37. (a) REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, strike the lock nut covering to remove it. SST SST 09930−00010 NOTICE:
Set the drive shaft’s groove so that it faces up. Then use the SST and hammer.
Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged. C65981
Do not sharpen the tip of the SST. (b) Using a 30 mm socket wrench, remove the lock nut. REMOVE FRONT AXLE HUB RH NUT 38. HINT: Use the same procedures described for the LH side. 39. DISCONNECT SPEED SENSOR FRONT LH (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. NOTICE: Keep the speed sensor tip and connection free from foreign matter. 40. DISCONNECT SPEED SENSOR FRONT RH HINT: Use the same procedures described for the LH side. 41. (a) (b) DISCONNECT TIE ROD ASSY LH Remove the cotter pin and nut. Using SST, disconnect the tie rod end from the steering knuckle. SST 09628−62011 NOTICE: Do not damage the dust cover of the ball joint. SST C65311 42. DISCONNECT TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 43. (a) (b) DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint. Using a plastic hammer, disconnect the drive shaft from the axle hub. C65935 WhereEverybodyKnowsYourName 14−168 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 44. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 45. REMOVE STARTER ASSY (See page 19−29) 46. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 47. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (a) Using SST, hold the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Remove the 2 bolts and flywheel housing under cover. SST A36243 (c) Remove the 6 torque converter setting bolts. 48. DISCONNECT STEERING INTERMEDIATE SHAFT ASSY Loosen the sliding yoke bolt. A52328 (a) A60062 (b) (c) Place matchmarks on the steering intermediate shaft and control valve shaft. Remove the bolt and disconnect the steering intermediate shaft. A60063 WhereEverybodyKnowsYourName 14−169 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (d) To prevent the steering wheel from rotating, fix the wheel with the seat belt. NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged. A59876 49. 50. REMOVE GENERATOR ASSY (See page 19−42) REMOVE GENERATOR BRACKET NO.2 51. (a) REMOVE GENERATOR BELT ADJUSTING BAR Remove the 2 bolts, 2 nuts and the adjusting bar. 52. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH Remove the bolt, nut and adjusting bar bracket. Remove the 3 bolts and disconnect the compressor. A52889 (a) (b) HINT: Hang up the hoses instead of detaching them. 53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. Adjusting Bar Bracket A52901 (b) Remove the 4 bolts, 2 nuts, and frame side rail plate sub− assembly RH and LH. A59877 WhereEverybodyKnowsYourName 14−170 ENGINE MECHANICAL (c) (d) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH. Carefully, remove the engine assembly from the vehicle. A59878 (e) (f) Install the engine hanger as shown in the illustration. No. 2 engine hanger: Part No. 12282−20020 Bolt: Part No. 91621−60822 Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Using a chain block and an engine sling device, hang the engine assembly. A36439 54. (a) (b) (c) REMOVE VANE PUMP ASSY Remove the power steering oil pressure sensor harness. Remove the pressure feed tube clamp. Remove the 2 bolts and vane pump. 55. (a) REMOVE FRONT FRAME ASSY Remove the 2 nuts and disconnect the engine mounting insulator RH and LH. (b) Remove the bolt and disconnect the engine mounting insulator FR. A52890 RH LH A78403 A60471 WhereEverybodyKnowsYourName 14−171 ENGINE MECHANICAL 56. 57. 58. 59. 60. 61. − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30−8) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30−8) REMOVE ENGINE WIRE REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40−9) REMOVE DRIVE PLATE & RING GEAR SUB−ASSY (See page 40−27) INSTALL ENGINE STAND (d) (a) (c) 62. (a) (b) (c) (d) REMOVE INTAKE AIR SURGE TANK Disconnect the throttle motor connector. Disconnect the water bypass hose No. 3. Disconnect the water bypass hose No. 2. Disconnect the union to check valve hose. (e) Disconnect the ventilation hose. (f) Remove the 3 nuts and separate the pressure feed tube. (g) (h) (i) Remove the 2 bolts and engine hunger No. 1. Remove the 2 bolts and surge tank stay No. 1. Remove the 2 bolts and surge tank stay No. 2. (b) A81623 (e) A79706 (f) A81678 (h) (g) (i) A81674 WhereEverybodyKnowsYourName 14−172 ENGINE MECHANICAL (j) (k) (l) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Using a socket hexagon wrench 8, remove the 4 bolts. Remove the 2 nuts, emission control valve bracket and surge tank. Remove the gasket from the surge tank. A82427 63. (a) INSPECT INTAKE AIR SURGE TANK Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the manifold. A85565 64. REMOVE IGNITION COIL ASSY (b) (a) (b) 65. (a) (b) (b) (b) REMOVE INTAKE MANIFOLD Remove the nut and disconnect the ground cable. Disconnect the 6 fuel injector connectors. (b) (b) A81200 WhereEverybodyKnowsYourName 14−173 ENGINE MECHANICAL 10 4 3 11 7 PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (c) Uniformly, loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold. 66. (a) INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake surge tank for warpage. Maximum warpage: 2 6 8 − 5 9 1 A81201 Cylinder Head Side Item Specified Condition Intake air surge tank side 0.15 mm (0.0059 in.) Cylinder head side 0.08 mm (0.0031 in.) If warpage is greater than the maximum, replace the manifold. Air Intake ChamberSide A85566 67. REMOVE WATER OUTLET (See page 14−239) WhereEverybodyKnowsYourName 14−174 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 68. (a) (b) REMOVE EXHAUST MANIFOLD SUB−ASSY RH Disconnect the A/F sensor connector. Remove the 3 bolts and insulator. (c) Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration. Remove the manifold and gasket. A86571 3 6 1 (d) 2 5 4 A86572 69. (a) INSPECT EXHAUST MANIFOLD SUB−ASSY RH Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If the warpage is greater than the maximum, replace the manifold. A90217 70. (a) REMOVE MANIFOLD STAY NO.2 Remove the 2 bolts and manifold stay. 71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 Remove the 2 bolts and insulator. A86568 (a) A86566 WhereEverybodyKnowsYourName 14−175 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (b) Remove the bolt, nut and insulator. 72. REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY NO.2 Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration. Remove the converter and gasket. A86565 4 7 2 (a) (b) 6 3 5 1 A86567 73. INSPECT EXHAUST MANIFOLD CONVERTER SUB−ASSY NO.2 (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If the warpage is greater than the maximum, replace the manifold. A90216 74. REMOVE DRIVE SHAFT BEARING BRACKET 75. (a) REMOVE PUMP BRACKET Remove the 3 bolts and pump bracket. A05189 WhereEverybodyKnowsYourName 14−176 ENGINE MECHANICAL 76. 77. 78. 79. 80. − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE REMOVE REMOVE REMOVE REMOVE GENERATOR BRACKET NO.1 COMPRESSOR MOUNTING BRACKET NO.1 WATER INLET PIPE WATER INLET THERMOSTAT 81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (a) Remove the oil pressure switch. Oil Pressure Switch A52637 82. (a) REMOVE KNOCK SENSOR 1MZ−FE: Using SST, remove the 2 sensors. SST 09816−30010 (b) 3MZ−FE: Remove the 2 nuts and 2 sensors. 84. (a) INSTALL KNOCK SENSOR 1MZ−FE: Using SST, install the 2 knock control sensors. SST 09816−30010 Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) (b) 3MZ−FE: Install the 2 knock sensors with the 2 nuts, as shown in the illustration. Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) Knock Sensor SST Knock Sensor P20115 83. REPLACE PARTIAL ENGINE ASSY Knock Sensor SST Knock Sensor P20115 Upper 0 to 5
Engine Front A79750 WhereEverybodyKnowsYourName 14−177 ENGINE MECHANICAL 85. (a) Oil Pressure Switch (b) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) INSTALL ENGINE OIL PRESSURE SWITCH ASSY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080 THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pressure switch. Torque: 15 N⋅m (152 kgf⋅cm, 11 ft⋅lbf) A52637 86. 87. 88. 89. 90. INSTALL THERMOSTAT (See page 16−32) INSTALL WATER INLET (See page 16−32) INSTALL WATER INLET PIPE (See page 16−32) INSTALL COMPRESSOR MOUNTING BRACKET NO.1 Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) INSTALL GENERATOR BRACKET NO.1 Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) 91. INSTALL PUMP BRACKET Torque: 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) A05189 92. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 4 1 93. 6 (a) 2 5 3 (b) INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY NO.2 Install a new gasket and the converter sub−assy No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) Retighten nuts 1 and 2 as shown in the illustration. 7 A86567 WhereEverybodyKnowsYourName 14−178 ENGINE MECHANICAL 94. 95. − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Torque: 8.5 N⋅m (87 kgf⋅cm, 55 in.⋅lbf) INSTALL MANIFOLD STAY NO.2 Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) 4 1 96. (a) 6 (b) 5 2 INSTALL EXHAUST MANIFOLD SUB−ASSY RH Install a new gasket and the exhaust manifold RH. Uniformly tighten the 5 nuts in the sequence shown in the illustration. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) Retighten nuts 1 and 2 shown in the illustration. 3 A86572 97. INSTALL WATER OUTLET (See page 14−239) 98. (a) (b) (c) (d) 2 8 10 6 4 9 1 5 INSTALL INTAKE MANIFOLD Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Retighten the water outlet mounting bolts and nuts. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the ground cable with the nut. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) Connect the heater inlet water hose. 7 3 11 A81201 99. INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 100. INSTALL INTAKE AIR SURGE TANK (a) Install a new gasket to the intake air surge tank. (b) Install the intake air surge tank and emission control valve bracket with the 2 nuts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) (c) Using a socket hexagon wrench 8, tighten the 4 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) (d) Install the surge tank stay No. 2 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) WhereEverybodyKnowsYourName 14−179 ENGINE MECHANICAL (e) (f) (g) (h) (i) (j) (k) (l) 101. 102. 103. 104. RH − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Install the surge tank stay No. 1 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) Install the engine hunger No. 1 with the 2 bolts. Torque: 20 N⋅m (199 kgf⋅cm, 15 ft⋅lbf) Install the pressure feed tube with the 3 nuts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) Connect the ventilation hose. Connect the union to check valve hose. Connect the water bypass hose No. 2. Connect the water bypass hose No. 3. Connect the throttle motor connector. INSTALL DRIVE PLATE & RING GEAR SUB−ASSY (See page 40−27) INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40−9) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30−8) INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30−8) 105. INSTALL FRONT FRAME ASSY LH (a) Install the engine mounting insulator RH and LH with the 2 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) A78403 (b) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) A60471 106. INSTALL VANE PUMP ASSY (a) Install the vane pump with the 2 bolts. Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) HINT: After adjusting the V−ribbed belt, tighten bolt A. A A52337 WhereEverybodyKnowsYourName 14−180 ENGINE MECHANICAL Nut B Nut B A A A59877 C Nut C PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 107. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt A 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut (d) Nut − Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt C 32N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt D and nut D D A59878 108. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor with the 3 bolts. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (b) Install the adjusting bar bracket with the bolt and nut. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) for bolt 26 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) for nut Adjusting Bar Bracket A52901 109. INSTALL GENERATOR BELT ADJUSTING BAR (a) Install the adjusting bar with the 2 bolts and 2 nuts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for nut A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt C A C B A52342 110. INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 111. INSTALL GENERATOR ASSY (See page 19−42) WhereEverybodyKnowsYourName 14−181 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 112. INSTALL STEERING INTERMEDIATE SHAFT ASSY (a) Align the matchmarks on the intermediate shaft and control valve shaft, and install the bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A60063 (b) Tighten the sliding yoke bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A60062 SST A36243 113. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (a) Using SST, hold the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Using kerosene or gasoline, clean the bolts thoroughly. (c) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (d) Install the 6 torque converter set bolts. Torque: 41 N⋅m (418 kgf⋅cm, 30 ft⋅lbf) NOTICE: First tighten the green colored bolt and then tighten the 5 bolts. (e) Install the flywheel housing under cover with the 2 bolts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) A52328 114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) 115. INSTALL STARTER ASSY (See page 19−29) WhereEverybodyKnowsYourName 14−182 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 116. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (a) Install the drive shaft to the steering knuckle. (b) Install the suspension lower arm with the bolt and 2 nuts. Torque: 75 N⋅m (764 kgf⋅cm, 55 ft⋅lbf) C65935 117. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 118. INSTALL TIE ROD ASSY LH (a) Connect the tie rod end to the steering knuckle and install a new castle nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) NOTICE:
Prevent any lubricant from contacting the thread and the taper portions.
After tightening the castle nut, tighten it to the additional direction within 60
to put into a cotter pin. (b) Insert a new cotter pin. 119. INSTALL TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 120. INSTALL SPEED SENSOR FRONT LH (See page 32−66) 121. INSTALL SPEED SENSOR FRONT RH HINT: Use the same procedures described for the LH side. 122. INSTALL FRONT AXLE HUB LH NUT (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 294 N⋅m (2,998 kgf⋅cm, 217 ft⋅lbf) (b) Using a chisel and hammer, tapped the front axle hub LH nut. C65982 123. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedures described for the LH side. 124. INSTALL FRONT STABILIZER LINK ASSY LH (a) Using a 6 mm socket hexagon wrench, hold the ball stud, and install the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) 125. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 126. INSTALL EXHAUST PIPE ASSY FRONT (See page 15−7) WhereEverybodyKnowsYourName 14−183 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 127. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET (See page 15−7) 128. CONNECT FUEL PIPE SUB−ASSY NO.1 (a) Push in the fuel tube connector to the fuel pipe until connector makes a ”click” sound. NOTICE:
Check for damage or contamination on the connected part of the pipe.
After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart. B12944 (b) Install the fuel pipe clamp. 129. INSTALL AIR CLEANER ASSEMBLY WITH HOSE 130. CONNECT VACUUM HOSES Vacuum Hose Routing Diagram (1MZ−FE) VSV for EVAP VSV for IAC Valve No. 1 From Canister Actuator Vacuum Tank Vacuum Surge Tank Actuator VSV for IAC Valve No. 2 VSV for IAC Valve No. 3 Engine Mounting Insulator FR Cap VSV for Active Control Engine Mount (ACM) A90543 WhereEverybodyKnowsYourName 14−184 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Vacuum Hose Routing Diagram (3MZ−FE) From Canister Actuator VSV for EVAP Vacuum Surge Tank Vacuum Tank VSV for IAC Valve No. 2 Actuator VSV for IAC Valve No. 3 Engine Mounting Insulator FR Cap VSV for Active Control Engine Mount (ACM) A80833 131. INSTALL V−BANK COVER SUB−ASSY (a) Using a 5 mm socket hexagon wrench, install the V−bank cover with the 2 nuts. Torque: 7.9 N⋅m (81 kgf⋅cm, 70 in.⋅lbf) 132. INSTALL ENGINE MOUNTING STAY NO.2 RH (a) Install the mounting stay and mounting bracket with the bolt. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A52344 WhereEverybodyKnowsYourName 14−185 ENGINE MECHANICAL B A A A − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 133. INSTALL ENGINE MOVING CONTROL ROD (a) Install the control rod and bracket with the 4 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt A 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bolt B A90268 134. INSTALL VANE PUMP V BELT (See page 51−17) 135. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) 136. INSPECT DRIVE BELT TENSION (See page 14−136) 137. INSTALL FRONT WHEELS 138. ADD AUTOMATIC TRANSAXLE FLUID (See page 40−2) 139. ADD ENGINE OIL 140. ADD ENGINE COOLANT (See page 16−27) 141. ADD POWER STEERING FLUID 142. BLEED POWER STEERING FLUID (See page 51−3) 143. CHECK FOR OIL LEAKS 144. CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) 145. INSPECT FOR FUEL LEAKS 146. CHECK FOR EXHAUST GAS LEAKS 147. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26−5) 148. INSPECT IGNITION TIMING (See page 14−136) 149. INSPECT ENGINE IDLE SPEED (See page 14−136) 150. INSPECT CO/HC (See page 14−136) 151. CHECK ABS SPEED SENSOR SIGNAL (See page 05−990) WhereEverybodyKnowsYourName 14−186 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 141IV−03 OVERHAUL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (a) (b) 11. 12. REMOVE SPARK PLUG REMOVE OIL FILLER CAP SUB−ASSY REMOVE OIL FILLER CAP GASKET REMOVE CYLINDER HEAD COVER SUB−ASSY LH REMOVE CYLINDER HEAD COVER GASKET NO.2 REMOVE CYLINDER HEAD COVER SUB−ASSY REMOVE CYLINDER HEAD COVER GASKET REMOVE VENTILATION VALVE SUB−ASSY REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY REMOVE VVT SENSOR Remove the sensor. Remove the O−ring from the sensor. REMOVE OIL LEVEL GAGE SUB−ASSY REMOVE OIL LEVEL GAGE GUIDE 13. (a) REMOVE CRANKSHAFT PULLEY Using SST, loosen the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 SST A78700 (b) Using SST and the pulley bolt, remove the pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05031) NOTICE: Before using SST, apply lubricating oil on the threads and tip of the center bolt 150. SST A78701 14. 15. 16. 17. REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 WhereEverybodyKnowsYourName 14−187 ENGINE MECHANICAL 18. (a) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE TIMING BELT Set the No. 1 cylinder to TDC/compression. (1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (2) Turn the crankshaft clockwise, and align the timing mark of the crankshaft timing pulley with the oil pump body. Turn A78326 (3) Check that timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360). (4) Remove the crankshaft pulley bolt. A05052 (b) If reusing the timing belt, check that there are 4 installation marks on the timing belt as shown in the illustration. (1) If the installation marks have disappeared, put new installation marks on the timing belt before removing. A52840 (c) Approx. 60 Turn A78327 Set the No. 1 cylinder to approximately 60 BTDC/ compression. (1) Turn the crankshaft counterclockwise by approximately 60. NOTICE: With timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and damaged. (d) Remove the timing belt tensioner. NOTICE: Do not reinstall the tensioner with its plunger extended. WhereEverybodyKnowsYourName 14−188 ENGINE MECHANICAL (e) (3) PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Remove the timing belt in this order. (5) (2) − (4) (1) 1st No. 1 idler pulley 2nd RH camshaft timing pulley 3rd No. 2 idler pulley 4th LH camshaft timing pulley 5th Water pump pulley 6th Crankshaft timing pulley (6) A78702 19. (a) 20. 21. REMOVE TIMING BELT IDLER SUB−ASSY NO.1 Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer. REMOVE TIMING BELT IDLER SUB−ASSY NO.2 REMOVE CRANKSHAFT POSITION SENSOR 22. (a) REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and RH timing pulley. SST 09960−10010 (09962−01000, 09963−01000) (b) Using SST, remove the bolt and LH timing pulley. SST 09960−10010 (09962−01000, 09963−01000) SST A32937 HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling. SST A32938 23. 24. REMOVE TIMING BELT NO.3 COVER REMOVE TIMING BELT IDLER BRACKET 25. (a) (b) (c) SST A15128 A32939 REMOVE CRANKSHAFT TIMING PULLEY Remove the bolt and the timing belt plate. Install the pulley bolt to the crankshaft. Using SST, remove the crankshaft timing pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05011) NOTICE:
Do not scratch the sensor part of the crankshaft timing pulley. WhereEverybodyKnowsYourName 14−189 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE)
Before using SST, apply lubricating oil on the threads and tip of the center bolt 150. 26. (a) REMOVE WATER PUMP ASSY Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket. A78535 27. REMOVE CAMSHAFT NOTICE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out. (a) Align the camshaft drive and driven gear’s timing marks (2 dot marks each) by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub−gear to the main gear with a service bolt. Recommended service bolt: Align A78706 Main Gear Sub−Gear Item Service Bolt A78707 Specified Condition Thread diameter 6 mm Thread pitch 1 mm Bolt length 16 to 20 mm Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. WhereEverybodyKnowsYourName 14−190 ENGINE MECHANICAL 10 PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (c) 2 6 − 8 1 5 4 9 7 3 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78708 28. (a) 1 5 9 7 2 6 3 10 8 4 A78709 Align REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 2 camshaft. 29. REMOVE NO.3 CAMSHAFT SUB−ASSY NOTICE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out. (a) Align the camshaft drive and driven gear’s timing marks (1 dot mark each) by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub−gear to the main gear with a service bolt. Recommended service bolt: A78710 Service Bolt Thread diameter 6 mm Thread pitch 1 mm Bolt length 16 to 20 mm Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Main Gear Sub−Gear A78711 WhereEverybodyKnowsYourName 14−191 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. (c) 1 5 2 9 6 7 10 8 3 4 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78712 6 30. (a) 2 10 1 8 5 9 4 7 3 A78713 REMOVE NO.4 CAMSHAFT SUB−ASSY Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 4 camshaft. 31. (a) (b) INSPECT CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise on the hexagonal lobe. Check that the VVT−i does not turn. A05739 (c) Convex Portion A78714 Cover all the oil ports with vinyl tape except the port on the advanced angle side (nearest to the convex portion) shown in the illustration. (d) Using an air gun, apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advanced angle side. NOTICE: Some oil spraying will occur. Contain the spray with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (e) Under the condition above, check that the VVT−i can be turned by hand to the advanced angle side, the direction of the white arrow in the illustration. Standard: Must turn WhereEverybodyKnowsYourName 14−192 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) HINT: The VVT−i will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock−pin may be difficult to release. (f) Check that the VVT−i moves freely within a 30 range. Avoid moving the VVT−i unit to the extreme retarded angle position as the lock−pin will re−engage. Standard: Smooth movable range is about 30 (g) Turn VVT−i by hand and lock it at the extreme retarded angle position. 32. REMOVE CAMSHAFT TIMING GEAR ASSY NOTICE: Do not remove or install the timing gear (VVT−i) unless you are replacing the VVT−i or the camshaft. (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. A05739 (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove it with the lock−pin engaged and locked at the extreme retarded angle position.
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. (c) Remove the timing gear (VVT−i). NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT−i, tap it lightly using a plastic− faced hammer and then remove it. 33. REMOVE CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12596 WhereEverybodyKnowsYourName 14−193 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (b) Using SST, turn the sub gear counterclockwise, and remove the service bolt. SST 09960−10010 (09962−01000, 09963−00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub gear and camshaft gear bolt washer. SST A78715 HINT: Arrange the camshaft sub gears and gear bolt washers (RH and LH sides) so that they can be returned to the original location when reassembling. A52353 34. 35. REMOVE ENGINE HANGER NO.2 REMOVE CYLINDER HEAD COVER REAR 36. (a) REMOVE OIL CONTROL VALVE FILTER Remove the plug, gasket and valve filter. 37. (a) REMOVE CYLINDER HEAD SUB−ASSY Using a socket hexagon wrench 8, remove the hexagon bolt. A05275 Front A78716 WhereEverybodyKnowsYourName 14−194 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 2 7 5 3 4 6 8 1 A78717 38. REMOVE CYLINDER HEAD GASKET 39. (a) Front REMOVE CYLINDER HEAD LH Using a socket hexagon wrench 8, remove the hexagon bolt. A78718 (b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 4 6 8 1 2 7 5 3 A78719 40. REMOVE CYLINDER HEAD GASKET NO.2 8 41. (a) 2 10 5 3 REMOVE WATER INLET HOUSING Uniformly loosen and remove the 8 bolts and 2 nuts in the sequence shown in the illustration. Remove the water inlet housing. 4 6 7 9 1 A78314 WhereEverybodyKnowsYourName 14−195 ENGINE MECHANICAL 42. (a) SST (b) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE OIL FILTER SUB−ASSY Using SST, remove the oil filter. SST 09228−07501 Using a socket hexagon wrench 12, remove the oil filter union. B06486 43. REMOVE OIL PAN DRAIN PLUG 44. (a) REMOVE OIL PAN SUB−ASSY NO.2 Remove the 10 bolts and 2 nuts. A36750 (b) SST SST Insert the blade of SST between oil pan No. 1 and oil pan No. 2, cut off the sealer and remove the oil pan No. 2. SST 09032−00100 NOTICE:
Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
Do not damage the flange portion of oil pan No. 2 during removal. A00019 45. (a) REMOVE OIL STRAINER SUB−ASSY Remove the bolt and 2 nuts, then remove the oil strainer and the gasket. 46. (a) REMOVE OIL PAN SUB−ASSY Uniformly loosen and remove the 15 bolts and 2 nuts in the sequence shown in the illustration. B04136 WhereEverybodyKnowsYourName 14−196 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block. B04137 47. REMOVE OIL PAN BAFFLE PLATE 48. (a) (b) REMOVE ENGINE REAR OIL SEAL RETAINER Uniformly loosen and remove the 6 bolts. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap. 49. (a) REMOVE ENGINE REAR OIL SEAL Using a screwdriver and a hammer, tap out the oil seal. 50. (a) (b) REMOVE OIL PUMP ASSY Remove the 9 bolts. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap. Remove the O−ring. P12508 P12589 (c) A51990 WhereEverybodyKnowsYourName 14−197 ENGINE MECHANICAL 51. (a) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) REMOVE OIL PUMP SEAL Using a screwdriver, pry out the oil seal. A62375 52. (a) REMOVE SPARK PLUG TUBE GASKET Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out. NOTICE: Be careful not to damage the baffle plate of the cylinder head cover. (b) Using a screwdriver and a hammer, tap out the gasket. A05245 (c) Using needle−nose pliers, pry out the gasket. NOTICE: Be careful not to damage the cylinder head cover. A05243 EM3336 53. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley. Check the belt for any defects, as shown in the illustrations. Also, check these points below. (a) If there is premature parting:
Check for proper installation.
Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. WhereEverybodyKnowsYourName 14−198 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign object on the pulley teeth. If there is any doubt about the belt condition, replace the timing belt. 54. (a) INSPECT CAMSHAFT Inspect the camshaft for runout. (1) Place the camshaft on V−blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the runout is greater than the maximum, replace the camshaft. EM1628 (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Specified cam lobe height: 1MZ−FE Item Specified Condition Intake 42.780 to 43.032 mm (1.6842 to 1.6942 in.) Exhaust 42.610 to 42.864 mm (1.6776 to 1.6876 in.) 3MZ−FE A51428 Item Specified Condition Intake 42.980 to 43.232 mm (1.6921 to 1.7020 in.) Exhaust 42.860 to 43.110 mm (1.6874 to 1.6972 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. A51429 WhereEverybodyKnowsYourName 14−199 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 55. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Specified outside diameter: 8.75 to 9.05 mm (0.3445 to 0.3563 in.) If the diameter is less than the minimum, replace the bolt. Tension Portion A78721 56. (a) SST (b) (c) INSTALL SPARK PLUG TUBE GASKET Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950−60010 (09951−00430), 09950−70010 (09951−07100) Return the ventilation plate tab to its original position. Apply a light coat of MP grease to the gasket lip. A78722 57. (a) SST A78723 Seal Width 2 to 3 mm A INSTALL ENGINE REAR OIL SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−15030, 09950−70010 (09951−07100) NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the rear oil seal retainer edge and the oil seal free of foreign matter. (b) Apply MP grease to the oil seal lip. 58. INSTALL ENGINE REAR OIL SEAL RETAINER (a) Remove any old packing material from the contact surface. (b) A B B A78724 Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the oil seal retainer within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil seal retainer. Tighten the 6 bolts uniformly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) WhereEverybodyKnowsYourName 14−200 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 59. (a) SST A78754 INSTALL OIL PUMP SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223−00010 NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the oil pump body edge and the oil seal free of foreign matter. (b) Apply MP grease to the oil seal lip. 60. (a) (b) INSTALL OIL PUMP ASSY Remove any old packing material from the contact surface. Apply a light coat of engine oil to a new O−ring and place it on the cylinder block. A36784 (c) B A C Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing the oil pump. Seal Packing A B Seal Width 2 to 3 mm C A78725 (d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place. A36785 WhereEverybodyKnowsYourName 14−201 ENGINE MECHANICAL (e) A B C A A B A − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C A A A51990 61. 62. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) INSTALL OIL PAN BAFFLE PLATE Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 63. (a) (b) INSTALL OIL PAN SUB−ASSY Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (diameter 3 to Region ”X” Region ”Y” 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes in region ”X”.
Apply seal packing to the inner side of the bolt holes in region ”Y”. B A
Install the oil pan within 3 minutes after applying seal packing. Seal Packing B A
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil pan No. 1 with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps. Seal Width Torque: 3 to 4 mm 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for 10 mm head A78726 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for 12 mm head 64. INSTALL OIL STRAINER SUB−ASSY (a) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) WhereEverybodyKnowsYourName 14−202 ENGINE MECHANICAL INSTALL OIL PAN SUB−ASSY NO.2 Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil pan No. 2 with the 10 bolts and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) B A PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 65. (a) (b) Seal Packing A − Seal Width 4 to 5 mm B A78727 66. (a) INSTALL OIL PAN DRAIN PLUG Install the drain plug with a new gasket. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) 67. (a) INSTALL WATER INLET HOUSING Remove any old packing material from the contact surface. (b) Seal Width 3 to 5 mm Seal Packing A78728 3 (c) 9 1 6 8 5 Apply a continuous bead of seal packing (diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration. Seal packing: Part No. 08826−00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the water inlet housing within 3 minutes after applying seal packing.
Do not expose the seal to coolant for at least 2 hours after installing. Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 7 2 4 10 A78314 WhereEverybodyKnowsYourName 14−203 ENGINE MECHANICAL 1MZ−FE 3MZ−FE − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 68. (a) INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Make sure the cylinder head gasket is facing in the correct direction.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head. 69. INSTALL CYLINDER HEAD SUB−ASSY NOTICE: The cylinder head bolts are tightened in 2 successive steps. Front Front A79818 A78324 A90678 (a) Front 7 2 4 6 5 3 1 8 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78717 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint as shown in the illustration. Retighten the cylinder head bolts by 90in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 (g) Front Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf) A78716 WhereEverybodyKnowsYourName 14−204 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 70. (a) Front A78325 INSTALL CYLINDER HEAD GASKET NO.2 Place a new cylinder head gasket on the cylinder block with the L mark as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Make sure the cylinder head gasket is facing in the correct direction.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head. 71. INSTALL CYLINDER HEAD LH NOTICE: The cylinder head bolts are tightened in 2 successive steps. (a) Front 5 3 1 8 7 2 4 6 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78719 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint as shown in the illustration. Retighten the cylinder head bolts by 90in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 (g) Front Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf) A78718 WhereEverybodyKnowsYourName 14−205 ENGINE MECHANICAL 72. (a) (b) (c) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) INSTALL OIL CONTROL VALVE FILTER Check that no foreign matter is on the mesh part of the filter. Assemble the valve filter and the plug. Install a new gasket and the plug. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) A05418 73. (a) INSTALL CYLINDER HEAD COVER REAR Install a new gasket and the rear cover with the 4 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) 74. INSTALL CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12595 (b) Wave Washer Camshaft Sub Gear Install the camshaft gear bolt washer and the camshaft sub gear. HINT: Attach the pins on the gears to the gear bolt washer ends. (c) Install the wave washer. Camshaft Gear Bolt Washer A78732 (d) Using snap ring pliers, install the snap ring. A52353 WhereEverybodyKnowsYourName 14−206 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (e) SST A78733 Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt. SST 09960−10010 (09962−01000, 09963−00500) (f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) NOTICE: Be careful not to damage the camshaft journals. HINT: When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 75. (a) Align A78734 INSTALL CAMSHAFT TIMING GEAR ASSY Align the alignment pin with the alignment pin groove and install the VVT−i on the camshaft. NOTICE: Install the VVT−i with the lock−pin engaged and locked at the extreme retarded angle position. (b) Apply engine oil on the nut, the mounting surface of the VVT−i and the screw threads. NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
New nuts must be used when replacing the VVT−i unit. (c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise. Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf) NOTICE:
The lock nut has LH threads.
Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor. A05738 76. INSTALL NO.2 CAMSHAFT NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. WhereEverybodyKnowsYourName 14−207 ENGINE MECHANICAL (a) 90 (b) (c) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 2 camshaft at a 90 angle of the timing mark (2 dot marks) on the cylinder head. Apply MP grease to a new oil seal lip. A78735 (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. (e) Remove any old packing material from the contact surface. Front A78736 (f) Apply seal packing to the No. 1 bearing cap as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. Seal Packing A78737 (g) (h) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (i) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) A05283 6 10 2 4 9 8 5 1 3 7 A78738 WhereEverybodyKnowsYourName 14−208 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 77. INSTALL CAMSHAFT NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) (b) (c) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (2 dot marks each). Place the camshaft on the cylinder head. Align A78739 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. A05204 5 (f) 9 1 3 10 6 7 2 4 8 A78740 Uniformly tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) (g) Remove the service bolt. 78. INSTALL NO.4 CAMSHAFT SUB−ASSY NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. WhereEverybodyKnowsYourName 14−209 ENGINE MECHANICAL (a) (b) 90 (c) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 4 camshaft at a 90 angle of the timing mark (1 dot mark) on the cylinder head. Apply MP grease to a new oil seal lip. A78741 (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front A78742 (e) Seal Packing A78737 Remove any old packing material from the contact surface. (f) Apply seal packing to the No. 1 bearing cap as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads of the bearing cap bolts. A05209 (i) 9 5 1 Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) 10 3 6 7 2 4 8 A78743 WhereEverybodyKnowsYourName 14−210 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) 79. INSTALL NO.3 CAMSHAFT SUB−ASSY NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) (c) Align the camshaft drive and driven gear’s timing marks (1 dot mark each). Place the camshaft on the cylinder head. Align A78744 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A05214 10 6 9 2 4 5 (g) 1 8 3 7 A78745 80. (a) Inward Sensor INSTALL CRANKSHAFT TIMING PULLEY Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place. NOTICE: Do not scratch the sensor area of the crankshaft timing pulley. (b) Install the timing belt plate with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A78746 WhereEverybodyKnowsYourName 14−211 ENGINE MECHANICAL 81. (a) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 3 bolts and 3 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A78535 82. (a) (b) INSTALL OIL LEVEL GAGE GUIDE Apply a light coat of engine oil to a new O−ring and install it to the level gage guide. Install the level gage guide. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 83. INSTALL OIL FILTER SUB−ASSY (a) Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) (b) Check and clean the oil filter installation surface. (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the SST gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228−07501 Additional 3/4 Turn A78747 84. INSTALL TIMING BELT IDLER BRACKET Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 85. INSTALL TIMING BELT NO.3 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 in.), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 in.), replace the gasket. (b) If the timing belt cover gasket needs to be repaired, follow Seal Packing the procedure below. Gasket (1) Repair the cracks and breaks by applying the seal packing to the damaged area. Seal packing: Part No. 08826−00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (c) If the timing belt cover gasket needs to be replaced, follow A78748 the procedure below. WhereEverybodyKnowsYourName 14−212 ENGINE MECHANICAL − (1) PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Using a screwdriver and gasket scraper, remove the remaining gasket. NOTICE: Be careful not to damage the timing belt cover. (2) E F D Joining Line Joining Portion Gasket E Joining G Line Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration. NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform. Length: Gasket D E F G Specified Condition 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.) (3) Seal Packing A78749 Front If there is a gap on the joint of the gasket, apply seal packing to close the gap. Seal packing: Part No. 08826−00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (d) Install the timing belt cover with the 6 bolts. Torque: 8.5 N⋅m (87 kgf⋅cm, 76 in.⋅lbf) 86. (a) Front INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily. HINT:

Face the belt guide of the RH timing pulley towards the front of the engine. Face the belt guide of the LH timing pulley towards the rear of the engine. A78750 (b) Using SST, tighten the RH pulley bolt. SST 09960−10010 (09962−01000, 09963−01000) Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST A78703 WhereEverybodyKnowsYourName 14−213 ENGINE MECHANICAL (c) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Using SST, tighten the LH pulley bolt. SST 09960−10010 (09962−01000, 09963−01000) Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST A78704 87. 88. (a) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSTALL TIMING BELT IDLER SUB−ASSY NO.1 Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) 89. INSTALL TIMING BELT (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Only wipe the pulleys. Do not use cleaning agents on the pulleys. (b) Inspect the idler pulleys. (1) Check that the idler pulley turns smoothly. (2) Visually check the sealed portion of the idler pulley for oil leakage. (c) Inspect the water pump. (1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise. (2) Visually check the drain hole for coolant leakage. (d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (e) Turn the crankshaft counterclockwise by approximately 60. NOTICE: To prevent contacting the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60 BTDC/compression position. Approx. 60 Turn A82349 WhereEverybodyKnowsYourName 14−214 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (f) Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulley with the No. 3 timing belt cover. SST 09960−10010 (09962−01000, 09963−01000) (g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body. (h) (i) Face the front mark on the timing belt forward. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. SST A78751 A05062 (j) A52840 (k) (4) Install the timing belt in this order. 1st (2) (5) (3) (6) Crankshaft timing pulley 2nd Water pump pulley 3rd LH camshaft timing pulley 4th No. 2 idler pulley 5th RH camshaft timing pulley 6th No. 1 idler pulley (1) A78702 A36238 90. INSTALL TIMING BELT TENSIONER ASSY (a) Set the timing belt tensioner uprightly on the press. (b) Slowly press in the push rod. NOTICE: Do not apply pressure of more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod. (c) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod. (d) Release the press. WhereEverybodyKnowsYourName 14−215 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) (e) Temporarily install the tensioner with the 2 bolts. Torque: 27 N⋅m (280 kgf⋅cm, 20 ft⋅lbf) NOTICE: Install the tensioner’s bolts uniformly and evenly. Installing the tenioner at an angle may cause it to malfunction. (f) Remove the 1.5 mm hexagon wrench from the tensioner. (g) Turn the crankshaft 2 revolutions slowly, and align the timing mark of the crankshaft timing pulley with the oil pump body. NOTICE: Always turn the crankshaft clockwise. Turn A78326 (h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (i) Remove the crankshaft pulley bolt. A05052 91. (a) INSTALL TIMING BELT GUIDE NO.2 Install the timing belt guide, facing the cup side toward the engine front. A36239 92. INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 93. INSTALL TIMING BELT NO.2 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) 94. INSTALL TIMING BELT NO.1 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. WhereEverybodyKnowsYourName 14−216 ENGINE MECHANICAL (b) − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE) Install the timing belt cover. Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) 95. (a) (b) INSTALL CRANKSHAFT PULLEY Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place. Using SST, install the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 Torque: 220 N⋅m (2,250 kgf⋅cm, 162 ft⋅lbf) SST A78753 96. INSTALL VVT SENSOR Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 98. INSTALL ENGINE HANGER NO.2 Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 99. INSPECT VALVE CLEARANCE (See page 14−142) 100. ADJUST VALVE CLEARANCE (See page 14−142) : Seal Packing Front A78673 : Seal Packing Front A78674 101. INSTALL CYLINDER HEAD COVER SUB−ASSY (a) Install the gasket to the cylinder head cover. (b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) 102. INSTALL CYLINDER HEAD COVER SUB−ASSY LH (a) Install the gasket to the cylinder head cover. (b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing. WhereEverybodyKnowsYourName 14−217 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1MZ−FE/3MZ−FE)
103. (a) (b) 104. 105. 106. Do not start the engine for at least 2 hours after installing. (c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) INSTALL VENTILATION VALVE SUB−ASSY Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833−00070, THREE BOND 1324 or eguivalent Install the ventilation valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) INSTALL GASKET, OIL FILLER CAP INSTALL OIL FILLER CAP SUB−ASSY INSTALL SPARK PLUG Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) WhereEverybodyKnowsYourName 14−218 ENGINE MECHANICAL − TIMING BELT (1MZ−FE/3MZ−FE) TIMING BELT (1MZ−FE/3MZ−FE) 141II−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 8. (a) REMOVE CRANKSHAFT PULLEY Using SST, loosen the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 SST A52823 SST (b) Using SST and the pulley bolt, remove the pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05010, 09954−05030) NOTICE: Before using SST, apply lubricating oil on the threads and tip of the center bolt 100. A52839 9. REMOVE TIMING BELT NO.1 COVER 10. (a) Clamp Clamp (b) REMOVE TIMING BELT NO.2 COVER Disconnect the engine wire protector clamps from the timing belt No. 3 cover. Remove the 5 bolts and timing belt cover. A05050 WhereEverybodyKnowsYourName 14−219 ENGINE MECHANICAL 11. 12. − TIMING BELT (1MZ−FE/3MZ−FE) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 13. (a) REMOVE TIMING BELT Set the No. 1 cylinder to TDC/compression. (1) Temporarily install the crankshaft pulley bolt with the washer to the crankshaft. (2) Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and oil pump body. A05051 (3) (4) Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360
). Remove the crankshaft pulley bolt. A05052 (b) If reusing the timing belt, check that there are 4 installation marks on the timing belt as shown in the illustration. (1) If the installation marks have disappeared, put new installation marks on the timing belt before removing. A52840 (c) Approx. 60
Turn A78327 Set the No. 1 cylinder to approximately 60
BTDC/compression. (1) Turn the crankshaft counterclockwise by approximately 60
. NOTICE: With timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and then the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and be damaged. (d) Remove the timing belt tensioner. NOTICE: Do not reinstall the tensioner with its plunger extended. WhereEverybodyKnowsYourName 14−220 ENGINE MECHANICAL (e) (3) (5) (2) (4) (1) − TIMING BELT (1MZ−FE/3MZ−FE) Remove the timing belt in this order. 1st No. 1 idler pulley 2nd RH camshaft timing pulley 3rd No. 2 idler pulley 4th LH camshaft timing pulley 5th Water pump pulley 6th Crankshaft timing pulley (6) A78702 EM3336 14. INSTALL TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when instaling the mounting bolt of the camshaft timing pulley. (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Only wipe the pulleys. Do not use cleaning agents on the pulleys. (b) Inspect the idler pulleys. (1) Check that the idler pulleys turn smoothly. (2) Visually check the sealed portion of the idler pulleys for oil leakage. (c) Inspect the water pump. (1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise. (2) Visually check the drain hole for coolant leakage. (d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (e) Turn the crankshaft counterclockwise by approximately 60
. NOTICE: To prevent the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60
BTDC/ compression position. Approx. 60
Turn A82349 WhereEverybodyKnowsYourName 14−221 ENGINE MECHANICAL − TIMING BELT (1MZ−FE/3MZ−FE) (f) Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No. 3 timing belt cover. SST 09960−10010 (09962−01000, 09963−01000) (g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body. (h) (i) Face the front mark on the timing belt forward. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. SST A78751 A05062 (j) A52840 (k) (4) Install the timing belt in this order. 1st (2) (5) (3) (6) Crankshaft timing pulley 2nd Water pump pulley 3rd LH camshaft timing pulley 4th No. 2 idler pulley 5th RH camshaft timing pulley 6th No. 1 idler pulley (1) A78702 A36238 15. INSTALL TIMING BELT TENSIONER ASSY (a) Set the timing belt tensioner uprightly on the press. (b) Slowly press in the push rod. NOTICE: Do not apply pressure of more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod. (c) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod. (d) Release the push rod. WhereEverybodyKnowsYourName 14−222 ENGINE MECHANICAL − TIMING BELT (1MZ−FE/3MZ−FE) (e) Temporarily install the tensioner with the 2 bolts. Torque: 27 N⋅m (280 kgf⋅cm, 20 ft⋅lbf) NOTICE: Install the tensioner’s bolts uniformly and evenly. Installing the tensioner at an angle may cause it to malfunction. (f) Remove the 1.5 mm hexagon wrench from the tensioner. (g) Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body. NOTICE: Always turn the crankshaft clockwise. Turn A78326 (h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (i) Remove the crankshaft pulley bolt. A05052 16. (a) INSTALL TIMING BELT GUIDE NO.2 Install the timing belt guide, facing the cup side toward the engine front. A36239 17. INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER Visually check for cracks and breaks on the gasket of the timing belt cover. 18. (a) HINT: If it is judged that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 8.5 N⋅m (87 kgf⋅cm, 76 in.⋅lbf) 19. INSTALL TIMING BELT NO.1 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. WhereEverybodyKnowsYourName 14−223 ENGINE MECHANICAL − TIMING BELT (1MZ−FE/3MZ−FE) HINT: If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) (c) Install the engine wire protector cover to the timing belt No. 3 cover. 20. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 Torque: 220 N⋅m (2250 kgf⋅cm, 162 ft⋅lbf) SST A52823 21. 22. 23. 24. 25. 26. 27. INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL FRONT WHEEL RH WhereEverybodyKnowsYourName 14−224 ENGINE MECHANICAL − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) 141IJ−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. DRAIN ENGINE COOLANT (See page 16−27) REMOVE V−BANK COVER SUB−ASSY (See page 14−164) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) REMOVE AIR CLEANER ASSEMBLY WITH HOSE REMOVE INTAKE AIR SURGE TANK (See page 14−142) REMOVE SPARK PLUG REMOVE CYLINDER HEAD COVER SUB−ASSY REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 (See page 14−186) REMOVE TIMING BELT (See page 14−186) REMOVE TIMING BELT IDLER SUB−ASSY NO.2 RH 22. (a) REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and RH timing pulley. SST 09960−10010 (09962−01000, 09963−01000), 09249−63010 (b) Using SST, remove the LH timing pulley. SST 09960−10010 (09962−01000, 09963−01000) SST A90211 LH HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling. SST A90212 WhereEverybodyKnowsYourName 14−225 ENGINE MECHANICAL 23. (a) Clamp Clamp (b) − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) REMOVE TIMING BELT NO.3 COVER Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover. Remove the 6 bolts and the timing belt cover. Clamp A05077 24. REMOVE CAMSHAFT NOTICE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Align the camshaft drive and driven gear’s timing marks (2 dot marks each) by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub−gear to the main gear with a service bolt. Recommended service bolt: Align A78706 Main Gear Sub−Gear Service Bolt A78707 Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) HINT: When removing the camshaft, make certain that the torsional spring force of the sub−gear has been eliminated by installation of the service bolt. WhereEverybodyKnowsYourName 14−226 ENGINE MECHANICAL 10 6 − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) (c) 2 8 1 5 4 9 7 3 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78708 5 25. (a) 1 9 7 2 6 3 10 8 4 A78709 REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 2 camshaft. 26. REMOVE CAMSHAFT TIMING GEAR ASSY NOTICE: Do not remove or install the camshaft timing gear (VVT−i) unless you are replacing the VVT−i or the camshaft. (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. A05739 (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove the locknut with the lock−pin engaged and locked at the extreme retarded angle position.
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. (c) Remove the timing gear (VVT−i). NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT−i, tap it lightly using a plastic− faced hammer and then remove it. WhereEverybodyKnowsYourName 14−227 ENGINE MECHANICAL − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) 27. REMOVE CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. P12596 (b) Using SST, turn the sub gear counterclockwise, and remove the service bolt. SST 09960−10010 (09962−01000, 09963−00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub gear and camshaft gear spring. SST P12797 A52353 28. INSTALL CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. P12595 (b) Wave Washer Camshaft Sub Gear Install the camshaft gear bolt washer and the camshaft sub gear. HINT: Attach the pins on the gears to the gear spring ends. (c) Install the wave washer. Camshaft Gear Bolt Washer A78732 WhereEverybodyKnowsYourName 14−228 ENGINE MECHANICAL (d) SST − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) Using snap ring pliers, install the snap ring. P12590 (e) SST P12974 Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt. SST 09960−10010 (09962−01000, 09963−00500) (f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) NOTICE: Do not damage the camshaft journals. HINT: When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 29. (a) Align A78734 INSTALL CAMSHAFT TIMING GEAR ASSY Align the alignment pin with the alignment pin groove and install the VVT−i on the camshaft. NOTICE: Install the VVT−i with the lock−pin engaged and locked at the most retarded angle position. (b) Apply engine oil on the nut, the mounting surface of the VVT−i and the screw threads. NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
A new nut must be used when replacing the the VVT−i unit. (c) Using a 46 mm socket wrench, install and tighten the lock nut by turning it counterclockwise. Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf) NOTICE:
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. A05738 WhereEverybodyKnowsYourName 14−229 ENGINE MECHANICAL − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) 30. INSTALL NO.2 CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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 must be carried out. (a) 90 (b) (c) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 2 camshaft at a 90 angle of the timing mark (2 dot marks) on the cylinder head. Apply MP grease to a new oil seal lip. A05201 (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front A52366 (e) Seal Packing A52367 Remove any old packing material from the contact surface. (f) Apply seal packing to the No. 1 bearing cap as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads of the bearing cap bolts. A05283 WhereEverybodyKnowsYourName 14−230 ENGINE MECHANICAL (i) 10 6 2 4 − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) 9 8 5 1 3 7 A78738 31. INSTALL CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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 must be carried out. (a) (b) (c) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (2 dot marks each). Place the camshaft on the cylinder head. Align A59546 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A59547 5 9 1 3 10 6 7 (g) 2 4 8 A78740 WhereEverybodyKnowsYourName 14−231 ENGINE MECHANICAL 32. (a) − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) INSTALL TIMING BELT NO.3 COVER Visually check for cracks and breaks in the gasket of the timing belt cover. HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 in.), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 in.), replace the gasket. Seal Packing (b) Gasket A52838 When repairing the timing belt cover gasket, follow the procedure below. (1) Repair the cracks and breaks by applying the seal packing to the damaged area. Seal packing: Part No. 08826−00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (c) If the timing belt cover gasket needs to be replaced, follow the procedure below. (1) Using a screwdriver and gasket scraper, remove the remaining gasket. NOTICE: Be careful not to damage the timing belt cover. (2) E F D Joining Line Joining Portion Gasket E Joining G Line Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration. NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform. Length: Gasket D E F G Specified Condition 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.) (3) Seal Packing A78749 If there is a gap on the joint of the gasket, apply seal packing to close the gap. Seal packing: Part No. 08826−00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (d) Install the timing belt cover with the 6 bolts. Torque: 8.5 N⋅m (87 kgf⋅cm, 76 in.⋅lbf) WhereEverybodyKnowsYourName 14−232 ENGINE MECHANICAL 33. (a) Front Front − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily. HINT:

Face the belt guide of the RH timing pulley towards the front of the engine. Face the belt guide of the LH timing pulley towards the rear of the engine. A52833 (b) RH SST 150 mm A78763 Using SST, tighten the RH pulley bolt. SST 09960−10010 (09962−01000, 09963−01000), 09249−63010 Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) NOTICE: The torque specification above is the SST without extension tool specification. Use the special formula to calculate the SST with extension tool torque specification (see page 01−5). Extended length of SST (09249−63010): 150 mm (5.91 in.) (c) LH Using SST, tighten the LH pulley bolt. SST 09960−10010 (09962−01000, 09963−01000) Torque: 125 N⋅m (1275 kgf⋅cm, 92 ft⋅lbf) SST A78762 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT TENSIONER ASSY (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 (See page 14−186) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) WhereEverybodyKnowsYourName 14−233 ENGINE MECHANICAL 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. − CAMSHAFT (RH BANK) (1MZ−FE/3MZ−FE) INSPECT VALVE CLEARANCE (See page 14−142) ADJUST VALVE CLEARANCE (See page 14−142) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL CYLINDER HEAD COVER SUB−ASSY (See page 14−142) INSTALL SPARK PLUG Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL INTAKE AIR SURGE TANK (See page 14−142) INSTALL AIR CLEANER ASSEMBLY WITH HOSE CONNECT VACUUM HOSES (See page 14−164) INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL V−BANK COVER SUB−ASSY (See page 14−164) INSTALL FRONT WHEEL RH ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) WhereEverybodyKnowsYourName 14−234 ENGINE MECHANICAL − CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) 141IK−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. DRAIN ENGINE COOLANT (See page 16−27) REMOVE V−BANK COVER SUB−ASSY (See page 14−164) REMOVE RADIATOR HOSE INLET REMOVE SPARK PLUG REMOVE CYLINDER HEAD COVER SUB−ASSY LH (See page 14−142) REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 (See page 14−186) REMOVE TIMING BELT (See page 14−186) REMOVE TIMING BELT IDLER SUB−ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT NO.3 COVER (See page 14−186) 22. REMOVE NO.3 CAMSHAFT SUB−ASSY NOTICE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Align Align the camshaft drive and driven gear’s timing marks (1 dot mark each) by turning the camshaft with a wrench. A78710 WhereEverybodyKnowsYourName 14−235 ENGINE MECHANICAL (b) Service Bolt − CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) Secure the exhaust camshaft sub gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1 mm Bolt length 16 to 20 mm Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Main Gear Sub Gear A78711 (c) 1 5 2 9 6 7 10 8 3 HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 4 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78712 6 23. (a) 2 10 1 8 5 9 4 7 3 24. 25. 26. 27. A78713 REMOVE NO.4 CAMSHAFT SUB−ASSY Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 4 camshaft. REMOVE CAMSHAFT TIMING GEAR ASSY (See page 14−186) REMOVE CAMSHAFT SUB GEAR NO.3 (See page 14−186) INSTALL CAMSHAFT SUB GEAR NO.3 (See page 14−186) INSTALL CAMSHAFT TIMING GEAR ASSY (See page 14−186) 28. INSTALL NO.4 CAMSHAFT SUB−ASSY NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. WhereEverybodyKnowsYourName 14−236 ENGINE MECHANICAL (a) (b) 90
(c) − CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 4 camshaft at a 90
angle of the timing mark (1 dot marks) on the cylinder head. Apply MP grease to a new oil seal lip. A78741 (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front A78742 (e) Seal Packing A78737 Remove any old packing material from the contact surface. (f) Apply seal packing to the No. 1 bearing cap as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads of the bearing cap bolts. A05209 (i) 9 5 1 Uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) 10 3 6 7 2 4 8 A78743 WhereEverybodyKnowsYourName 14−237 ENGINE MECHANICAL − CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) 29. INSTALL NO.3 CAMSHAFT SUB−ASSY NOTICE: 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) (b) (c) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing mark (1 dot mark each). Place the camshaft on the cylinder head. Align A78744 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (f) Uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A05214 10 6 9 2 4 5 (g) 1 8 3 7 A78745 30. 31. 32. 33. 34. 35. 36. 37. INSTALL TIMING BELT NO.3 COVER (See page 14−186) INSTALL CAMSHAFT TIMING PULLEY (See page 14−186) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT TENSIONER ASSY (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 (See page 14−186) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) WhereEverybodyKnowsYourName 14−238 ENGINE MECHANICAL 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. − CAMSHAFT (LH BANK) (1MZ−FE/3MZ−FE) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSPECT VALVE CLEARANCE (See page 14−142) ADJUST VALVE CLEARANCE (See page 14−142) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL CYLINDER HEAD COVER SUB−ASSY LH (See page 14−142) INSTALL SPARK PLUG Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL V−BANK COVER SUB−ASSY (See page 14−164) INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) WhereEverybodyKnowsYourName 14−239 ENGINE MECHANICAL − CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) 141IL−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−26) DRAIN ENGINE COOLANT (See page 16−27) DRAIN ENGINE OIL REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET (See page 15−7) REMOVE EXHAUST PIPE ASSY FRONT (See page 15−7) REMOVE EXHAUST MANIFOLD SUB−ASSY RH (See page 14−164) REMOVE V−BANK COVER SUB−ASSY (See page 14−164) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) REMOVE AIR CLEANER ASSEMBLY WITH HOSE REMOVE INTAKE AIR SURGE TANK (See page 14−142) DISCONNECT FUEL PIPE SUB−ASSY NO.1 (See page 11−26) 12. (a) (b) DISCONNECT HEATER INLET WATER HOSE Lock the hose clamp as shown in the illustration. Disconnect the heater inlet water hose. 13. (a) (b) REMOVE INTAKE MANIFOLD Remove the nut and disconnect the ground cable. Disconnect the 6 fuel injector connectors. (b) (a) A79759 (b) (a) (b) (b) (b) (b) (b) A81200 WhereEverybodyKnowsYourName 14−240 ENGINE MECHANICAL (c) 10 4 3 11 Uniformly loosen and remove the intake manifold’s 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold. 5 1 9 7 CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) 2 6 8 − A81201 14. DISCONNECT RADIATOR HOSE INLET 15. (a) (b) (e) (b) (c) (d) (e) (c) (f) REMOVE WATER OUTLET Disconnect the radiator hose inlet. Disconnect the engine coolant temperature sensor connector. Remove the clamp. Remove the 2 bolts, 2 nuts and 2 washers. Lock the hose clamp as shown in the illustration and remove the water outlet together with the water by−pass hose No. 1. Remove the 2 gaskets from the 2 cylinder heads. A81203 16. 17. 18. 19. 20. 21. 22. 23. 24. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) WhereEverybodyKnowsYourName 14−241 ENGINE MECHANICAL 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. − CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14−186) REMOVE TIMING BELT IDLER SUB−ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT NO.3 COVER (See page 14−186) REMOVE VANE PUMP ASSY (See page 51−17) REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB−ASSY (See page 14−186) REMOVE CAMSHAFT (See page 14−186) REMOVE NO.2 CAMSHAFT (See page 14−186) 37. (a) (b) (b) (c) (c) (a) REMOVE CYLINDER HEAD SUB−ASSY Disconnect the VVT sensor connector. Disconnect the camshaft timing oil control valve connector. Remove the nut and disconnect the engine wire harness clamp. A78401 (d) Front Using a socket hexagon wrench 8, remove the hexagon bolt. A78716 (e) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 2 7 5 3 4 6 8 1 A78717 38. REMOVE CYLINDER HEAD GASKET WhereEverybodyKnowsYourName 14−242 ENGINE MECHANICAL − CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) 39. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Specified outside diameter: 8.75 to 9.05 mm (0.3445 to 0.3563 in.) If the diameter is less than the minimum, replace the bolt. Tension Portion A52828 1MZ−FE 3MZ−FE 40. (a) INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. 41. INSTALL CYLINDER HEAD SUB−ASSY NOTICE: The cylinder head bolts are tightened in 2 successive steps. Front Front A79818 A78324 A90678 (a) Front 7 2 4 6 5 3 1 8 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78717 (d) (e) 90
(f) Front Mark the front side of each cylinder head bolt head with paint as shown in the illustration. Retighten the cylinder head bolts by 90
in the same sequence as step (c). Check that each painted mark is now at a 90
angle to the front. Painted mark A78730 WhereEverybodyKnowsYourName 14−243 ENGINE MECHANICAL (g) Front (h) − CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf) Connect the engine wire harness clamp with the nut. Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf) A78716 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. (a) (b) (c) (d) (e) (f) INSTALL NO.2 CAMSHAFT (See page 14−186) INSTALL CAMSHAFT (See page 14−186) INSTALL CYLINDER HEAD COVER SUB−ASSY (See page 14−186) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL VANE PUMP ASSY (See page 51−17) INSTALL TIMING BELT NO.3 COVER (See page 14−186) INSTALL CAMSHAFT TIMING PULLEY (See page 14−186) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT TENSIONER ASSY (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 (See page 14−186) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL WATER OUTLET Install 2 new gaskets to the 2 cylinder heads. Install the water outlet together the with water by−pass hose No. 1 and unlock the hose clamp. Tighten the 2 bolts, 2 nuts and 2 washers. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the clamp. Connect the engine coolant temperature sensor connector. Connect the radiator hose inlet. WhereEverybodyKnowsYourName 14−244 ENGINE MECHANICAL 65. (a) (b) (c) (d) 2 8 9 1 5 CYLINDER HEAD GASKET (1MZ−FE/3MZ−FE) INSTALL INTAKE MANIFOLD Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Retighten the water outlet mounting bolts and nuts. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the ground cable with the nut. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) Connect the heater inlet water hose. 10 6 4 − 7 3 11 A81201 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. CONNECT FUEL PIPE SUB−ASSY NO.1 (See page 11−26) INSTALL INTAKE AIR SURGE TANK (See page 14−142) INSTALL AIR CLEANER ASSEMBLY WITH HOSE CONNECT VACUUM HOSES (See page 14−164) INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL V−BANK COVER SUB−ASSY (See page 14−164) INSTALL EXHAUST MANIFOLD SUB−ASSY RH (See page 14−164) INSTALL EXHAUST PIPE ASSY FRONT (See page 15−7) INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET (See page 15−7) INSTALL FRONT WHEEL RH ADD ENGINE OIL ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) CHECK FOR FUEL LEAKS (See page 11−29) CHECK FOR EXHAUST GAS LEAKS INSPECT IGNITION TIMING (See page 14−136) INSPECT ENGINE IDLE SPEED (See page 14−136) INSPECT COMPRESSION (See page 14−136) INSPECT CO/HC (See page 14−136) WhereEverybodyKnowsYourName 14−245 ENGINE MECHANICAL − CYLINDER HEAD GASKET NO.2 (1MZ−FE/3MZ−FE) CYLINDER HEAD GASKET NO.2 (1MZ−FE/3MZ−FE) 141IM−03 REPLACEMENT 1. 2. 3. 4. 5. (a) 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−26) DRAIN ENGINE COOLANT (See page 16−27) DRAIN ENGINE OIL REMOVE MANIFOLD STAY NO.2 DISCONNECT EXHAUST MANIFOLD CONVERTER SUB−ASSY NO.2 Remove the 2 nuts, and disconnect the exhaust manifold converter from the front exhaust pipe. REMOVE V−BANK COVER SUB−ASSY (See page 14−164) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) REMOVE AIR CLEANER ASSEMBLY WITH HOSE REMOVE INTAKE AIR SURGE TANK (See page 14−142) DISCONNECT FUEL PIPE SUB−ASSY NO.1 (See page 11−38) DISCONNECT HEATER INLET WATER HOSE REMOVE INTAKE MANIFOLD (See page 14−239) REMOVE RADIATOR HOSE INLET REMOVE WATER OUTLET (See page 14−239) DISCONNECT RADIATOR HOSE OUTLET REMOVE WATER INLET PIPE REMOVE OIL LEVEL GAGE SUB−ASSY REMOVE OIL LEVEL GAGE GUIDE REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 (See page 14−186) REMOVE TIMING BELT (See page 14−186) REMOVE TIMING BELT IDLER SUB−ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT NO.3 COVER (See page 14−186) REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB−ASSY LH (See page 14−186) REMOVE NO.3 CAMSHAFT SUB−ASSY (See page 14−186) REMOVE NO.4 CAMSHAFT SUB−ASSY (See page 14−186) WhereEverybodyKnowsYourName 14−246 ENGINE MECHANICAL 39. (a) (b) (c) (d) − CYLINDER HEAD GASKET NO.2 (1MZ−FE/3MZ−FE) REMOVE CYLINDER HEAD LH Disconnect the VVT sensor connector. Disconnect the camshaft timing oil control valve connector. Remove the bolt and disconnect the ground cable. Remove the bolt and the wire harness clamp bracket. A80822 (e) Front Using a socket hexagon wrench 8, remove the hexagon bolt. A78718 (f) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 4 6 8 1 2 7 5 3 A78719 40. 41. REMOVE CYLINDER HEAD GASKET NO.2 INSPECT CYLINDER HEAD SET BOLT (See page 14−186) 42. (a) Front A78325 INSTALL CYLINDER HEAD GASKET NO.2 Place a new cylinder head gasket on the cylinder block with the L mark as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. 43. INSTALL CYLINDER HEAD LH NOTICE: The cylinder head bolts are tightened in 2 successive steps. WhereEverybodyKnowsYourName 14−247 ENGINE MECHANICAL (a) Front 5 3 1 8 7 2 4 6 (b) (c) − CYLINDER HEAD GASKET NO.2 (1MZ−FE/3MZ−FE) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78719 (d) (e) 90
(f) Front Mark the front side of each cylinder head bolt head with paint as shown in the illustration. Retighten the cylinder head bolts by 90
in the same sequence as step (c). Check that each painted mark is now at a 90
angle to the front. Painted mark A78730 (g) Front 5 3 1 8 (h) (i) 7 2 4 Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf) Install the wire harness clamp bracket with the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Connect the ground cable with the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 6 A78719 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. INSTALL NO.4 CAMSHAFT SUB−ASSY (See page 14−186) INSTALL NO.3 CAMSHAFT SUB−ASSY (See page 14−186) INSTALL CYLINDER HEAD COVER SUB−ASSY LH (See page 14−186) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL TIMING BELT NO.3 COVER (See page 14−186) INSTALL CAMSHAFT TIMING PULLEY (See page 14−186) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT TENSIONER ASSY (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 (See page 14−186) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) WhereEverybodyKnowsYourName 14−248 ENGINE MECHANICAL 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. (a) 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. − CYLINDER HEAD GASKET NO.2 (1MZ−FE/3MZ−FE) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL OIL LEVEL GAGE GUIDE (See page 17−41) INSTALL WATER INLET PIPE (See page 16−32) INSTALL WATER OUTLET (See page 14−239) INSTALL INTAKE MANIFOLD (See page 14−164) CONNECT FUEL PIPE SUB−ASSY NO.1 (See page 11−38) INSTALL INTAKE AIR SURGE TANK (See page 14−142) INSTALL AIR CLEANER ASSEMBLY WITH HOSE CONNECT VACUUM HOSES (See page 14−164) INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL V−BANK COVER SUB−ASSY (See page 14−164) INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY NO.2 Install a new gasket and the exhaust manifold converter to the front exhaust pipe. Torque: 62 N⋅m (633 kgf⋅cm, 46 ft⋅lbf) INSTALL MANIFOLD STAY NO.2 (See page 14−164) INSTALL FRONT WHEEL RH ADD ENGINE OIL ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) CHECK FOR FUEL LEAKS CHECK FOR EXHAUST GAS LEAKS INSPECT IGNITION TIMING (See page 14−136) INSPECT ENGINE IDLE SPEED (See page 14−136) INSPECT COMPRESSION (See page 14−136) INSPECT CO/HC (See page 14−136) WhereEverybodyKnowsYourName 14−249 ENGINE MECHANICAL − OIL PUMP SEAL (1MZ−FE/3MZ−FE) OIL PUMP SEAL (1MZ−FE/3MZ−FE) 141IN−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14−186) 14. (a) (b) (c) SST A78764 REMOVE CRANKSHAFT TIMING PULLEY Remove the bolt and the timing belt plate. Install the pulley bolt to the crankshaft. Using SST, remove the crankshaft timing pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05010) NOTICE:
Do not scratch the sensor part of the crankshaft timing pulley.
Before using SST, apply lubricating oil on the threads and tip of the center bolt 150. 15. (a) (b) Cut Position A52844 REMOVE OIL PUMP SEAL Using a knife, cut through the oil seal lip. Using a screwdriver with its tip wrapped in tape, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400−grit sandpaper. 16. INSTALL OIL PUMP SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free of foreign matter. WhereEverybodyKnowsYourName 14−250 ENGINE MECHANICAL − OIL PUMP SEAL (1MZ−FE/3MZ−FE) (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump edge. SST 09223−00010 NOTICE:
Be careful not to tap the oil seal slantingly.
Wipe off extra grease on the crankshaft. SST A13770 17. (a) Inward INSTALL CRANKSHAFT TIMING PULLEY Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place. NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. (b) Install the timing belt plate with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Sensor A52818 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 (See page 14−186) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL FRONT WHEEL RH CHECK FOR ENGINE OIL LEAKS WhereEverybodyKnowsYourName 14−251 ENGINE MECHANICAL − ENGINE REAR OIL SEAL (1MZ−FE/3MZ−FE) ENGINE REAR OIL SEAL (1MZ−FE/3MZ−FE) 1405R−09 REPLACEMENT 1. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40−9) 2. (a) REMOVE DRIVE PLATE & RING GEAR SUB−ASSY Using SST, hold the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Remove the 8 bolts, the rear spacer, the drive plate and the front spacer. SST A36243 A91073 3. (a) (b) REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped in tape, pry out the oil seal. NOTICE: After the removal, check if the crankshaft is not damaged. If it is damaged, smooth the surface with 400−grit sandpaper. Cut Position Cut Position A52843 SST A36743 4. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip off foreign materials. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−15030, 09950−70010 (09951−07100) NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease from the crankshaft. WhereEverybodyKnowsYourName 14−252 ENGINE MECHANICAL − ENGINE REAR OIL SEAL (1MZ−FE/3MZ−FE) 5. (a) SST A36243 1 5 7 3 4 8 6 2 6. INSTALL DRIVE PLATE & RING GEAR SUB−ASSY Using SST, hold the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Clean the bolts and bolt holes. (c) Apply adhesive to 2 or 3 threads of the bolts. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (d) Install the front spacer, the drive plate and the rear spacer on the crankshaft. (e) Uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83 N⋅m (846 kgf⋅cm, 61 ft⋅lbf) NOTICE: Do not start the engine for at least an hour after installing. A05416 INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40−9) WhereEverybodyKnowsYourName 14−253 ENGINE MECHANICAL − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) 141IO−02 COMPONENTS Valve Adjusting Shim Valve Lifter Valve Spring Retainer Rock Valve Spring Retainer RH Cylinder: w/ Head Straight Screw Plug No. 1 Inner Compression Spring
Valve Stem Oil Seal LH Cylinder: w/ Head Straight Screw Plug No. 2 Valve Spring Seat
Valve Stem Oil Seal
Exhaust Valve Guide Bushing
Gasket
Intake Valve Guide Bushing Semicircular Plug 44 (449, 32)
Gasket RH Cylinder: w/ Head Straight Screw Plug No. 1 LH Cylinder: w/ Head Straight Screw Plug No. 2 Intake Valve Exhaust Valve N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A78310 14−254 ENGINE MECHANICAL − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) 141IP−02 OVERHAUL 1. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER) (a) Using a straight hexagon wrench 14, remove the 2 screw plugs. 2. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER) (a) Using a straight hexagon wrench 14, remove the 2 screw plugs. 3. REMOVE VALVE LIFTER HINT: Store the lifters in correct order so that they can be returned to the original locations when reassembling. 4. (a) REMOVE INTAKE VALVE Using SST, compress the valve spring and remove the 2 keepers, retainer, spring and valve. SST 09202−70020 (09202−00010) HINT: Store the valves, valve springs, spring seats and spring retainers in correct order so that they can be returned to the original locations when reassembling. SST A05224 5. (a) REMOVE EXHAUST VALVE Using SST, compress the valve spring and remove the 2 keepers, retainer, spring and valve. SST 09202−70020 (09202−00010) HINT: Store the valves, valve springs, spring seats and spring retainers in correct order so that they can be returned to the original locations when reassembling. SST A51796 6. (a) 7. 8. REMOVE VALVE STEM OIL O SEAL OR RING Using needle−nose pliers, remove the oil seal. REMOVE VALVE SPRING SEAT REMOVE SEMICIRCULAR PLUG WhereEverybodyKnowsYourName 14−255 ENGINE MECHANICAL 9. (a) Cylinder Block Surface: − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Item Specified Condition Cylinder block surface 0.05 mm (0.0020 in.) Intake manifold surface 0.10 mm (0.0039 in.) Exhaust manifold surface 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the cylinder head. Intake Manifold Surface: Exhaust Manifold Surface: A78773 10. (a) INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A05227 11. (a) Overall Length INSPECT INTAKE VALVE Check the valve overall length. Specified overall length: 94.95 − 95.45 mm (3.7382 − 3.7579 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Z00052 WhereEverybodyKnowsYourName 14−256 ENGINE MECHANICAL − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) (c) Check the valve head margin thickness. Specified margin thickness: 0.5 − 1.0 mm (0.020 − 0.039 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 12. (a) Overall Length INSPECT EXHAUST VALVE Check the valve overall length. Specified overall length: 94.90 − 95.40 mm (3.7362 − 3.7559 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Z00052 (c) Check the valve head margin thickness. Specified margin thickness: 0.5 − 1.0 mm (0.020 − 0.039 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 13. (a) INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the valve spring. Free length: 45.50 mm (1.7913 in.) If the free length is not as specified, replace the valve spring. EM0801 WhereEverybodyKnowsYourName 14−257 ENGINE MECHANICAL − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the valve spring. Deviation EM0988 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 86 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring. EM0281 14. (a) (b) P12754 INSPECT VALVE GUIDE BUSHING OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Specified oil clearance: Item Specified Condition Intake 0.025 to 0.080 mm (0.0010 to 0.0031 in.) Exhaust 0.030 to 0.100 mm (0.0012 to 0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bushing. 15. (a) REMOVE VALVE GUIDE BUSHING Heat the cylinder head to approximately 80 to 100
C (176 to 212
F). A05234 WhereEverybodyKnowsYourName 14−258 ENGINE MECHANICAL (b) SST − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) Using SST and a hammer, tap out the guide bushing. SST 09201−10000, 09201−01055, 09950−70010 (09951−07100) P12803 16. (a) INSTALL VALVE GUIDE BUSHING Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.) If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bushing bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.). Bushing diameter: P12956 34.5 mm (1.358 in.) 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 10.383 to 10.394 mm (0.4088 to 0.4092 in.) HINT: Different the bushes are used for the intake and exhaust. Bushing length: Exhaust Intake STD 40.5 mm (1.594 in.) Intake 34.5 mm (1.358 in.) Exhaust 40.5 mm (1.594 in.) A52198 (b) SST (c) A78778 Heat the cylinder head to approximately 80 to 100
C (176 to 212
F) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201−10000, 09201−01055, 09950−70010 (09951−07100) Protrusion height: Item Specified Condition Intake 11.1 to 11.5 mm (0.437 to 0.453 in.) Exhaust 8.9 to 9.3 mm (0.350 to 0.336 in.) WhereEverybodyKnowsYourName 14−259 ENGINE MECHANICAL (d) − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and the valve stem. Standard oil clearance: Item Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Z09124 17. (a) INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve against the seat. NOTICE: Do not rotate the valve. (c) Width A78779 45
30
Check the valve face and valve seat according to the following procedure. (1) If blue appears 360
around the valve face, the valve face is concentric. If not, replace the valve. (2) If blue appears 360
around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.). 18. REPAIR VALVE SEATS NOTICE: Releasing the seat−cutter pressure gradually helps to make smoother valve seat faces. (a) If the seating is too high on the valve face, use 30
and 45
cutters to correct the seat. 1.0−1.4mmA51797 (b) (c) 60
45
1.0 to 1.4 mm (d) If the seating is too low on the valve face, use 60
and 45
cutters to correct the seat. Handrub the valve and valve seat with an abrasive compound. Recheck the valve seating position. A78781 WhereEverybodyKnowsYourName 14−260 ENGINE MECHANICAL 19. (a) − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) EM6368 20. (a) P12685 INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Specified oil clearance: 0.033 to 0.070 mm (0.0013 to 0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 21. INSPECT CAMSHAFT GEAR BACKLASH (a) Install the camshaft timing gear assembly. (b) Install the camshafts to the cylinder head. NOTICE:
Install without valves and sub−gear.
Install with its timing mark matched. (c) Set the dial indicator to the teeth of the intake camshaft at a right angle (90
). (d) Measure the backlash of the camshaft timing gear at least 4 positions. Specified backlash: 0.020 to 0.300 mm (0.0008 to 0.0118 in.) If the backlash is greater than the maximum, replace the camshafts. A33264 22. (a) (b) A05238 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Specified thrust clearance: 0.040 to 0.120 mm (0.0016 to 0.0047 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head together. WhereEverybodyKnowsYourName 14−261 ENGINE MECHANICAL 23. (a) (b) − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. (c) Lay a strip of plastigage across each of the camshaft journal. (d) Install the bearing caps. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A05239 (f) Measure the plastigage at its widest point. Specified oil clearance: 0.025 to 0.100 mm (0.0010 to 0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head together. NOTICE: Completely remove the plastigage. A05240 RH Cylinder 10 mm 24. (a) INSTALL RING W/HEAD PIN (RH CYLINDER) Using a plastic−faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 25. (a) INSTALL RING PIN (LH CYLINDER) Using a plastic−faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 8 mm A78782 LH Cylinder 10 mm 8 mm A78783 WhereEverybodyKnowsYourName 14−262 ENGINE MECHANICAL 26. (a) Protrusion Height Mark P05423 A51817 CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSTALL SPARK PLUG TUBE Using paint, mark the standard position from the edge. Standard protrusion height: 42.4 to 43.4 mm (1.669 to 1.709 in.) HINT: Use either end of the spark plug tube. (b) Apply adhesive to the spark plug tube where it will be pressed into the cylinder head. Adhesive: Part No. 08833−00070 THREE BOND 1324 or equivalent NOTICE:
Install the spark plug tube within 3 minutes after applying adhesive.
Do not deform the spark plug tube.
Do not expose the seal to coolant for at least 1 hour after installing. (c) Press Wooden Block − Protrusion Height Using a press and wooden block, install the spark plug tube to the required protrusion height. NOTICE: Be careful not to drip the adhesive. A78785 27. (a) INSTALL PCV PIPE Using a wooden block and hammer, tap in 2 new PCV pipes until its top edge is flush with the cylinder head edge. NOTICE: Be careful not to damage the cylinder head edge. Wooden Block Flush P12869 A51801 WhereEverybodyKnowsYourName 14−263 ENGINE MECHANICAL 28. (a) RH Cylinder − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSTALL STUD BOLT Install the stud bolts on the intake side. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) 49 mm (1.93 in.) M8 LH Cylinder 49 mm (1.93 in.) M8 A78787 A78788 29. (a) A87849 INSTALL STUD BOLT Install the stud bolts on the exhaust side. Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) Intake Exhaust Light Brown Gray A78789 SST 30. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil on the valve stem. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later. HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. (b) Using SST, push in a new oil seal. SST 09201−41020 NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated. A78790 WhereEverybodyKnowsYourName 14−264 ENGINE MECHANICAL − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) 31. (a) SST A78770 INSTALL INTAKE VALVE Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same part in the same combination to the original locations. (b) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202−70020 (09202−00010) (c) Using a plastic−faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the installed valve stem tip. A05246 32. (a) SST A78772 INSTALL EXHAUST VALVE Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same parts in the same combination to the original locations. (b) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202−70020 (09202−00010) (c) Using a plastic−faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the installed valve stem tip. A05246 33. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil on the valve lifter. NOTICE: Install the same part in the same combination to the original locations. (b) Install the valve lifter. (c) Check that the valve lifter rotates smoothly by hand. WhereEverybodyKnowsYourName 14−265 ENGINE MECHANICAL 34. (a) (b) Seal Packing − CYLINDER HEAD ASSY (1MZ−FE/3MZ−FE) INSTALL SEMICIRCULAR PLUG Remove any old seal packing (FIPG) material. Apply seal packing to the semi circular plug grooves. Seal packing: Part No. 08826−00080 or equivalent A51804 (c) Install the 2 semi circular plugs to the cylinder heads. NOTICE:
Install the plugs so that it is flush with the top of the cylinder head.
Install the semi circular plugs within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. : Semi circular Plug RH Cylinder Front LH Cylinder A78792 35. (a) 36. (a) INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) WhereEverybodyKnowsYourName 14−266 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 141IQ−02 COMPONENTS Piston Ring (No. 1 Compression Ring) Piston Ring (No. 2 Compression Ring) Piston Ring (Expander) Piston Ring (Side Rail)  Piston Pin Hole Snap Ring Piston Pin Piston Pin  Piston Pin Hole Snap Ring  Connecting Rod Small End Bush Connecting Rod Sub−assy Connecting Rod Bearing Connecting Rod Cap See page (14−268) 1st: 25 (250, 18) 2st: Turn 90
Cylinder Block Sub−assy  Gasket 50 (510, 37) Cylinder Block w/ Head Straight Screw No. 3 Plug 39 (398, 29) Cylinder Block Water Drain Cock Sub−assy 30 (306, 22) Cylinder Block w/ Head Straight Screw No. 1 Plug  Gasket  Gasket 30 (306, 22) Cylinder Block w/ Head Straight Screw No. 2 Plug Water Seal Plate 39 (398, 29) Cylinder Block Water Drain Cock Sub−assy 18 (184, 13) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A78311 WhereEverybodyKnowsYourName 14−267 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) Cylinder Block Sub−assy  Seal Washer 27 (275, 20) Crankshaft Bearing Upper Crankshaft Thrust Washer Crankshaft Lower Crankshaft Thrust Washer Crankshaft Bearing Crankshaft Bearing Cap  Seal Washer See page (14−268) 1st: 22 (224, 16) 2st: Turn 90
27 (275, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part A78312 WhereEverybodyKnowsYourName 14−268 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 141IY−02 OVERHAUL 1. 2. 3. (a) 4. (a) 5. (a) REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY REMOVE WATER SEAL PLATE REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG Using a socket hexagon wrench 10, remove the screw plug. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG Using a socket hexagon wrench 10, remove the screw plug. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG Using a socket hexagon wrench 10, remove the screw plug. 6. (a) P12695 Plastigage INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Specified thrust clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 20.80 to 20.85 mm (0.8189 to 0.8209 in.) 7. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. (c) Clean the crank pin, the bearing and the connecting rod. (d) Check the crank pin and bearing for pitting and scratches. (e) Lay a strip of plastigage across the crank pin. (f) Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil on the threads of the connecting rod cap bolts. A78793 Front (g) Protrusion A78794 WhereEverybodyKnowsYourName 14−269 ENGINE MECHANICAL (h) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) Tighten the bolts in several steps by the specified torque. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) P12697 (i) Mark the front side of each connecting cap bolt with paint. (j) Retighten the cap bolts by 90 as shown in the illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, the connecting rod cap and the lower bearing. Painted Mark 90 90 Front A78795 (l) Measure the plastigage at its widest point. Specified oil clearance: 0.038 to 0.080 mm (0.0015 to 0.0031 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft. (m) Completely remove the plastigage. P12698 HINT: If replacing the bearing, replace it with one that has the same number as the connecting rod. There are 4 sizes of standard bearings: 1, 2, 3 and 4. Standard bearing center wall thickness: Number Mark A79803 Mark Specified Condition 1 1.484 to 1.487 mm (0.0584 to 0.0585 in.) 2 1.487 to 1.490 mm (0.0585 to 0.0587 in.) 3 1.490 to 1.493 mm (0.0587 to 0.0588 in.) 4 1.493 to 1.496 mm (0.0588 to 0.0589 in.) WhereEverybodyKnowsYourName 14−270 ENGINE MECHANICAL 8. (a) (b) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) REMOVE PISTON SUB−ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push out the piston and the connecting rod assembly from the top of the cylinder block. HINT:
A05258 9.
Keep the bearings, the connecting rod and the cap together. Arrange the piston and the connecting rod assemblies in correct order so they can be returned to the original locations when reassembling. REMOVE CONNECTING ROD BEARING 10. (a) (b) REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. 11. (a) REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings. 12. (a) REMOVE W/PIN PISTON SUB−ASSY Gradually heat the piston to approximately 80C (176F). A78315 P12403 80C A78797 WhereEverybodyKnowsYourName 14−271 ENGINE MECHANICAL (b) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) Using a plastic−faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod. HINT:

The piston and pin are a matched set. Store the pistons, the pins, the rings, the connecting rods and the bearings in correct order so that they can be returned to the original locations when re assembling. P12415 13. (a) P12799 5 8 7 6 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Specified thrust clearance: 0.04 to 0.30 mm (0.0016 to 0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary. Thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 in.). 14. CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration. 2 3 4 1 6 14 2 10 8 16 A87850 4 (b) Uniformly loosen and remove the 16 main bearing cap bolts the sequence shown in the illustration. (c) Remove the 4 main bearing caps and 4 lower bearings. Also remove the 2 lower thrust washers, located under the No. 2 main bearing cap. 12 11 3 15 13 7 9 5 1 A87851 A87852 WhereEverybodyKnowsYourName 14−272 ENGINE MECHANICAL Cylinder Block M a i n Bearing Cap Joint Surface A87853 − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) NOTICE: Using a screwdriver, push up on the cap little by little, alternating from the right and left side until the cap is free. Take care not to damage the contact surfaces of the cap and cylinder block. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers in correct order. (d) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (e) Clean each main journal and bearing. (f) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. A87854 (g) (h) Plastigage Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. A87856 (i) Install the 4 main bearing caps (see step 42). NOTICE: Do not turn the crankshaft. (j) Remove the main bearing caps (see steps (a) to (c)). A87855 (k) Measure the Plastigage at its widest point. Specified oil clearance: No. 1 and No. 4 journals 0.014 to 0.050 mm (0.0006 to 0.0020 in.) No. 2 and No. 3 journals 0.026 to 0.060 mm (0.0010 to 0.0024 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. A87857 WhereEverybodyKnowsYourName 14−273 ENGINE MECHANICAL No.2 No.1 CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) HINT: If using a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table on the next page for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6 and 7 accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4 and 5 accordingly. No. 1 and No. 4 journal bearings No.3 No.4 Number Mark No.2 No.3 No.4 No.1 Number Mark Number Mark − Cylinder block + Crankshaft = 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Replacement Bearing 3 4 5 6 7 HINT: EXAMPLE: Cylinder block imprinted number mark is 06 Crankshaft imprinted number mark is 08 6 + 8 = 14 Select the bearing marked ”5” A87858 No. 1 and No. 4 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 01 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 02 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 03 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 04 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 05 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 06 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 07 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 08 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 09 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 10 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 11 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 12 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”5” WhereEverybodyKnowsYourName 14−274 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) No. 2 and No. 3 journal bearings Cylinder block + Crankshaft = 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Replacement Bearing 3 4 5 6 7 HINT: EXAMPLE Cylinder block imprinted number mark is 06 Crankshaft imprinted number mark is 08 6 + 8 = 14 Select the bearing marked ”3” No.2 and No.3 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 01 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 02 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 03 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 04 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 05 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 06 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 07 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 08 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 09 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 10 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 11 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 12 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”3” WhereEverybodyKnowsYourName 14−275 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) Reference Item Mark Specified Condition Cylinder block main journal bore diameter (A) 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 66.000 mm (2.5984 in.) 66.001 mm (2.5985 in.) 66.002 mm (2.5985 in.) 66.003 mm (2.5985 in.) 66.004 mm (2.5986 in.) 66.005 mm(2.5986 in.) 66.006 mm (2.5987 in.) 66.007 mm (2.5987 in.) 66.008 mm (2.5987 in.) 66.009 mm (2.5988 in.) 66.010 mm (2.5988 in.) 66.011 mm (2.5989 in.) 66.012 mm (2.5989 in.) 66.013 mm (2.5989 in.) 66.014 mm (2.5990 in.) 66.015 mm (2.5990 in.) 66.016 mm (2.5990 in.) Crankshaft main journal diameter (B) 00 01 02 03 04 05 06 07 08 09 10 11 12 61.000 mm (2.4016 in.) 60.999 mm (2.4015 in.) 60.998 mm (2.4015 in.) 60.997 mm (2.4015 in.) 60.996 mm (2.4014 in.) 60.995 mm (2.4014 in.) 60.994 mm (2.4013 in.) 60.993 mm (2.4012 in.) 60.992 mm (2.4012 in.) 60.991 mm (2.4012 in.) 60.990 mm (2.4012 in.) 60.989 mm (2.4011 in.) 60.988 mm (2.4011 in.) Standard bearing center wall thickness 1 2 3 4 5 6 7 2.486 to 2.489 mm (0.0979 to 0.0980 in.) 2.489 to 2.492 mm (0.0980 to 0.0981 in.) 2.492 to 2.495 mm (0.0981 to 0.0982 in.) 2.495 to 2.498 mm (0.0982 to 0.0983 in.) 2.498 to 2.501 mm (0.0983 to 0.0985 in.) 2.501 to 2.504 mm (0.0985 to 0.0986 in.) 2.504 to 2.507 mm (0.0986 to 0.0987 in.) (l) Completely remove the Plastigage. 15. REMOVE CRANKSHAFT (a) Lift the crankshaft. (b) Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. 16. REMOVE CRANKSHAFT THRUST WASHER SET 17. REMOVE CRANKSHAFT BEARING 18. CLEAN CYLINDER BLOCK NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45C (113F) or less. WhereEverybodyKnowsYourName 14−276 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 19. (a) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. Z09222 20. (a) INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Specified diameter: Item Specified Condition 1MZ−FE 87.500 to 87.632 mm (3.4449 to 3.4501 in.) 3MZ−FE 92.000 to 92.132 mm (3.6220 to 3.6272 in.) If the average of the measured diameters is greater than the maximum, replace the cylinder block. Thrust Direction Front Axial Direction A 10 mm B A88898 WhereEverybodyKnowsYourName 14−277 ENGINE MECHANICAL 21. (a) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSPECT W/PIN PISTON SUB−ASSY 1MZ−FE: Using a micrometer, measure the diameter at right angles to the piston pin center line and the distance from the piston head. Distance: Item Specified Condition 1MZ−FE for AISIN made 23.2 mm (0.913 in.) 1MZ−FE for MAHLE made 41.2 mm (1.922 in.) Piston diameter: Item Specified Condition 1MZ−FE for AISIN made 87.406 to 87.416 mm (3.4412 to 3.4416 in.) 1MZ−FE for MAHLE made 87.453 to 87.467 mm (3.4430 to 3.4436 in.) HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. A80054 A80055 A90699 (b) 3MZ−FE: Using a micrometer, measure a diameter at right angles to the piston pin center line and the distance from the piston bottom. Distance: 13.0 mm (0.512 in.) Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 in.) 13.0 mm A78316 WhereEverybodyKnowsYourName 14−278 ENGINE MECHANICAL 22. (a) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Specified oil clearance: 0.033 to 0.130 mm (0.0013 to 0.0051 in.) Item Specified Condition: 1MZ−FE for AISIN made 0.084 to 0.130 mm (0.0033 to 0.0051 in.) 1MZ−FE for MAHLE made 0.033 to 0.130 mm (0.0013 to 0.0051 in.) 3MZ−FE 0.033 to 0.130 mm (0.0013 to 0.0051 in.) If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block. 23. (a) INSPECT CONNECTING ROD SUB−ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If misalignment is greater than the maximum, replace the connecting rod assembly. Z00064 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z00065 24. (a) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) EM6525 (b) EM0227 Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Specified oil clearance: 0.005 to 0.050 mm (0.0002 to 0.0020 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and the piston pin together. WhereEverybodyKnowsYourName 14−279 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 25. (a) REMOVE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bushing. SST 09222−30010 26. (a) INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new bushing and the connecting rod. (b) Using SST and a press, press in the bushing. SST 09222−30010 (c) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) (d) Check that the piston pin fits at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. SST A78803 Oil Hole A78804 SST A78803 EM6535 P00326 WhereEverybodyKnowsYourName 14−280 ENGINE MECHANICAL 27. (a) A78317 − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: 1MZ−FE Item Specified Condition No. 1 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil 0.04 to 0.12 mm (0.0016 to 0.0047 in.) 3MZ−FE: Item Specified Condition No. 1 0.03 to 0.08 mm (0.0012 to 0.0031 in.) No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil 0.03 to 0.11 mm (0.0012 to 0.0043 in.) If the clearance is not as specified, replace the piston. 28. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (b) Using a feeler gauge, measure the end gap. Specified end gap: 1MZ−FE 110 mm A78805 Item Specified Condition No. 1 0.25 to 0.95 mm (0.0098 to 0.0374 in.) No. 2 0.35 to 1.05 mm (0.0138 to 0.0413 in.) Oil (Side rail) 0.15 to 1.00 mm (0.0059 to 0.0394 in.) 3MZ−FE: A37355 Item Specified Condition No. 1 0.30 to 0.95 mm (0.0118 to 0.0374 in.) No. 2 0.50 to 1.05 mm (0.0197 to 0.0413 in.) Oil (Side rail) 0.15 to 1.00 mm (0.0059 to 0.0394 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block. WhereEverybodyKnowsYourName 14−281 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 29. (a) INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Specified diameter: 7.2 to 7.6 mm (0.283 to 0.299 in.) If the diameter is less than the minimum, replace the bolt. EM6347 A15065 30. (a) INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a dial indicator and V−blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. EM6347 A15065 31. (a) INSPECT CRANKSHAFT Using a dial indicator and V−blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. P12406 (b) A37157 Using a micrometer, measure the diameter of each main journal. Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance (see step 7). If necessary, replace the crankshaft. (c) Check each main journal for taper and out−of−round as shown in the illustration. Maximum taper and out−of−round: 0.02 mm (0.0008 in.) If the taper and out−of−round is greater than the maximum, replace the crankshaft. WhereEverybodyKnowsYourName 14−282 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) (d) ZF6928 Using a micrometer, measure the diameter of each crank pin. Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance (see step 7). (e) Check each crank pin for taper and out−of−round as shown in the illustration. Maximum taper and out−of−round: 0.02 mm (0.0008 in.) If the taper and out−of−round is greater than the maximum, replace the crankshaft. WhereEverybodyKnowsYourName 14−283 ENGINE MECHANICAL 32. − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSTALL STUD BOLT Front Side Front Side 99 mm (3.90 in.) 29 mm (1.14 in.) M8 M6 Torque: 6.0 N⋅m (60 kgf⋅cm, 53 in.⋅lbf) Torque: 15 N⋅m (145 kgf⋅cm, 11 ft⋅lbf) Front Side Left Side 80 mm (3.15 in.) 28.5 mm (1.12 in.) M8 M10 Torque: 21 N⋅m (220 kgf⋅cm, 15 ft⋅lbf) Torque: 7.0 N⋅m (70 kgf⋅cm, 62 in.⋅lbf) Top Side Top Side 52.5 mm (2.07 in.) 27.5 mm (1.08 in.) M6 Torque: 4.0 N⋅m (40 kgf⋅cm, 35 in.⋅lbf) Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) A78318 WhereEverybodyKnowsYourName 14−284 ENGINE MECHANICAL 33. − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSTALL STRAIGHT PIN Front Side Right Side (FF) 4 mm (0.16 in.) 4 mm (0.16 in.) 12 mm (0.47 in.) 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) Top Side Bottom Side 4 mm (0.16 in.) 4 mm (0.16 in.) 12 mm (0.47 in.) 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) Backside Backside 4 mm (0.16 in.) 10 mm 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) 22 mm (0.87 in.) Protrusion Height: 11 mm (0.43 in.) A78319 WhereEverybodyKnowsYourName 14−285 ENGINE MECHANICAL 34. − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSTALL RING PIN Top Side 11 mm (0.43 in.) 16 mm (0.63 in.) 8 mm (0.31 in.) 20 mm (0.79 in.) Protrusion Height: 10 mm (0.39 in.) Protrusion Height: 4 mm (0.16 in.) A78816 35. (a) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A32958 P12418 36. (a) 80C INSTALL W/PIN PISTON SUB−ASSY Gradually heat the piston to about 80C (176F). A78817 WhereEverybodyKnowsYourName 14−286 ENGINE MECHANICAL (b) (c) 1MZ−FE for AISIN made Front Mark (2 Cavities) − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb until the pin contacts the snap ring. 1MZ−FE for MAHLE made Front Mark (1 Cavity) 3MZ−FE Front Mark (1 Cavity) Front Mark (Mold Mark) Front Mark (Mold Mark) Front Mark (1 Cavity) Front Mark (2 Cavities) Front Mark (Mold Mark) Front Mark (Mold Mark) A80056 A80057 A78376 Front Mark (Mold Mark) A90700 37. (a) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. HINT: Be sure that the end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston. P12418 A32958 WhereEverybodyKnowsYourName 14−287 ENGINE MECHANICAL No. 1 No. 2 1R or G1 38. (a) (b) 1MZ−FE 2R 3MZ−FE No. 1 No. 2 CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) INSTALL PISTON RING SET Install the oil ring expander and the 2 side rails by hand. Using a piston ring expander, install the 2 compression rings. HINT: The No. 1 and No. 2 compression rings are installed with code mark faced upward as shown in the illustration. Code mark: 1MZ−FE: G2 No. 2 − Item Code Mark No. 1 1R or G1 No. 2 2R or G1 3MZ−FE 2A A78320 A78819 Code Mark 2A A90701 (c) 1MZ−FE for RH Piston Lower Side Rail No. 2 Compression Item No. 2 Front Mark Position the piston rings so that the ring ends are arranged as shown in the illustration. NOTICE: Do not align the ring ends. Front Mark Expander No. 1 Compression Upper Side Rail 1MZ−FE for LH Piston Lower Side Rail No. 2 Compression or Front Mark Expander No. 1 Front Mark Compression Upper Side Rail 3MZ−FE Lower Side Rail No. 2 Compression Front Mark Expander No. 1 Compression Upper Side Rail A80831 A78321 A90702 WhereEverybodyKnowsYourName 14−288 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 39. (a) INSTALL CONNECTING ROD BEARING Align the key of the bearing with the keyway of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils. P12402 No. 1 and No. 4 No. 2 and No. 3 Upper Lower 22.4 mm 40. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in width of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. 19.0 mm A78806 (a) Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. P12599 (b) Align the key of the bearing with the keyway of the main bearing cap, and push in the 4 lower bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. HINT: A number is marked on each main bearing cap to indicate the installation position. Mark 1, 2, 3 or 4 A78807 41. (a) INSTALL CRANKSHAFT THRUST WASHER SET Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward. P12600 WhereEverybodyKnowsYourName 14−289 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) (b) Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward. 42. (a) INSTALL CRANKSHAFT Apply engine oil to the upper bearing and install the crankshaft on the cylinder block. (b) Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads of the bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. A05264 (c) (d) A10530 (e) Install the main bearing cap by hand using the inner bolt as a guide. Stop the main bearing cap is about 6 mm (0.23 in.) away from contacting with the block. (f) Using a plastic−faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil on the threads of the main bearing cap bolts. Less than 6 mm A78809 (g) A10529 WhereEverybodyKnowsYourName 14−290 ENGINE MECHANICAL 11 3 9 1 7 15 13 6 4 8 Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) (i) (j) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts by 90 in the same sequence as step (h). Check that each painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. Install a new seal washer to the main bearing cap bolt 14 10 12 16 A78810 Painted Mark 90 (k) 90 Front CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) (h) 5 2 − (l) (m) A78811 2 1 (n) 4 7 3 HINT: Use the short bolt for the marked position (arrow). 6 8 Uniformly install and tighten the 8 main bearing cap bolts in the sequence shown in the illustration. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) 5 A91571 43. (a) Front Mark (Cavity) Front A78322 Front INSTALL PISTON SUB−ASSY W/CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. (d) Check that the protrusion of the connecting rod cap is facing the correct direction. (e) Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Protrusion A78794 WhereEverybodyKnowsYourName 14−291 ENGINE MECHANICAL − CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) (f) Tighten the bolts in several steps by the specified torque. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (g) (h) (i) Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts by 90 as shown in the illustration. Check that the crankshaft turns smoothly. 44. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) P12697 Painted Mark 90 90 Front A78795 Front Side (a) A78822 45. Left Side (a) INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A78823 46. Back Side (a) INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 50 N⋅m (510 kgf⋅cm, 37 ft⋅lbf) A78824 WhereEverybodyKnowsYourName 14−292 ENGINE MECHANICAL CYLINDER BLOCK ASSY (1MZ−FE/3MZ−FE) 47. (a) (b) A A B B − Seal Width 3 to 5 mm A62377 INSTALL WATER SEAL PLATE Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration. Seal packing: Part No. 08826−00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the seal plate within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the seal plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) 48. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY (a) Apply adhesive to 2 or 3 threads of the drain cock end. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (b) After applying the specified torque, rotate the drain cock clockwise as shown in the illustration. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) NOTICE:
Install the drain cock within 3 minutes after applying adhesive.
Do not expose the seal to coolant for at least 1 hour after installing.
Do not rotate the drain cock more than 1 revolution (360) after tightening the drain cock with the specified torque.
Do not loosen the drain cock after setting it correctly. 10 45 A78323 WhereEverybodyKnowsYourName 14−29 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 141J2−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. (a) (b) 9. (a) 10. 11. 12. 13. 14. 15. 16. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−1) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL DRAIN ENGINE COOLANT (See page 16−6) DRAIN AUTOMATIC TRANSAXLE FLUID (A/T) Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain automatic transaxle fluid. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) DRAIN MANUAL TRANSAXLE OIL (M/T) Install a new gasket and the drain plug after draining transaxle oil. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) REMOVE BATTERY REMOVE AIR CLEANER ASSY REMOVE ENGINE COVER SUB−ASSY NO.1 DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET DISCONNECT OIL COOLER OUTLET HOSE NO.2 (A/T) DISCONNECT OIL COOLER OUTLET HOSE NO.3 (A/T) 17. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and the engine moving control rod w/ bracket. A59888 18. 19. 20. REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE MOUNTING BRACKET NO.2 RH REMOVE FAN AND GENERATOR V BELT (See page 14−5) 21. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 A60072 WhereEverybodyKnowsYourName 14−30 ENGINE MECHANICAL 22. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) DISCONNECT RETURN TUBE SUB−ASSY A60073 23. 24. 25. 26. 27. (a) (b) 28. 29. 30. DISCONNECT UNION TO CONNECTOR TUBE HOSE DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T) (See page 40−65) DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T) DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T) REMOVE CLUTCH RELEASE CYLINDER ASSY (M/T) Remove the bolt and flexible hose. Remove the 2 bolts and clutch release cylinder. DISCONNECT HEATER INLET WATER HOSE DISCONNECT HEATER OUTLET WATER HOSE DISCONNECT FUEL TUBE SUB−ASSY (See page 11−1) 31. DISCONNECT ENGINE WIRE (a) Disconnect the engine wire from the ECM and J/B. (b) (1) Disconnect the engine wire from the engine room J/B. (1) Remove the nut fixing the wire harness. (2) Using a screwdriver, unlock the engine room J/B. Disconnect the engine wire by pulling it upward. (2) A59893 (c) (3) Disconnect the connectors. Pull out the engine wire. A59894 WhereEverybodyKnowsYourName 14−31 ENGINE MECHANICAL B Terminal − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (d) (e) (f) Disconnect the B terminal of the generator. Remove the body ground. Remove the starter connector. 32. (a) DISCONNECT ENGINE WIRE NO.2 Remove the nut and disconnect terminal 30 of the starter. A88595 A88596 33. REMOVE GENERATOR ASSY 34. REMOVE COMPRESSOR AND MAGNETIC CLUTCH HINT: Hang up the hoses instead of detaching. 35. REMOVE EXHAUST PIPE ASSY FRONT 36. REMOVE FRONT STABILIZER LINK ASSY LH (a) Using a 6 mm socket hexagon wrench, fix the stud bolt. (b) Remove the nut and disconnect the stabilizer link. 37. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 38. (a) REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, strike the lock nut covering to remove it. SST SST 09930−00010 NOTICE:
Set the drive shaft’s groove so that it faces up. Then use the SST and hammer.
Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged. C65981
Do not sharpen the tip of the SST. (b) Using a 30 mm socket wrench, remove the lock nut. REMOVE FRONT AXLE HUB RH NUT 39. HINT: Use the same procedures described for the LH side. WhereEverybodyKnowsYourName 14−32 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 40. REMOVE SPEED SENSOR FRONT LH (W/ ABS) (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. NOTICE: Keep the speed sensor tip and connection free from foreign matter. 41. REMOVE SPEED SENSOR FRONT RH (W/ ABS) HINT: Use the same procedures described for the LH side. 42. (a) (b) DISCONNECT TIE ROD ASSY LH Remove the cotter pin and castle nut. Using SST, disconnect the tie rod end from the steering knuckle. SST 09628−62011 NOTICE: Be careful not to damage the cover of the ball joint. SST C65311 43. DISCONNECT TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 44. (a) (b) DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, as shown in the illustration. Using a plastic hammer, disconnect the drive shaft from the axle hub. C65935 45. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 46. (a) REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT Fix the crankshaft and remove the 6 setting bolts. A62253 WhereEverybodyKnowsYourName 14−33 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 47. (a) REMOVE STEERING INTERMEDIATE SHAFT ASSY Loosen the sliding yoke bolt. (b) Place matchmarks on the intermediate shaft and control valve shaft. Remove the bolt and the steering intermediate shaft. A60062 Matchmarks (c) A60063 (d) To prevent the steering wheel from rotating, fix the wheel with the seat belt. NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged. A59876 48. (a) (b) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH. (c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH. Carefully remove the engine assembly from the vehicle. A59877 (d) A59878 WhereEverybodyKnowsYourName 14−34 ENGINE MECHANICAL Engine Hanger No. 1 (e) Engine Hanger No. 2 − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Install the 2 engine hangers as shown in the illustration. Parts No.: Engine hanger No. 1 12281−28010 Engine hanger No. 2 12282−28010 Bolt 91512−61020 (f) Torque: 38 N⋅m (387 kgf⋅cm, 28 ft lbf) Using a chain block and an engine sling device, hang the engine assembly. 49. (a) (b) REMOVE VANE PUMP ASSY Disconnect the PS oil pressure switch connector. Remove the 2 bolts and vane pump from the engine. 50. (a) REMOVE FRONT FRAME ASSY A/T: Remove the nut installing the engine mounting insulator LH. (b) M/T: Remove the bolt installing the engine mounting insulator LH. (c) Remove the nut installing the engine mounting insulator RH. A90847 A59879 A/T A52490 M/T A59881 A52482 WhereEverybodyKnowsYourName 14−35 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (d) Remove the bolt installing the engine mounting insulator FR. (e) M/T: Remove the bolt installing the engine lateral control rod. Raise the engine assembly and separate the front frame. A59880 M/T (f) A60825 51. 52. 53. 54. 55. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30−8) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30−8) REMOVE STARTER ASSY (See page 19−5) SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T) (See page 40−18) SEPARATE MANUAL TRANSAXLE ASSY (M/T) (See page 41−11) 56. REMOVE DRIVE PLATE & RING GEAR SUB−ASSY (A/T) (a) TMC made: Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 SST A32665 (b) TMMK made: Using SST, fix the crankshaft. SST 09960−10010 (09962−01000, 09963−01000) SST A62061 WhereEverybodyKnowsYourName 14−36 ENGINE MECHANICAL (c) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Remove the 8 bolts, rear spacer, drive plate and front spacer. A91018 57. 58. REMOVE CLUTCH COVER ASSY (M/T) (See page 42−15) REMOVE CLUTCH DISC ASSY (M/T) (See page 42−15) 59. (a) REMOVE FLYWHEEL SUB−ASSY (M/T) Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 (b) Remove the 8 bolts, rear spacer and flywheel. 61. (a) REMOVE INTAKE MANIFOLD Remove the 5 bolts, 2 nuts, intake manifold and gasket. SST A32665 A91020 60. INSTALL ENGINE STAND A61987 WhereEverybodyKnowsYourName 14−37 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 62. (a) INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.20 mm (0.0079 in.) If the warpage is greater than maximum, replace the manifold. A85564 63. 64. 65. 66. 67. 68. 69. 70. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV only) (See page 13−5) VENTILATION HOSE VENTILATION HOSE NO.2 ENGINE WIRE INTAKE MANIFOLD INSULATOR NO.1 OIL LEVEL GAGE SUB−ASSY OIL LEVEL GAGE GUIDE MANIFOLD CONVERTER INSULATOR NO.1 71. (a) REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY Remove the 3 bolts, 2 nuts, and the No. 1 and No. 2 exhaust manifold stays. A60067 (b) Remove the 5 nuts, exhaust manifold converter and gasket. A89788 72. INSPECT CONVERTER SUB−ASSY, EXHAUST MANIFOLD (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If the warpage is greater than the maximum, replace the manifold. A85567 WhereEverybodyKnowsYourName 14−38 ENGINE MECHANICAL 73. 74. 75. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) REMOVE WATER INLET REMOVE THERMOSTAT REMOVE IGNITION COIL ASSY 76. (a) REMOVE V−RIBBED BELT TENSIONER ASSY Remove the bolt, nut and belt tensioner. A32676 77. 78. 79. 80. REMOVE DRIVE SHAFT BEARING BRACKET REMOVE ENGINE MOUNTING BRACKET RH REMOVE FUEL DELIVERY PIPE W/INJECTOR (See page 11−10) REMOVE WATER BY−PASS PIPE NO.1 Oil Pressure Switch 81. (a) REMOVE ENGINE OIL PRESSURE SWITCH ASSY Remove the oil pressure switch. B11410 82. (a) (b) 83. 84. 85. (a) (b) REMOVE KNOCK SENSOR Disconnect the sensor connector. Remove the nut and sensor. REMOVE ENGINE COOLANT TEMPERATURE SENSOR REPLACE PARTIAL ENGINE ASSY INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the sensor. Install the sensor. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 86. (a) Upper 10
Engine Front INSTALL KNOCK SENSOR Install the sensor with the nut, as shown in the illustration. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 10
A78436 WhereEverybodyKnowsYourName 14−39 ENGINE MECHANICAL 87. (a) (b) 88. (a) 89. 90. 91. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL ENGINE OIL PRESSURE SWITCH ASSY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil. Adhesive: Part No. 08833−00080 THREE BOND 1344 or equivalent Install the oil pressure switch. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) INSTALL WATER BY−PASS PIPE NO.1 Install a new gasket and the by−pass pipe with the bolt and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL FUEL DELIVERY PIPE W/INJECTOR (See page 11−10) INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 92. (a) INSTALL V−RIBBED BELT TENSIONER ASSY Install the belt tensioner with the bolt and the nut. Torque: 59.5 N⋅m (607 kgf⋅cm, 44 ft⋅lbf) A32676 93. 94. 95. INSTALL IGNITION COIL ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL THERMOSTAT (See page 16−11) INSTALL WATER INLET Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 96. INSTALL EXHAUST MANIFOLD CONVERTER 2 3 SUB−ASSY (a) Install a new gasket and the exhaust manifold converter. Uniformly tighten the 5 nuts in the sequence shown in the illustration. Torque: 37 N⋅m (378 kgf⋅cm, 27 ft⋅lbf) 4 1 5 A60084 (b) Install the No. 1 and No. 2 exhaust manifold stays with the 3 bolts and 2 nuts. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) A60067 WhereEverybodyKnowsYourName 14−40 ENGINE MECHANICAL 97. 98. (a) (b) 99. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL MANIFOLD CONVERTER INSULATOR NO.1 Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) INSTALL OIL LEVEL GAGE GUIDE Apply a light coat of engine oil to the O−ring and install it to the guide. Install the oil level gage and guide with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV only) (See page 13−5) 100. INSTALL INTAKE MANIFOLD (a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A61987 101. INSTALL DRIVE PLATE & RING GEAR SUB−ASSY (A/T) (a) TMC made: Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 SST A32665 (b) TMMK made: Using SST, fix the crankshaft. SST 09960−10010 (09962−01000, 09963−01000) (c) (d) Clean the bolt and the bolt hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND or equivalent. Install the front spacer, drive plate and rear spacer with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 98 N⋅m (1,000 kgf⋅cm, 72 ft⋅lbf) SST A62061 1 6 3 (e) 7 8 4 2 5 A61988 WhereEverybodyKnowsYourName 14−41 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 102. INSTALL FLYWHEEL SUB−ASSY (a) Using SST, fix the crankshaft. SST 09213−54015 (91651−60855), 09330−00021 SST A32665 (b) (c) 8 1 3 6 (d) 5 7 4 Clean the bolt and the bolt hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND or equivalent. Install the flywheel. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 130 N⋅m (1,330 kgf⋅cm, 96 ft⋅lbf) 2 A91020 103. 104. 105. 106. 107. INSTALL CLUTCH DISC ASSY (M/T) (See page 42−15) INSTALL CLUTCH COVER ASSY (M/T) (See page 42−15) INSTALL AUTOMATIC TRANSAXLE ASSY (A/T) (See page 40−18) INSTALL MANUAL TRANSAXLE ASSY (M/T) (See page 41−11) INSTALL STARTER ASSY (See page 19−5) Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) 108. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30−8) 109. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30−8) 110. INSTALL FRONT FRAME ASSY (a) A/T: Install the engine mounting insulator LH with the nut. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) A/T A52490 (b) M/T M/T: Install the engine mounting insulator LH with the bolt. Torque: 143 N⋅m (1,459 kgf⋅cm, 105 ft⋅lbf) A59881 WhereEverybodyKnowsYourName 14−42 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (c) Install the engine mounting insulator RH with the nut. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf) (e) M/T: Install the engine lateral control rod with the bolt. Torque: 89 N⋅m (910 kgf⋅cm, 66 ft⋅lbf) A52482 A59880 M/T A60825 111. INSTALL VANE PUMP ASSY (a) Install the vane pump to the engine with the 2 bolts. (b) Connect the PS oil pressure switch connector. Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) A59879 Nut A B B Nut A A59877 112. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side plate LH and RH with the 4 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt A 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut WhereEverybodyKnowsYourName 14−43 ENGINE MECHANICAL (d) Nut C Nut C D D − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt C 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt D and nut A59878 113. INSTALL STEERING INTERMEDIATE SHAFT ASSY (a) Align the matchmarks on the intermediate shaft and control valve shaft. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) Matchmarks A60063 (b) Tighten the bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A60062 114. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T) (a) Fix the crankshaft, and install the 6 setting bolts. Torque: 41 N⋅m (418 kgf⋅cm, 30 ft⋅lbf) A62253 115. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (a) Install the drive shaft to the steering knuckle. (b) Install the suspension lower arm with the bolt and the 2 nuts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) C65935 WhereEverybodyKnowsYourName 14−44 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 116. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 117. INSTALL TIE ROD ASSY LH (a) Connect the tie rod end to the steering knuckle and install a new castle nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) NOTICE:
Prevent any lubricant from contacting the thread and the taper portions.
After tightening the castle nut, tighten it to the additional direction within 60
to put into a cotter pin. (b) Insert a new cotter pin. 118. INSTALL TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 119. INSTALL SPEED SENSOR FRONT LH (W/ABS) Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 120. INSTALL SPEED SENSOR FRONT RH (W/ABS) Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 121. INSTALL FRONT AXLE HUB LH NUT (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Using a chisel and hammer, tapped the front axle hub LH nut. C65982 122. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedures described for the LH side. 123. INSTALL FRONT STABILIZER LINK ASSY LH (a) Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) 124. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 125. INSTALL EXHAUST PIPE ASSY FRONT (See page 15−3) 126. CONNECT FUEL TUBE SUB−ASSY (See page 11−1) WhereEverybodyKnowsYourName 14−45 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 127. INSTALL RETURN TUBE SUB−ASSY A60073 128. INSTALL OIL RESERVOIR TO PUMP HOSE NO.1 A60072 129. 130. 131. 132. 133. 134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 55−68) INSTALL GENERATOR ASSY (See page 19−17) INSTALL FAN AND GENERATOR V BELT (See page 14−5) CONNECT ENGINE WIRE NO.2 CONNECT ENGINE WIRE INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) 135. INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 136. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (a) Install the engine mounting control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A59888 137. INSTALL AIR CLEANER ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) 138. ADD AUTOMATIC TRANSAXLE FLUID (A/T) 139. ADD MANUAL TRANSAXLE OIL (M/T) 140. ADD ENGINE OIL 141. ADD ENGINE COOLANT (See page 16−6) 142. ADD POWER STEERING FLUID 143. BLEED POWER STEERING FLUID 144. CHECK FOR OIL LEAKS 145. CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName 14−46 ENGINE MECHANICAL 146. 147. 148. 149. 150. 151. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) CHECK FOR FUEL LEAKS (See page 11−4) INSTALL FRONT WHEEL ADJUST FRONT WHEEL ALIGNMENT (See page 26−5) INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14−1) INSPECT CO/HC CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) (See page 05−873, 05−933 or 05−990) WhereEverybodyKnowsYourName 14−47 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 141J4−01 OVERHAUL 1. (a) REMOVE OIL FILTER SUB−ASSY Using SST, remove the oil filter. SST 09228−06501 SST A36541 2. (a) 3. 4. 5. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the union. REMOVE OIL FILLER CAP SUB−ASSY REMOVE VENTILATION VALVE SUB−ASSY REMOVE SPARK PLUG 6. REMOVE CYLINDER HEAD COVER SUB−ASSY (a) Remove the 8 bolts, 2 nuts, and cylinder head cover. A52450 7. 8. REMOVE CYLINDER HEAD COVER GASKET REMOVE CRANKSHAFT POSITION SENSOR 9. (a) Timing Marks (b) REMOVE CRANKSHAFT PULLEY Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration. Timing Marks Groove A53043 WhereEverybodyKnowsYourName 14−48 ENGINE MECHANICAL (c) SST − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) TMC made: Remove the crankshaft pulley. (1) Using SST, fix the pulley and loosen the bolt. SST 09213−54015 (91651−60855), 09330−00021 A36684 (2) Using SST, remove the bolt and pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) SST A36685 (d) TMMK made: Remove the crankshaft pulley. (1) Using SST, fix the crankshaft pulley and loosen a pulley set bolt. SST 09960−10010 (09962−01000, 09963−01000) SST A62057 Hooking Point (2) Using SST, remove the crankshaft pulley. SST 09950−40011 (09951−04010, 09952−04010, 09953−04030, 09954−04010, 09955−04041, 09957−04010, 91111−51014) SST A62058 10. REMOVE CHAIN TENSIONER ASSY NO.1 (a) Remove the 2 nuts, chain tensioner and gasket. NOTICE: Do not to turn the crankshaft without the chain tensioner. A13325 WhereEverybodyKnowsYourName 14−49 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 11. (a) REMOVE WATER PUMP PULLEY Using SST, remove the water pump pulley. SST 09960−10010 (09962−01000, 09963−00700) 12. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump. 14. (a) REMOVE OIL PAN SUB−ASSY Remove the 12 bolts and 2 nuts. SST A36335 Bracket A53037 13. REMOVE OIL PAN DRAIN PLUG A64641 (b) Insert the blade of SST between the crankcase and oil pan. Cut off applied sealer and remove the oil pan. SST 09032−00100 NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan. SST A00019 WhereEverybodyKnowsYourName 14−50 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 15. REMOVE TIMING CHAIN OR BELT COVER SUB−ASSY (a) Remove the 14 bolts and 2 nuts. (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. A64642 16. (a) REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and a hammer, remove the oil seal. A32626 17. 18. 19. 20. 21. 22. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 TIMING CHAIN GUIDE CHAIN TENSIONER SLIPPER CHAIN VIBRATION DAMPER NO.1 CHAIN SUB−ASSY CRANKSHAFT TIMING GEAR OR SPROCKET WhereEverybodyKnowsYourName 14−51 ENGINE MECHANICAL 90
− PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 23. (a) REMOVE NO.2 CHAIN SUB−ASSY Turn the crankshaft counterclockwise by 90
, and align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump. (b) Put a bar (φ 4 mm) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut. (c) (d) Remove the bolt, chain tensioner plate and spring. Remove the oil pump drive sprocket, oil pump driven sprocket and chain. 24. (a) REMOVE OIL PUMP ASSY Remove the 3 bolts, oil pump and gasket. Groove A52508 Groove A52509 B11415 A32684 WhereEverybodyKnowsYourName 14−52 ENGINE MECHANICAL 25. (a) (b) 1 3 5 4 2 1 3 5 4 2 − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. A36530 26. (a) (b) REMOVE CAMSHAFT Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. A36531 27. REMOVE CAMSHAFT BEARING NO.1 28. (a) REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Fix the camshaft with a vise and remove the camshaft timing sprocket. NOTICE: Be careful not to damage the camshaft. A32167 29. (a) Advanced Angle Side (b) REMOVE CAMSHAFT TIMING GEAR ASSY Fix the camshaft with a vise, and make sure that the camshaft timing gear does not move. Cover all the oil ports with vinyl tape except the advanced angle side, as shown in the illustration. A90848 WhereEverybodyKnowsYourName 14−53 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (c) A31032 Using an air gun, apply about 150 kPA (1.5 kgf/cm, 21 psi) of air pressure to the port on the advanced angle side. CAUTION: Some oil spraying will occur. Contain the spray with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (d) Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow in the illustration. Standard: Must turn HINT: The camshaft timing gear will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock−pin may be difficult to release. (e) Remove the fringe bolt from the camshaft timing gear. NOTICE:
Be sure not to remove the other 4 bolts.
If planning to reuse the camshaft timing gear, release the straight pin lock first, and then install the gear. A32639 30. 31. 33. 34. 35. (a) 36. REMOVE CAMSHAFT BEARING NO.2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 3 7 9 6 2 1 5 10 8 4A32653 32. (a) REMOVE CYLINDER HEAD SUB−ASSY Using a 10 mm bi−hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. REMOVE CYLINDER HEAD GASKET REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY REMOVE OIL CONTROL VALVE FILTER Using a 6 mm socket hexagon wrench, remove the plug and filter. REMOVE W/HEAD TAPER SCREW PLUG NO.1 WhereEverybodyKnowsYourName 14−54 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 37. (a) INSPECT BALANCESHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth. Specified thrust clearance: 0.050 to 0.090 mm (0.0020 to 0.0035 in.) If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft. A53071 38. (a) 4 1 8 5 6 7 2 3 A92400 INSPECT BALANCESHAFT OIL CLEARANCE Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. NOTICE: Be careful not to damage the contact surfaces of the balance shaft housing and crankcase. HINT: Keep the lower bearing and balance shaft housing together. (b) Lift out the No. 1 and No. 2 balance shafts. HINT: Keep the upper bearing with the crankcase. (c) Clean each bearing and journal. (d) Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft. (e) Place the No. 1 and No. 2 balance shafts on the crankcase. (f) (g) Plastigage Lay a strip of Plastigage across each journal, and install the balance shaft housing. Apply light coat of engine oil on the threads and under the heads of the balance shaft housing bolts. A90849 (h) 5 8 1 4 3 2 7 6 Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 22 N⋅m (220 kgf⋅cm, 16 ft⋅lbf) HINT: The balance shaft housing bolts are tightened in 2 progressive steps. A92400 WhereEverybodyKnowsYourName 14−55 ENGINE MECHANICAL (i) Paint Mark 90
(j) (k) Engine Front − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Mark the front side of each balance shaft housing bolt head with paint. Retighten the bolts by 90
as shown in the illustration. Check that the paint marks are now at a 90
angle to the front. A50671 (l) Remove the balance shaft housing, and measure the Plastigage at its widest point. Specified oil clearance: 0.004 to 0.031 mm (0.0002 to 0.0012 in.) (m) Completely remove the plastigage after the inspection. If the clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft. A13392 HINT: If replacing a bearing, replace it with one that has the same number as the stiffening crankcase. There are 3 sizes of standard bearings: 1, 2 and 3. Balance shaft housing journal bore diameter: No. 1 Shaft FR No. 2 Shaft FR 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.006 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.012 to 26.018 mm (1.0241 to 1.0243 in.) Balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Standard bearing center wall thickness: No. 1 Shaft RR (n) No. 2 Shaft RR Mark 1 Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.492 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) Completely remove the Plastigage after the inspection. Mark A53040 39. 40. REMOVE BALANCESHAFT REMOVE BALANCESHAFT BEARING NO. 1 WhereEverybodyKnowsYourName 14−56 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 41. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400−grit sandpaper. Cut Position A13493 7 3 9 10 5 6 4 8 11 42. (a) 1 2 A36837 REMOVE STIFFENING CRANKCASE ASSY Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. (b) Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. (c) Remove the O−ring from the cylinder block. 43. (a) (b) A53035 INSPECT OIL PUMP DRIVE SPROCKET Wrap the chain around the drive sprocket. Using a vernier caliper, measure the drive sprocket diameter with the chain. NOTICE: The vernier caliper must contact the chain rollers for the measurement. Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 in.) If the diameter is less than the minimum, replace the chain and sprocket. 44. (a) (b) A53036 INSPECT OIL PUMP DRIVEN SPROCKET Wrap the chain around the driven sprocket. Using a vernier caliper, measure the driven sprocket diameter with the chain. NOTICE: The vernier caliper must contact the chain rollers for the measurement. Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 in.) If the diameter is less than the minimum, replace the chain and drive shaft gear. WhereEverybodyKnowsYourName 14−57 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 45. A53035 INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET (a) Wrap the chain around the timing sprocket. (b) Using a vernier caliper, measure the timing sprocket diameter with the chain. NOTICE: The vernier caliper must contact the chain rollers for the measurement. Minimum sprocket diameter (w/ chain): 51.6 mm (2.031 in.) If the diameter is less than the minimum, replace the chain and timing gear. 46. (a) INSPECT CHAIN TENSIONER SLIPPER Measure the tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the tensioner slipper. A33838 47. (a) INSPECT CHAIN VIBRATION DAMPER NO.1 Measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the vibration damper. A36686 48. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the head bolts from the seat to the end. Specified bolt length: 161.3 to 164.2 mm (6.350 to 6.465 in.) If the length is greater than the maximum, replace the bolt. Overall Length A88619 WhereEverybodyKnowsYourName 14−58 ENGINE MECHANICAL 49. (a) Raise Move (b) Lock − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSPECT CHAIN TENSIONER ASSY NO.1 Check that the plunger moves smoothly when the ratchet pawl is raised. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with finger. A53049 50. (a) 115.4 mm 15 Links A57478 INSPECT CHAIN SUB−ASSY Using a vernier caliper, measure the length of 15 links with the chain fully stretched. Maximum chain elongation: 115.4 mm (4.543 in.) If the elongation is greater than the maximum, replace the chain. NOTICE: Make the same measurements pulling at 3 or more places selected at random. Average the measurements. 51. (a) (b) A30206 INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing sprocket. Using a vernier caliper, measure the timing sprocket diameter with the chain. Minimum sprocket diameter (w/chain): 97.3 mm (3.831 in.) NOTICE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and timing gear. 52. (a) INSPECT CAMSHAFT Check the camshaft for runout. (1) Place the camshaft on V−blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM1628 WhereEverybodyKnowsYourName 14−59 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (b) Using a micrometer, measure the cam lobe height. Specified cam lobe height: 46.599 to 46.809 mm (1.8346 to 1.8429 in.) If the cam lobe height is less than the minimum, replace the camshaft. A36687 (c) Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. A36688 53. (a) INSPECT NO.2 CAMSHAFT Check the camshaft for runout. (1) Place the camshaft on V−blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM1628 (b) Using a micrometer, measure the cam lobe height. Specified cam lobe height: 45.599 to 46.809 mm (1.8346 to 1.8429 in.) If the cam lobe height is less than the minimum, replace the camshaft. A36687 (c) Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. A36688 WhereEverybodyKnowsYourName 14−60 ENGINE MECHANICAL 54. (a) (b) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL BALANCESHAFT BEARING NO.1 Install the bearings in the crankcase and balance shaft housing. Apply a light coat of engine oil on the bearings. 55. (a) Matchmarks (b) INSTALL BALANCESHAFT NO. 1 AND NO. 2 Rotate the driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper. Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched. Rotating Direction A90850 (c) Timing Marks (d) (e) Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration. Place the No. 1 and No. 2 balance shafts on the crank case. Apply a light coat of engine oil under the heads of the balance shaft housing bolts. A13508 (f) 5 8 1 4 3 2 7 6 Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 22 N⋅m (220 kgf⋅cm, 16 ft⋅lbf) HINT: The balance shaft housing bolts are tightened in 2 progressive steps. A92400 90
(g) Paint Mark (h) (i) Engine Front Mark the front side of each balance shaft housing bolt head with paint. Retighten the bolts by 90
as shown in the illustration. Check that the painted marks are now at a 90
angle to the front. A50671 WhereEverybodyKnowsYourName 14−61 ENGINE MECHANICAL INSTALL STIFFENING CRANKCASE ASSY Apply seal packing in a continuous bead (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to the places shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the crankcase within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. A C D B B PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 56. (a) Seal Packing A − C, D 7.5 4 7.5 A53042 O−ring (b) Place a new O−ring on the cylinder block, as shown in the illustration. (c) With the No. 1 crank pin of the crankshaft placed at 6 o’clock, install the No. 1 and No. 2 balanceshaft and the adjusting hole as shown in the illustration. (d) Uniformly tighten the 11 bolts in the sequence shown in the illustration. Torque: 33 N⋅m (332 kgf⋅cm, 24 ft⋅lbf) A53026 No. 1 Crank Pin Timing Mark A91021 5 9 3 2 7 6 8 4 1 11 10 A36840 WhereEverybodyKnowsYourName 14−62 ENGINE MECHANICAL (e) Timing Marks − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Confirm that the timing marks of the balanceshafts are matched when the key groove is placed at 6 o’clock, as shown in the illustration. Key A13514 SST A32658 57. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip off the foreign materials. (b) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−15030, 09950−70010 (09951−07100) NOTICE: Wipe off extra grease on the crankshaft. 58. (a) INSTALL W/HEAD TAPER SCREW PLUG NO.1 Apply adhesive to the threads of the plug and install it. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 59. (a) INSTALL OIL CONTROL VALVE FILTER Check that no foreign substance is on the mesh part of the filter. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A36850 (b) Mesh Part A53039 60. (a) 45
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY Install the water drain cock within the range shown in the illustration. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 45
A36835 WhereEverybodyKnowsYourName 14−63 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 61. (a) INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. Lot No. A53013 62. INSTALL CYLINDER HEAD SUB−ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the 10 bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. 8 4 2 5 9 10 6 1 3 7 A53060 90
(c) Using a 10 mm bi−hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration. Torque: 79 N⋅m (806 kgf⋅cm, 58 ft⋅lbf) (d) (e) Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 90
in the sequence shown in the illustration. Check that the painted marks are now at a 90
angle to the front. (f) Engine Front Paint Mark A00976 63. A53074 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) WhereEverybodyKnowsYourName 14−64 ENGINE MECHANICAL 64. − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL CAMSHAFT BEARING NO.2 A13383 65. (a) Straight Pin Key Groove A31033 INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and the camshaft together with the straight pin and key groove. (b) Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right angle). (c) Check that there is no clearance between the gear’s fringe and the camshaft. (d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) (e) Check that the camshaft timing gear can move to the retarded angle side (the right direction) and is locked at the extreme retarded angle position. 66. (a) INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Fix the camshaft with a vise, and install the camshaft No. 2 timing gear. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) A32167 67. INSTALL CAMSHAFT BEARING NO.1 WhereEverybodyKnowsYourName 14−65 ENGINE MECHANICAL 5 3 1 2 Bearing Cap No. 3 Bearing Cap No. 2 Bearing Cap No. 3 1 A52475 2 PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 68. (a) 4 Bearing Cap No. 1 5 3 − 4 A52476 INSTALL CAMSHAFT Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 NOTICE:
Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 1.
Install the camshaft with its timing mark of the camshaft timing gear on top. 69. (a) INSTALL NO.2 CAMSHAFT Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 NOTICE:
Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 2.
Install the camshaft with its timing mark of the camshaft timing gear on top. 70. (a) INSTALL OIL PUMP ASSY Install a new gasket and oil pump with the 3 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 71. (a) (b) INSTALL NO.2 CHAIN SUB−ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. A32684 B11424 WhereEverybodyKnowsYourName 14−66 ENGINE MECHANICAL (c) Mark Link Timing Mark (d) (e) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration. Insert the sprocket with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump driven sprocket with the nut. Timing Mark Mark Link A52510 Chain Tensiner Plate (f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate by the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) (g) Align the adjusting hole of the sprocket with the groove of the oil pump. Put a bar (φ 4 mm) into the adjusting hole of the sprocket to temporarily lock the sprocket in position. Install the nut. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) Bolt Spring A90851 (h) Groove A52512 (i) 90
Rotate the crankshaft clockwise by 90
, and align the crankshaft key with the top. A36525 WhereEverybodyKnowsYourName 14−67 ENGINE MECHANICAL 72. 73. (a) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 74. (a) INSTALL CHAIN SUB−ASSY Set the No. 1 cylinder to TDC/compression. (1) Align the timing marks of the camshaft timing gear/ sprocket and bearing caps (No. 1 and No. 2). Timing Marks Timing Marks A53018 (2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A52505 (b) Align the mark link (blue or orange colored link) with the timing mark of the crankshaft timing sprocket. (c) Using SST, tap in the sprocket. SST 09309−37010 Timing Mark Mark Link A52523 SST A13337 WhereEverybodyKnowsYourName 14−68 ENGINE MECHANICAL (d) Mark Links Timing Marks Timing Mark − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket, and install the chain. A52513 75. 76. INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL TIMING CHAIN GUIDE Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 77. (a) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Install the sensor plate with the F mark facing forward. A53064 78. SST A13767 Seal Packing A53053 INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223−22010 (b) Apply a light coat of MP grease to the lip of the oil seal. NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter. 79. INSTALL TIMING CHAIN OR BELT COVER SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply seal packing in a continuous bead (diameter: 2 mm (0.09 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent WhereEverybodyKnowsYourName 14−69 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (c) Apply seal packing in a continuous bead (diameter: 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent (d) Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for nut Seal Packing 4 mm (0.16 in.) A A A−A 3 to 4 mm 2.5 mm (0.098 in.) A92184 C Nut Nut C C C C A B B B B B B B B A77251 WhereEverybodyKnowsYourName 14−70 ENGINE MECHANICAL 6 mm (0.24 in.) Seal Packing A92185 − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) 80. INSTALL OIL PAN SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. (b) Apply seal packing in a continuous bead (diameter: 3 mm to 4 mm (0.157 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826−00080 or equivalent (c) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) A64641 81. (a) INSTALL OIL PAN DRAIN PLUG Install a new gasket and oil pan drain plug with a new gasket. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 82. (a) (b) 2.2 to 2.5 mm A89934 INSTALL WATER PUMP ASSY Clean the contact surface of the cylinder block. Apply seal packing in a continuous bead (diameter: 2.2 to 2.5 mm (0.09 to 0.10 in.)) to the outside edge of the water pump. Seal packing: Part No. 08826−00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the water pump within 5 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. WhereEverybodyKnowsYourName 14−71 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (c) Bracket Install the water pump and bracket with the 4 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: Tighten the outside bolts and nuts with the clamp. A53037 83. (a) INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley. SST 09960−10010 (09962−01000, 09963−00700) Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 84. (a) INSTALL CRANKSHAFT POSITION SENSOR Install the sensor with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (b) Confirm that the wire harness of the sensor is placed as shown in the illustration. 85. (a) (b) INSTALL CRANKSHAFT PULLEY Install the pulley. TMC made: Using SST, tighten the bolt. SST 09213−54015 (91651−60855), 09330−00021 Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft⋅lbf) SST A36335 Wire Harness Clamp Rib A52071 SST A53034 WhereEverybodyKnowsYourName 14−72 ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) (c) TMMK made: Using SST, tighten the set bolt. SST 09960−10010 (09962−01000, 09963−01000) Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft⋅lbf) 86. (a) INSTALL CHAIN TENSIONER ASSY NO.1 Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. SST A62057 Raise Push Pin Hook A52461 (b) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner. Engine Front A52462 (c) Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook. Disconnect Turn Hook Pin A89786 WhereEverybodyKnowsYourName 14−73 ENGINE MECHANICAL (d) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Plunger Push Turn 87. 88. 89. (a) A89787 INSPECT VALVE CLEARANCE (See page 14−7) ADJUST VALVE CLEARANCE (See page 14−7) INSTALL CYLINDER HEAD COVER GASKET Install the gasket to the cylinder head cover. 90. INSTALL CYLINDER HEAD COVER SUB−ASSY (a) Remove any old packing (FIPG) material. (b) Seal Packing A53051 Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after applying seal packing.
Do not apply engine oil for at least 2 hours after installing. (c) Nut 91. 92. (a) 93. 94. (a) Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) Nut A61989 INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL VENTILATION VALVE SUB−ASSY Apply adhesive on the threads of the ventilation valve. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Adhesive: Part No. 08833−00070 THREE BOND 1324 or equivalent INSTALL OIL FILLER CAP SUB−ASSY INSTALL OIL FILTER UNION Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) WhereEverybodyKnowsYourName 14−74 ENGINE MECHANICAL 95. (a) (b) (c) (d) − PARTIAL ENGINE ASSY (2AZ−FE)(From July, 2003) INSTALL OIL FILTER SUB−ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn. SST 09228−06501 SST A36541 WhereEverybodyKnowsYourName 14−5 ENGINE MECHANICAL − DRIVE BELT (2AZ−FE)(From July, 2003) DRIVE BELT (2AZ−FE)(From July, 2003) 1405U−06 REPLACEMENT 1. 2. 3. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB−ASSY NO.1 4. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and control rod. A59888 5. 6. REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE MOUNTING BRACKET NO.2 RH 7. (a) REMOVE DRIVE BELT Slowly turn the belt tensioner clockwise for more than 3 seconds, and remove the drive belt by using SST. SST 09249−63010 8. (a) INSTALL DRIVE BELT Slowly turn the belt tensioner clockwise for more than 3 seconds, and install the drive belt by using SST. SST 09249−63010 SST A62240 SST A62240 9. 10. INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) WhereEverybodyKnowsYourName 14−6 ENGINE MECHANICAL 11. (a) − DRIVE BELT (2AZ−FE)(From July, 2003) INSTALL ENGINE MOVING CONTROL W/BRACKET Install the engine control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A59888 12. INSTALL FRONT WHEEL RH WhereEverybodyKnowsYourName ROD 14−7 ENGINE MECHANICAL − VALVE CLEARANCE (2AZ−FE)(From July, 2003) VALVE CLEARANCE (2AZ−FE) 141I7−01 ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB−ASSY NO.1 REMOVE SPARK PLUG DISCONNECT VENTILATION HOSE DISCONNECT VENTILATION HOSE NO.2 DISCONNECT ENGINE WIRE 8. (a) (b) REMOVE CYLINDER HEAD COVER SUB−ASSY Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket. A52450 9. (a) Timing Marks (b) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of bearing caps No. 1 and No. 2, as shown in the illustration. Timing Marks Groove A52504 WhereEverybodyKnowsYourName 14−8 ENGINE MECHANICAL − VALVE CLEARANCE (2AZ−FE)(From July, 2003) 10. INSPECT VALVE CLEARANCE HINT: Inspect and adjust the valve clearance when the engine is cold. (a) No. 1 Cylinder TDC/Compression IN EX Item A52469 No. 4 Cylinder TDC/Compression IN EX Paint Mark Timing Mark A52470 Paint Mark Timing Mark Groove Check only the valves indicated on the left. (1) Using a feeler gauge, measure the clearance between each valve lifter and camshaft. (2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. Valve clearance (Cold): Specified Condition Intake 0.19 to 0.29 mm (0.008 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) (b) Turn the crankshaft clockwise 1 revolution (360) and set the No. 4 cylinder to TDC/compression. (c) Check only the valves indicated on the left. (1) Using a feeler gauge, measure the clearance between each valve lifter and camshaft. (2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. Valve clearance (Cold): Item Specified Condition Intake 0.19 to 0.29 mm (0.008 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) 11. ADJUST VALVE CLEARANCE NOTICE: Be sure not to turn the crankshaft without the chain tensioner. (a) Turn the crankshaft clockwise 1 revolution (360) and set the No. 1 cylinder to the TDC/compression. (b) Place paint marks on the timing chain and camshaft timing gear/sprocket. A52471 WhereEverybodyKnowsYourName 14−9 ENGINE MECHANICAL (c) − VALVE CLEARANCE (2AZ−FE)(From July, 2003) Remove the 2 bolts and chain tensioner. A13325 Loosen (d) Remove the No. 2 camshaft. (1) Fix the camshaft with a wrench and then loosen the sproket bolt. NOTICE: Be careful not to damage the valve lifter. Fix A52454 1 3 5 4 2 (2) Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. (3) Raise the No. 2 camshaft and remove it. Then remove the sprocket bolt. Remove the camshaft timing sprocket and the timing chain from the No. 2 camshaft. Remove the camshaft timing sprocket from the timing chain. A32636 (4) (5) A87614 1 3 5 4 (e) 2 Remove the camshaft. (1) Uniformly loosen and remove the camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. (2) Remove the camshaft. A36526 WhereEverybodyKnowsYourName 14−10 ENGINE MECHANICAL − VALVE CLEARANCE (2AZ−FE)(From July, 2003) (f) Tie the timing chain with a string. NOTICE: Be careful not to drop anything inside the timing chain cover. (g) Remove the valve lifters. A52474 (h) Adjust the valve clearance. (1) Using a micrometer, measure the thickness of the removed lifter. (2) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. A A01082 Thickness of new lifter B Thickness of used lifter C Measured valve clearance Valve clearance: Item Specified Condition Intake A = B + (C − 0.24 mm (0.0094 in.)) Exhaust A = B + (C − 0.35 mm (0.0138 in.)) EXAMPLE: (Intake) Measured valve clearance = 0.44 mm (0.0173 in.) 0.44 mm (0.0173 in.) − 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.) (Measured − Specification = Excess clearance) Used shim measurement = 5.30 mm (0.2087 in.) 0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.) (Excess clearance + Used shim = Ideal new shim) Closest new shim = 5.50 mm (0.2165 in.) = Shim No. ”50” (3) Select a new lifter with a thickness as close as possible to the calculated values. HINT:
Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
Refer to valve lifter selection chart on the following 2 pages. WhereEverybodyKnowsYourName Valve Lifter Selection Chart (Intake) ENGINE MECHANICAL − Thickness Thickness 30 5.300 (0.2087) 54 5.540 (0.2181) 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) Thickness Lifter No. 06 5.060 (0.1992) 08 WhereEverybodyKnowsYourName 14−11 A77296 Intake valve clearance (Cold): 0.19 to 0.29 mm (0.008 to 0.011 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter. mm (in.) Lifter No. Lifter No. VALVE CLEARANCE (2AZ−FE)(From July, 2003) New Lifter Thickness 14−12 Valve Lifter Selection Chart (Exhaust) ENGINE MECHANICAL − A77297 Exhaust valve clearance (Cold): 0.30 to 0.40 mm (0.012 to 0.016 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 44 lifter. WhereEverybodyKnowsYourName Lifter mm (in.) Lifter Thickness No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) No. No. Thickness 5.660 (0.2228) VALVE CLEARANCE (2AZ−FE)(From July, 2003) New lifter thickness Lifter 14−13 ENGINE MECHANICAL (i) Paint Mark − VALVE CLEARANCE (2AZ−FE)(From July, 2003) Install the camshaft. (1) Install the timing chain on the camshaft timing gear, with the paint mark aligned with the timing marks on the camshaft timing gear. Timing Marks A52456 5 3 1 Bearing Cap No. 1 2 (2) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 4 Bearing Cap No. 3 A52457 (j) Paint Mark Timing Mark Install the No. 2 camshaft. (1) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket. A53011 (2) Raise the No. 2 camshaft and temporarily tighten the sprocket bolt. A52473 Bearing Cap No. 2 Bearing Cap No. 3 5 3 1 2 4 (3) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 A52458 WhereEverybodyKnowsYourName 14−14 ENGINE MECHANICAL Tighten − VALVE CLEARANCE (2AZ−FE)(From July, 2003) (4) Fix the camshaft with a wrench, then tighten the sprocket bolt. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) NOTICE: Be careful not to damage the valve lifter. Fix A52459 (k) Check that the timing chain paint marks are aligned with the camshaft timing sprocket timing mark and the camshaft timing gear timing mark. Also check the alignment of the pulley groove and chain cover timing mark 0. (l) Install the chain tensioner. (1) Raise the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. 7 Links Paint Mark Paint Mark Timing Marks Timing Mark Groove A52460 Raise Push Pin Hook A52461 (2) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger. Engine Front A52462 WhereEverybodyKnowsYourName 14−15 ENGINE MECHANICAL − VALVE CLEARANCE (2AZ−FE)(From July, 2003) (3) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. (4) Turn the crankshaft clockwise, and check that the chain tensioner slipper is pushed by the plunger. Disconnect Turn Pin Hook A89786 Plunger Push Turn A89787 12. (a) INSTALL CYLINDER HEAD COVER SUB−ASSY Remove any old packing (FIPG) material. (b) Seal Packing A53051 Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover. (c) Nut 13. 14. 15. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) Nut A61989 INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 in.⋅lbf) INSTALL FRONT WHEEL RH INSPECT OIL LEAK WhereEverybodyKnowsYourName 14−75 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) CHAIN (2AZ−FE)(From July, 2003) 141J1−01 REPLACEMENT 1. 2. 3. 4. 5. 6. (a) 7. REMOVE HOOD SUB−ASSY REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) REMOVE EXHAUST PIPE ASSY FRONT 8. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and control rod. A59888 9. REMOVE ENGINE MOUNTING STAY NO.2 RH 10. REMOVE ENGINE MOUNTING BRACKET NO.2 RH 11. REMOVE FAN AND GENERATOR V BELT (See page 14−29) 12. REMOVE ENGINE COVER SUB−ASSY NO.1 13. DISCONNECT ENGINE WIRE 14. REMOVE GENERATOR ASSY 15. REMOVE VANE PUMP ASSY (See page 51−8) NOTICE: Do not disconnect the hose. 16. REMOVE IGNITION COIL ASSY 17. DISCONNECT VENTILATION HOSE 18. DISCONNECT VENTILATION HOSE NO.2 19. (a) (b) REMOVE CYLINDER HEAD COVER SUB−ASSY Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover. A52450 WhereEverybodyKnowsYourName 14−76 ENGINE MECHANICAL 20. − CHAIN (2AZ−FE)(From July, 2003) SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14−7) 21. (a) REMOVE CRANKSHAFT PULLEY TMC made: Remove the crankshaft pulley. (1) Using SST, fix the pulley and loosen the bolt. SST 09213−54015 (91651−60855), 09330−00021 SST A52485 (2) Using SST, remove the bolt and pulley. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) SST A36685 (b) TMMK made: Remove the crankshaft pulley. (1) Using SST, fix the pulley and remove the bolt. SST 09960−10010 (09962−01000, 09963−01000) SST A62057 Hooking Point (2) Using SST, remove the crankshaft pulley. SST 09950−40011 (09951−04010, 09952−04010, 09953−04030, 09954−04010, 09955−04041, 09957−04010, 91111−51014) SST A62058 22. REMOVE CRANKSHAFT POSITION SENSOR WhereEverybodyKnowsYourName 14−77 ENGINE MECHANICAL 23. (a) − CHAIN (2AZ−FE)(From July, 2003) REMOVE OIL PAN SUB−ASSY Remove the 12 bolts and 2 nuts. A64641 (b) Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan. SST 09032−00100 NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan. A00019 24. REMOVE CHAIN TENSIONER ASSY NO.1 (a) Remove the 2 nuts, tensioner and gasket. NOTICE: Do not revolve the crankshaft without the tensioner. A13325 25. (a) REMOVE V−RIBBED BELT TENSIONER ASSY Remove the bolt, nut and tensioner. 26. (a) INSTALL ENGINE HANGER NO.1 Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Parts No.: A52478 Engine Hanger No.1 Engine Hanger No.2 Engine hanger No. 1 12281−28010 Engine hanger No. 2 12282−28010 Bolt 91512−61020 Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf) A52507 WhereEverybodyKnowsYourName 14−78 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) 27. REMOVE ENGINE MOUNTING INSULATOR (a) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. (b) Remove the bolt and disconnect the engine mounting insulator FR. A59880 M/T (c) M/T: Remove the bolt and disconnect the engine lateral control rod. (d) Remove the bolt and disconnect the steering gear return hose clamp from the frame. (e) Remove the 4 nuts from the engine mounting insulator RH. Raise the engine and remove the engine mounting insulator RH. A60825 A59901 (f) A59900 28. (a) REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket. A52481 WhereEverybodyKnowsYourName 14−79 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) 29. REMOVE TIMING CHAIN OR BELT COVER SUB−ASSY (a) Remove the stud bolt for the drive belt tensioner from the cylinder block. (b) Remove the 14 bolts and 2 nuts. (c) Pry out the timing chain cover with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. A92013 30. 31. 32. 33. 34. REMOVE REMOVE REMOVE REMOVE REMOVE Groove CRANKSHAFT POSITION SENSOR PLATE NO.1 CHAIN TENSIONER SLIPPER CHAIN VIBRATION DAMPER NO.1 CHAIN SUB−ASSY CRANKSHAFT TIMING GEAR OR SPROCKET 35. REMOVE NO.2 CHAIN SUB−ASSY 90
(a) Turn the crankshaft counterclockwise by 90
, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump. A52508 (b) Put a bar (φ 4 mm) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut. Groove A52509 WhereEverybodyKnowsYourName 14−80 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) (c) (d) Remove the bolt, chain tensioner plate and spring. Remove the chain tensioner, oil pump driven sprocket and chain. 36. (a) (b) INSTALL NO.2 CHAIN SUB−ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. (c) Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration. Insert the sprockets with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump driven sprocket with the nut. B11415 B11424 Mark Link Timing Mark (d) (e) Timing Mark Mark Link A52510 Chain Tensioner Plate Bolt (f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) Spring A90851 WhereEverybodyKnowsYourName 14−81 ENGINE MECHANICAL (g) (h) − CHAIN (2AZ−FE)(From July, 2003) Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump. Put a bar (φ 4 mm) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Install the nut. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) Groove A52512 (i) 90
Rotate the crankshaft counterclockwise by 90
, and align the crankshaft key to the top. A36525 37. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 38. (a) INSTALL CHAIN SUB−ASSY Set the No.1 cylinder to TDC/compression. (1) Align the timing marks of the camshaft timing sprockets and bearing caps (No. 1 and No. 2). Timing Marks Timing Marks A53018 (2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A52505 WhereEverybodyKnowsYourName 14−82 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) (b) Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing sprocket. (c) Using SST, tap in the sprocket. SST 09309−37010 (d) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain. Timing Mark Mark Link A52523 SST A13337 Mark Links Timing Marks Timing Mark A52513 39. INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 40. (a) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Install the sensor plate with the F mark facing forward. A53064 WhereEverybodyKnowsYourName 14−83 ENGINE MECHANICAL Seal Packing A53053 CHAIN (2AZ−FE)(From July, 2003) 41. INSTALL TIMING CHAIN OR BELT COVER SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply seal packing in a continuous bead (diameter: 2 mm (0.099 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent (c) Seal Packing − Apply seal packing in a continuous bead (diameter: 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent 4 mm (0.16 in.) A A A−A 3 to 4 mm 2.5 mm (0.098 in.) A92184 WhereEverybodyKnowsYourName 14−84 ENGINE MECHANICAL (d) Nut Nut C C C (e) C C − CHAIN (2AZ−FE)(From July, 2003) Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for nut Install the stud bolt to the drive belt tensioner. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) B B B B A B B B B A92013 42. (a) INSTALL V−RIBBED BELT TENSIONER ASSY Install the tensioner with the bolt and nut. Torque: 59.5 N⋅m (607 kgf⋅cm, 44 ft⋅lbf) 43. (a) INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket with the 3 bolts. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) 44. (a) INSTALL ENGINE MOUNTING INSULATOR Raise the engine and install the engine mounting insulator RH. Install the engine mounting insulator RH with the 4 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for bolt A 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf) for bolt B A52478 A52481 A (b) B B B A59900 WhereEverybodyKnowsYourName 14−85 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) (c) Install the steering gear return hose clamp to the frame with the bolt. Torque: 8.0 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf) (e) M/T: Install the engine lateral control rod with the bolt. Torque: 89 N⋅m (910 kgf⋅cm, 66 ft⋅lbf) A59901 A59880 M/T A60825 6 mm (0.24 in.) Seal Packing A92185 45. INSTALL OIL PAN SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan. (b) Apply seal packing in a continuous bead (diameter: 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826−00080 or equivalent WhereEverybodyKnowsYourName 14−86 ENGINE MECHANICAL (c) − CHAIN (2AZ−FE)(From July, 2003) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) A64641 46. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14−47) 47. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the bolt and sensor. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Wire Harness (b) Confirm that the wire harness of the sensor is placed as shown in the illustration. 48. (a) INSTALL CRANKSHAFT PULLEY TMC made: Install the crankshaft pulley. (1) Align the pulley set key with the key groove of the pulley, and side on the pulley. (2) Using SST, install the pulley bolt. SST 09213−54015 (91651−60855), 09330−00021 Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft lbf) (b) TMMK made: Install the crankshaft pulley. (1) Align the pulley set key with the key groove of the pulley, and side on the pulley. SST 09960−10010 (09962−01000, 09963−01000) (2) Using SST, install the pulley bolt. Torque: 170 N⋅m (1,733 kgf⋅cm, 125 ft lbf) Clamp Rib A52071 SST A52486 SST A62057 WhereEverybodyKnowsYourName 14−87 ENGINE MECHANICAL − CHAIN (2AZ−FE)(From July, 2003) (c) Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook. (d) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Disconnect Turn Pin Hook A89786 Plunger Push Turn 49. 50. 51. 52. 53. 54. 55. 56. A89787 INSTALL CYLINDER HEAD COVER SUB−ASSY (See page 14−47) INSTALL IGNITION COIL ASSY Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL VANE PUMP ASSY (See page 51−8) INSTALL GENERATOR ASSY (See page 19−17) INSTALL ENGINE WIRE INSTALL FAN AND GENERATOR V BELT (See page 14−5) INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 57. (a) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET Install the engine mounting control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A59888 58. 59. 60. 61. INSTALL EXHAUST PIPE ASSY FRONT (See page 15−3) INSTALL FRONT WHEEL RH INSTALL HOOD SUB−ASSY Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) ADD ENGINE OIL WhereEverybodyKnowsYourName 14−88 ENGINE MECHANICAL 62. − CHAIN (2AZ−FE)(From July, 2003) INSPECT CHECK FOR ENGINE OIL LEAKS WhereEverybodyKnowsYourName 14−89 ENGINE MECHANICAL − CAMSHAFT (2AZ−FE)(From July, 2003) CAMSHAFT (2AZ−FE)(From July, 2003) 1405Y−06 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB−ASSY NO.1 REMOVE SPARK PLUG DISCONNECT VENTILATION HOSE DISCONNECT VENTILATION HOSE NO.2 DISCONNECT ENGINE WIRE 8. (a) (b) REMOVE CYLINDER HEAD COVER SUB−ASSY Remove the bolt and disconnect the engine wire harness clamp. Remove the bolts, 2 nuts, cylinder head cover and gasket. A52450 9. (a) Timing Marks (b) (c) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing gear and camshaft timing sprocket are aligned with the timing marks of the bearing cap as shown in the illustration. Place a paint mark on the timing chain. Timing Marks Paint Mark Timing Marks Paint Mark Timing Mark Groove A52453 WhereEverybodyKnowsYourName 14−90 ENGINE MECHANICAL − CAMSHAFT (2AZ−FE)(From July, 2003) 10. REMOVE CHAIN TENSIONER ASSY NO.1 (a) Remove the 2 nuts, tensioner and gasket. NOTICE: Be sure not to revolve the crankshaft without the tensioner. A13325 Loosen 11. (a) REMOVE CAMSHAFT SUB−ASSY, NO.2 Fix the camshaft with a wrench and then loosen the sprocket bolt. NOTICE: Be careful not to damage the valve lifter. Fix A52454 1 3 5 4 2 (b) Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. (c) Raise the No. 2 camahaft and remove it. Then remove the sprocket bolt. Remove the timing chain sprocket and the timing chain from the No. 2 camshaft. Remove the camshaft timing sprocket from the timing chain. A32636 (d) (e) A86659 1 3 5 4 12. (a) 2 (b) REMOVE CAMSHAFT Uniformly loosen and remove the camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. Remove the camshaft. A36526 WhereEverybodyKnowsYourName 14−91 ENGINE MECHANICAL − CAMSHAFT (2AZ−FE)(From July, 2003) (c) Tie the timing chain with a string. NOTICE: Do not drop anything inside the timing chain cover. A52474 Advanced Angle Side 13. (a) (b) REMOVE CAMSHAFT TIMING GEAR ASSY Fix the No. 1 camshaft with a vise, and make sure that the camshaft timing gear does not rotate. Cover all the paths with vinyl tape except the advanced side path shown in the illustration. A90848 (c) A31032 Using an air gun, apply about 150 kPA (1.5kgf/cm), 21 psi) of air pressure to the port on the advanced angle side. CAUTION: Some oil spraying will occur. Contain the spray with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (d) Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclokwise), the direction of the arrow in the illustration. Standard: Must turn HINT: The camshaft timing gear will turn to the advanced angle side without applying foce by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock−pin may be difficult to release. (e) Remove the fringe bolt from the camshaft timing gear. NOTICE:
Be sure not to remove the other 4 bolts.
If planning to reuse the camshaft timing gear assembly, release the straight pin lock first, and then install the gear. A32639 WhereEverybodyKnowsYourName 14−92 ENGINE MECHANICAL − CAMSHAFT (2AZ−FE)(From July, 2003) 14. (a) Straight Pin Key Groove A31033 Paint Mark INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and the camshaft together with the straight pin and key groove. (b) Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove. NOTICE: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right direction). (c) Check that there is no clearance between the gear’s fringe and the camshaft. (d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) (e) Check that the camshaft timing gear can move to the retarded angle side (to the right direction) and is locked at the extrene retard angleed position. 15. (a) INSTALL CAMSHAFT Install the timing chain on the camshaft timing gear, with the painted mark of the link aligned with the timing marks of the camshaft timing sprocket. (b) Examine the front marks and unmbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 16. (a) INSTALL NO.2 CAMSHAFT Put the camshaft on the cylinder head with the painted mark of the link of chain aligned with the timing mark of the camshaft timing sprocket. Timing Marks A52456 5 3 1 Bearing Cap No. 1 2 4 Bearing Cap No. 3 A52457 Paint Mark Timing Mark A53011 WhereEverybodyKnowsYourName 14−93 ENGINE MECHANICAL − CAMSHAFT (2AZ−FE)(From July, 2003) (b) Raising the camshaft, temporarily tighten the sprocket bolt. (c) Examine the front marks and unmbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 A52473 Bearing Cap No. 2 Bearing Cap No. 3 5 3 1 Tighten 2 4 A52458 (d) Fix the camshaft with a wrench, and then tighten the sprocket bolt. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) NOTICE: Be careful not to damage the valve lifter. Fix A52459 (e) 7 Links Paint Mark Timing Marks As shown in the illustration, check the paint marks of the timing chain, camshaft timing gear and camshaft timing sprocket and the alignment of the pulley groove with timing mark of the chain cover. Paint Mark Timing Mark Groove A52460 WhereEverybodyKnowsYourName 14−94 ENGINE MECHANICAL 17. (a) Raise − CAMSHAFT (2AZ−FE)(From July, 2003) INSTALL CHAIN TENSIONER ASSY NO.1 Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Push Pin Hook A52461 (b) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger. Engine Front A52462 (c) Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook. (d) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Disconnect Turn Pin Hook A89786 Plunger Push Turn A89787 WhereEverybodyKnowsYourName 14−95 ENGINE MECHANICAL A53051 INSTALL CYLINDER HEAD COVER SUB−ASSY Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil the contact surface.
Install the cylinder head cover within 5 minutes after applying seal packing.
Do not apply engine oil for at least 2 hours after installing. (c) 19. 20. 21. 22. CAMSHAFT (2AZ−FE)(From July, 2003) 18. (a) (b) Seal Packing Nut − Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) Nut A61989 CONNECT ENGINE WIRE INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT OIL LEAK WhereEverybodyKnowsYourName 14−96 ENGINE MECHANICAL − CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) 141J3−02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−1) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) DRAIN COOLANT (See page 16−6) DISCONNECT RADIATOR HOSE OUTLET DISCONNECT UNION TO CONNECTOR TUBE HOSE DISCONNECT HEATER INLET WATER HOSE DISCONNECT FUEL TUBE SUB−ASSY (See page 11−1) 8. (a) (b) REMOVE INTAKE MANIFOLD Disconnect the 2 water by−pass hoses of the throttle body. Remove the 5 bolts, 2 nuts, intake manifold and gasket. A61987 9. 10. 11. 12. REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY (See page 13−5) DISCONNECT ENGINE WIRE REMOVE INTAKE MANIFOLD INSULATOR NO.1 REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 13. (a) REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY Remove the 3 bolts, 2 nuts, No. 1 and No. 2 exhaust manifold stays. A60067 (b) Remove the 5 nuts, exhaust manifold and gasket. A89788 WhereEverybodyKnowsYourName 14−97 ENGINE MECHANICAL 14. − CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) REMOVE CHAIN SUB−ASSY (See page 14−75) 15. (a) (b) 1 3 5 4 2 1 3 5 4 2 REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. A36530 16. (a) (b) REMOVE CAMSHAFT Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. A36531 17. 18. 20. REMOVE CAMSHAFT BEARING NO.2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 3 7 9 6 2 1 5 10 8 4A32653 19. (a) REMOVE CYLINDER HEAD SUB−ASSY Using a 10 mm bi−hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. REMOVE CYLINDER HEAD GASKET WhereEverybodyKnowsYourName 14−98 ENGINE MECHANICAL − CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) 21. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the head bolts from the seat to the end. Specified bolt length: 161.3 to 164.2 mm (6.350 to 6.465 in.) If the length is greater than the maximum, replace the bolt. Overall Length A88619 22. (a) Lot No. A53013 8 4 2 5 9 10 6 1 3 7 A53060 90
INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. 23. INSTALL CYLINDER HEAD SUB−ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. (c) Using a 10 mm bi−hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration. Torque: 79 N⋅m (806 kgf⋅cm, 58 ft⋅lbf) (d) (e) Mark the front side of the cylinder head bolt with paint. Retighten the cylinder head bolts by 90
in the sequence shown in the illustration. Check that the painted mark is now at a 90
angle to the front. (f) Engine Front Paint Mark A00976 A53074 WhereEverybodyKnowsYourName 14−99 ENGINE MECHANICAL 24. 25. CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL CAMSHAFT BEARING NO.2 5 3 1 2 4 Bearing Cap No. 1 Bearing Cap No. 3 Bearing Cap No. 2 Bearing Cap No. 3 5 3 28. − 26. (a) INSTALL CAMSHAFT Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 27. (a) INSTALL NO.2 CAMSHAFT Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No.2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No.3 A52475 1 4 2 A52476 INSTALL CHAIN SUB−ASSY (See page 14−75) 29. 2 3 (a) 4 1 INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY Install a new gasket and the exhaust manifold with the 5 nuts. Torque: 37 N⋅m (378 kgf⋅cm, 27 ft⋅lbf) 5 A89788 (b) Install the No. 1 and No. 2 exhaust manifold stays with the 3 bolts and 2 nuts. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) A60067 WhereEverybodyKnowsYourName 14−100 ENGINE MECHANICAL 30. 31. − CYLINDER HEAD GASKET (2AZ−FE)(From July, 2003) INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY (See page 13−5) 32. (a) INSTALL INTAKE MANIFOLD Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A61987 33. 34. 35. 36. 37. 38. 39. 40. CONNECT FUEL TUBE SUB−ASSY (See page 11−1) ADD ENGINE OIL ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) INSPECT FOR FUEL LEAKS (See page 11−4) INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14−1) INSPECT CO/HC (See page 14−1) WhereEverybodyKnowsYourName 70−1 WINDSHIELD/WINDOWGLASS/MIRROR − POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM 700H6−02 ON−VEHICLE INSPECTION 1. (a) (b) (c) (d) CHECK POWER WINDOW (MANUAL OPERATION FUNCTION) Turn the ignition switch ON. Check that the door glass moves up when the power window regulator master switch is pulled UP halfway, and the door glass moves down when the switch is pushed DOWN halfway. Check that the door glass moves up when the power window regulator switch is pulled UP, and the door glass moves down when the switch is pushed DOWN. Check that the door glasses other than the driver side door glass do not operate when the window lock switch is turned to LOCK. CHECK AUTOMATIC OPERATION FUNCTION 2. HINT: Only steps (a), (b), and (d) are applicable to the models without the jam protection function. (a) Turn the ignition switch ON. (b) Check that the AUTO UP function operates to fully close the door glass when each window switch of the regulator master switch is pulled UP fully. (c) Check that the AUTO DOWN function operates to fully open the door glass when each window switch of the regulator master switch is pushed DOWN fully. (d) Check that the door glass stops when the applicable switch is pulled UP during AUTO DOWN operation. (However, if the switch is held in the UP position, it will change to manual operation.) (e) Check that the door glass stops when the applicable switch is pushed DOWN during AUTO UP operation. (However, if the switch is held in the DOWN position, it will change to manual operation.) 3. CHECK JAM PROTECTION FUNCTION (FOR DRIVER SIDE DOOR GLASS OF MODELS W/ JAM PROTECTION FUNCTION) (a) Check the basic function. NOTICE:
Do not check this function using a part of your body such as a hand. Also, pay thorough attention that nothing gets caught by accident in this process.
If the power window regulator motor assembly has just been reset, raise and lower the door glass several times using AUTO and MANUAL operation before performing check. HINT: The jam protection function only works during UP operation. (1) Fully open the door glass. Handle of the hammer (2) Insert the handle of the hammer when the door glass is almost in the fully closed position. (3) Try to close the door glass with AUTO UP and MANUAL UP operation, check that the door glass moves down about 200 mm (7.87 in.) and stops there, so that the hammer handle is not caught. HINT: The door glass goes down by about 50 mm. However, when the B51853 opening between the glass and body is less than 200 mm, the door glass goes down by 200 mm or keeps going down for 5 seconds, and then stops. (4) During DOWN operation, check that the door glass does not move up even when the window regulator master switch is pulled UP. WhereEverybodyKnowsYourName 70−13 WINDSHIELD/WINDOWGLASS/MIRROR − BACK WINDOW GLASS BACK WINDOW GLASS 700B1−03 COMPONENTS Assist Grip Sub−assy Roof Headlining Assy (Partial) Assist Grip Sub−assy
Back Window Glass Stopper No. 2*1
Back Window Glass Stopper No. 2*2
Back Window Glass Stopper No. 1*2 Back Window Outside Moulding Roof Side Garnish Inner RH Back Window Glass Rear Door Opening Trim Weatherstrip LH (Partial) Rear Door Opening Trim Weatherstrip RH (Partial) w/ Curtain Shield Airbag: Roof Side Garnish Inner Cover Roof Side Garnish Inner LH Center Stop Lamp Assy w/ Curtain Shield Airbag: Roof Side Garnish Inner Cover Package Tray Panel Assy 42 (420, 31) 42 (420, 31) N⋅m (kgf⋅cm ft⋅lbf) : Specified torque
Non−reusable part 42 (420, 31) *1: 1−piece *2: 2−piece type type B57718 WhereEverybodyKnowsYourName 70−14 WINDSHIELD/WINDOWGLASS/MIRROR − BACK WINDOW GLASS 700YC−02 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without torque specification is a standard bolt (see page 03−2). REMOVE REAR SEAT CUSHION ASSY (See page 72−32) REMOVE REAR SEATBACK ASSY (See page 72−32) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH REMOVE ROOF SIDE GARNISH INNER RH (w/o CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE ROOF SIDE GARNISH INNER LH (w/o CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE ROOF SIDE GARNISH INNER RH (w/ CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE ROOF SIDE GARNISH INNER LH (w/ CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE ROOF HEADLINING ASSY (See page 76−22) 9. HINT: It is not necessary to completely remove the roof headlining. Slightly lower the rear section of the roof headlining so that the back window glass can be removed later in step 13. 10. REMOVE CENTER STOP LAMP ASSY (See page 65−22) 11. REMOVE PACKAGE TRAY TRIM PANEL ASSY (See pages 61−13 and 61−16) Cut 12. (a) Vehicle Body Back Window Glass Cut Moulding B56882 REMOVE BACK WINDOW MOULDING OUTSIDE Using a knife, cut off the moulding, as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (b) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. 13. REMOVE BACK WINDOW GLASS HINT: In some cases, 1−piece type and 2−piece type stoppers are installed in the same vehicle. 2−Piece Type Stopper 1−Piece Type Stopper B57139 WhereEverybodyKnowsYourName 70−15 WINDSHIELD/WINDOWGLASS/MIRROR − (a) Backside (b) BACK WINDOW GLASS From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends. Stopper Piano Wire B56909 Protective Tape B64495 HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE: When separating the glass from the vehicle, be careful not to damage the vehicle’s paint or interior / exterior ornaments. (c) Cut through the adhesive by pulling the piano wire around the glass. (d) Disengage the stoppers. (e) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. 14. (a) B73128 Adhesive 15. (a) Adhesive Vehicle Body CLEAN BACK WINDOW GLASS Using a scraper, remove the damaged stoppers and adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gasoline. NOTICE:
Do not touch the glass surface after cleaning it.
Even if using new glass, clean the glass with white gasoline. B73084 CLEAN VEHICLE BODY Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WhereEverybodyKnowsYourName 70−16 WINDSHIELD/WINDOWGLASS/MIRROR − Backside BACK WINDOW GLASS 16. INSTALL BACK WINDW GLASS STOPPER NO.2 (a) Coat the installation part of the stopper with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G,
Do not apply too much Primer G. (b) Install 2 new stoppers onto the glass, as shown in the illustration. Specification: Stopper Ceramic Line Area Measurement A 11.2 mm (0.441 in.) B 40.0 mm (1.575 in.) A B B B56894 17. (a) Stopper INSTALL BACK WINDOW GLASS STOPPER NO.1 Install 2 new stoppers to the vehicle body, as shown in the illustration. Vehicle Body B63758 18. INSTALL BACK WINDOW MOULDING OUTSIDE (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install the moulding. WhereEverybodyKnowsYourName 70−17 WINDSHIELD/WINDOWGLASS/MIRROR − 19. (a) Mark B64130 Primer M CORRECT Primer M Adhesive WRONG Primer M BACK WINDOW GLASS INSTALL BACK WINDOW GLASS Position the glass. (1) Using a suction cup, place the glass in the correct position. (2) Check that the whole contact surface of the glass rim in perfectly even. (3) Place reference marks between the glass and vehicle body. NOTICE: Check that the stoppers are attached to the vehicle body correctly. HINT: When reusing the glass, check and correct the reference mark’s positions. (4) Using a suction cup, remove the glass. (b) Using a brush, coat the exposed part of the vehicle body with Primer M. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not coat the adhesive with Primer M.
Throw away any leftover Primer M.
Do not apply too much Primer M. (c) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. B67820 WhereEverybodyKnowsYourName 70−18 WINDSHIELD/WINDOWGLASS/MIRROR − (d) Backside A A BACK WINDOW GLASS Apply adhesive. Adhesive: Part No. 08850−00801 or equivalent (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe: Temperature A −A a 15 minutes 20C (68F) 1 hour 40 minutes 5C (41F) 8 hours Load the sealer gun with the cartridge. Coat the glass with adhesive, as shown in the illustration. Specification: c a 35C (95F) (2) (3) b b Usage Timeframe B56898 Area Measurement a 8.0 mm (0.315 in.) b 12.0 mm (0.472 in.) c 6.5 mm (0.256 in.) (e) Mark B64131 Install the glass. (1) Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Check that the stoppers are attached to the vehicle body correctly.
Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. WhereEverybodyKnowsYourName 70−19 WINDSHIELD/WINDOWGLASS/MIRROR − (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive on the glass rim. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time: Adhesive B73131 20. (a) (b) BACK WINDOW GLASS Temperature Minimum time prior to driving vehicle 35C (95F) 1 hour 30 minutes 20C (68F) 5 hours 5C (41F) 24 hours CHECK FOR LEAKS AND REPAIR Conduct a leak test after the adhesive has completely hardened. Seal any leaks with auto glass sealer. WhereEverybodyKnowsYourName 70−2 WINDSHIELD/WINDOWGLASS/MIRROR − POWER WINDOW CONTROL SYSTEM 700H7−02 INSPECTION 1. INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSY (a) Check the continuity between each terminal of the connector. NOTICE: Whether the operation is good or bad can be judged by the basic function check, because the continuity cannot be checked by UP/DOWN operation of the driver side switch. B50518 Standard (Window unlock): Switch position Passenger Side Terminals No. Rear RH Terminals No. Rear LH Terminals No. UP 6 − 13 *1 (6 − 18 *2), 1 − 15 6 − 18 *1 (6 − 10 *2), 1 − 16 6 − 12, 1 − 10 *1 (1 − 13 *2) OFF DOWN 1 − 13 *1 (1 − 18 6 − 15, 1 − 13 *1 *2), 1 − 15 (1 − 18 1 − 18 *2) *1 (1 − 10 6 − 16, 1 − 18 *1 *2), 1 − 16 6 − 12, 1 − 10 *1 (1 − 12 *2) *2) 6 − 10 *1 (6 − 13 *2), 1 − 12 (1 − 10 Standard (Window lock): Switch position Passenger Side Terminals No. UP 6 − 13 *1 (6 − 18 *2) OFF *1 (18 DOWN 13 − 15 − 15 Rear RH Terminals No. Rear LH Terminals No. 6 − 18 *1 (6 − 10 *2) *2) 16 − 18 6 − 15 *1 (1 − 10 *2) 6 − 12 10 − 12 6 − 10 *1 (6 − 13 *2) 6 − 16 *1: w/ Jam protection *2: w/o Jam protection If the continuity is not as specified, replace the switch. 2. (a) B31201 INSPECT POWER WINDOW REGULATOR SWITCH ASSY Check the continuity between each terminal of the connector when operating the switch. Standard: Switch position Terminals No. Condition UP 1−2 3−4 Continuity OFF 1−2 3−5 Continuity DOWN 1−4 3−5 Continuity If the continuity is not as specified, replace the switch. WhereEverybodyKnowsYourName 70−3 WINDSHIELD/WINDOWGLASS/MIRROR − POWER WINDOW CONTROL SYSTEM 3. INSPECT POWER WINDOW REGULATOR MOTOR ASSY LH NOTICE:
Be sure not to apply battery voltage to terminals 2, 3 and 6 of the power window regulator motor assy LH connector, because it might damage the pulse sensor and the limit switch.
Be sure to reset the power window regulator motor assembly (initial position setting of the limit switch) when the power window regulator motor assy LH is installed to the regulator. (a) Driving Axis Counterclockwise Clockwise B56305 Inspect operation of the front LH power window regulator motor assembly. (1) When adding battery voltage to each connector terminal, check that the motor operates smoothly. Standard: Measurement condition Operational direction Battery positive − Terminal 5 Battery negative − Terminal 4 Clockwise Battery positive − Terminal 4 Battery negative − Terminal 5 Counterclockwise (b) Check operation of the PTC inside the power window regulator motor. NOTICE: Work must be performed with the power window regulator and door glass installed to the vehicle. (1) Set the DC 400 A probe to terminal 4 or 5 of the wire harness. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass at the fully closed position. (3) When approximately 60 seconds have passed after fully closing the door glass, check how long the current takes to change from approximately 16 − 34 A to less than 1 A when pulling the power regulator switch UP furthermore (at initial time). Standard: Approximately 4 − 90 seconds (4) When approximately 60 seconds have passed after the cut−off check, check that the door glass goes down when the power regulator switch is pressed DOWN. 4. Driving Axis (a) Clockwise Counterclockwise B56304 INSPECT POWER WINDOW REGULATOR MOTOR ASSY RH Inspect operation of the front RH power window regulator motor assembly. (1) When adding battery voltage to each connector terminal, check that the motor operates smoothly. Standard: Measurement condition Operational direction Battery positive − Terminal 5 Battery negative − Terminal 4 Clockwise Battery positive − Terminal 4 Battery negative − Terminal 5 Counterclockwise WhereEverybodyKnowsYourName 70−4 WINDSHIELD/WINDOWGLASS/MIRROR − POWER WINDOW CONTROL SYSTEM (b) Check operation of the PTC inside the power window regulator motor. NOTICE: Work must be performed with the power window regulator and door glass installed to the vehicle. (1) Set the DC 400 A probe to terminal 4 or 5 of the wire harness. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass at the fully closed position. (3) When approximately 60 seconds have passed after fully closing the door glass, check how long the current takes to change from approximately 16 − 34 A to less than 1 A when pulling the power regulator switch UP furthermore (at initial time). Standard: Approximately 4 − 90 seconds (4) When approximately 60 seconds have passed after the cut−off check, check that the door glass goes down when the power regulator switch is pressed DOWN. 5. Driving Axis (a) Clockwise Counterclockwise B56306 INSPECT POWER WINDOW REGULATOR MOTOR ASSY LH Inspect operation of the rear LH power window regulator motor assembly. (1) When adding battery voltage to each connector terminal, check that the motor operates smoothly. Standard: Measurement condition Operational direction Battery positive − Terminal 5 Battery negative − Terminal 4 Clockwise Battery positive − Terminal 4 Battery negative − Terminal 5 Counterclockwise (b) Check operation of the PTC inside the power window regulator motor. NOTICE: Work must be performed with the power window regulator and door glass installed to the vehicle. (1) Set the DC 400 A probe terminal 4 or 5 of the wire harness. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass at the fully closed position. (3) When approximately 60 seconds have passed after fully closing the door glass, check how long the current takes to change from approximately 16 − 34 A to less than 1 A when pulling the power regulator switch UP furthermore (at initial time). Standard: Approximately 4 − 90 seconds (4) When approximately 60 seconds have passed after the cut−off check, check that the door glass goes down when the power regulator switch is pressed DOWN. WhereEverybodyKnowsYourName 70−5 WINDSHIELD/WINDOWGLASS/MIRROR − 6. Driving Axis (a) Counterclockwise Clockwise B56307 POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSY RH Inspect operation of the rear RH power window regulator motor assembly. (1) When adding battery voltage to each connector terminal, check that the motor operates smoothly. Standard: Measurement condition Operational direction Battery positive − Terminal 5 Battery negative − Terminal 4 Clockwise Battery positive − Terminal 4 Battery negative − Terminal 5 Counterclockwise (b) Check operation of the PTC inside the power window regulator motor. NOTICE: Work must be performed with the power window regulator and door glass installed to the vehicle. (1) Set the DC 400 A probe to terminal 4 or 5 of the wire harness. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass at the fully closed position. (3) When approximately 60 seconds have passed after fully closing the door glass, check how long the current takes to change from approximately 16 − 34 A to less than 1 A when pulling the power regulator switch UP furthermore (at initial time). Standard: Approximately 4 − 90 seconds (4) When approximately 60 seconds have passed after the cut−off check, check that the door glass goes down when the power regulator switch is pressed DOWN. 7. (a) 3 2 5 1 B32032 INSPECT POWER WINDOW RELAY ASSY Inspect the power window relay continuity. Standard: Terminals No. Condition Specified Condition 1−2 Constant Continuity 3−5 Constant No continuity 3−5 Apply B + to terminals 1 and 2 Continuity If the continuity is not as specified, replace the relay. WhereEverybodyKnowsYourName 70−20 WINDSHIELD/WINDOWGLASS/MIRROR − WINDOW DEFOGGER SYSTEM WINDOW DEFOGGER SYSTEM 700BB−03 PROBLEM SYMPTOMS TABLE Symptom Suspected Area Rear window defogger does not operate (Indicator lamp on) 1. 2. 3. 4. 5. 6. 7. DEF fuse (Instrument panel J/B) GAUGE 2 fuse (Instrument panel J/B) DEF relay (Instrument panel J/B) Rear window defogger wire Wire harness Body ECU (2AZ−FE) Body ECU (1MZ−FE) Rear window defogger does not operate (Indicator lamp off) 1. 2. 3. 4. HTR fuse (Instrument panel J/B) Defogger switch (Heater control housing) Wire harness Heater control base WhereEverybodyKnowsYourName See page 68−1 68−1 70−22 − − − − 68−1 05−1370 − 05−1370 70−21 WINDSHIELD/WINDOWGLASS/MIRROR − WINDOW DEFOGGER SYSTEM 700BA−02 LOCATION Heater Control Housing Instrument Panel J/B Heater Control Base ECM Defogger Wire Manual A/C Rear Window Defogger Switch Auto A/C Rear Window Defogger Switch B56290 WhereEverybodyKnowsYourName 70−22 WINDSHIELD/WINDOWGLASS/MIRROR − WINDOW DEFOGGER SYSTEM 700BC−02 INSPECTION 1. (a) B57491 INSPECT DEFOGGER RELAY Inspect the defogger relay (marking: DEF) continuity. Standard: Terminals No. Condition Specified condition 1⇔2 Constant Continuity 3⇔5 Constant No continuity 3⇔5 Apply B+ between terminals 1 and 2 Continuity If the continuity is not as specified, replace the relay. WhereEverybodyKnowsYourName 70−23 WINDSHIELD/WINDOWGLASS/MIRROR − POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM 700H5−02 PROBLEM SYMPTOMS TABLE Symptom Suspected Area Mirror does not operate 1. 2. 3. 4. ECU−ACC fuse (Instrument panel J/B) Mirror switch Mirror motor Wire harness Mirror operates abnormally 1. Mirror switch 2. Mirror motor 3. Wire harness WhereEverybodyKnowsYourName See page 68−1 70−25 70−25 − 70−25 70−25 − 70−24 WINDSHIELD/WINDOWGLASS/MIRROR − POWER MIRROR CONTROL SYSTEM 700BD−02 LOCATION Outer Mirror Switch Assy Outer Rear View Mirror Assy LH Outer Rear View Mirror Assy RH ECM Instrument Panel J/B Manual A/C Heater Control Housing Auto A/C Heater Control Base Mirror Heater Switch (Defogger Switch) B56289 WhereEverybodyKnowsYourName 70−25 WINDSHIELD/WINDOWGLASS/MIRROR − POWER MIRROR CONTROL SYSTEM 700BE−02 INSPECTION 1. (a) No Pin No Pin B56312 INSPECT OUTER MIRROR SWITCH ASSY Inspect the mirror switch continuity. (1) Left side for left/right adjustment switch: Inspect the left side mirror switch continuity. Standard: Terminal No. Switch position Specified condition − OFF No continuity 4−8 6−7 UP Continuity 4−7 6−8 DOWN Continuity 5−8 6−7 LEFT Continuity 5−7 6−8 RIGHT Continuity If the continuity is not as specified, replace the switch. (2) Right side for left/right adjustment switch: Inspect the right side mirror switch continuity. Standard: Terminal No. Switch position Specified condition − OFF No continuity 3−8 6−7 UP Continuity 3−7 6−8 DOWN Continuity 2−8 6−7 LEFT Continuity 2−7 6−8 RIGHT Continuity If the continuity is not as specified, replace the switch. WhereEverybodyKnowsYourName 70−26 WINDSHIELD/WINDOWGLASS/MIRROR − 2. TMC Made (a) TMMK Made POWER MIRROR CONTROL SYSTEM INSPECT OUTER REAR VIEW MIRROR ASSY LH (W/O OUTER MIRROR HEATER) Inspect the mirror motor operation. Standard (TMC Made): Battery connection Mirror position Positive (+) − 1 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 1 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right Standard (TMMK Made): B59988 Battery connection Mirror position Positive (+) − 6 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 6 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right If the continuity is not as specified, replace the outer rear view mirror assy LH. 3. TMC Made (a) TMMK Made INSPECT OUTER REAR VIEW MIRROR ASSY RH (W/O OUTER MIRROR HEATER) Inspect the mirror motor operation. Standard (TMC Made): Battery connection Mirror position Positive (+) − 1 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 1 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right Standard (TMMK Made): B59988 Battery connection Mirror position Positive (+) − 6 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 6 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right If the continuity is not as specified, replace the outer rear view mirror assy RH. WhereEverybodyKnowsYourName 70−27 WINDSHIELD/WINDOWGLASS/MIRROR − 4. (a) B59987 POWER MIRROR CONTROL SYSTEM INSPECT OUTER REAR VIEW MIRROR ASSY LH (W/ OUTER MIRROR HEATER, TMC MADE) Inspect the mirror heater operation. Standard: Battery connection Mirror position Positive (+) − 2 Negative (−) − 3 Turn upward Positive (+) − 3 Negative (−) − 2 Turn downward Positive (+) − 4 Negative (−) − 3 Turn left Positive (+) − 3 Negative (−) − 4 Turn right If the continuity is not as specified, replace the outer rear view mirror assy LH. (1) Check the resistance between terminals 1 and 5 of the connector. Resistance: 4.0 − 5.4 Ω (2) Check that the mirror is heated up when connecting the battery positive (+) to terminal 4 and the battery negative (−) to terminal 5 of the connector. 5. (a) B31263 INSPECT OUTER REAR VIEW MIRROR ASSY LH (W/ OUTER MIRROR HEATER, TMMK MADE) Inspect the mirror motor operation. Standard: Battery connection Mirror position Positive (+) − 6 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 6 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right If the continuity is not as specified, replace the outer rear view mirror assy LH. (b) Inspect the mirror heater operation. (1) Check the resistance between terminals 1 and 4 of the connector. Resistance: 4.0 − 5.4 Ω (2) Check that the mirror is heated up when connecting the battery positive (+) to terminal 4 and the battery negative (−) to terminal 5 of the connector. WhereEverybodyKnowsYourName 70−28 WINDSHIELD/WINDOWGLASS/MIRROR − 6. (a) B59987 POWER MIRROR CONTROL SYSTEM INSPECT OUTER REAR VIEW MIRROR ASSY RH (W/ OUTER MIRROR HEATER, TMC MADE) Inspect the mirror motor operation. Standard: Battery connection Mirror position Positive (+) − 2 Negative (−) − 3 Turn upward Positive (+) − 3 Negative (−) − 2 Turn downward Positive (+) − 4 Negative (−) − 3 Turn left Positive (+) − 3 Negative (−) − 4 Turn right If the continuity is not as specified, replace the outer rear view mirror assy RH. (b) Check the mirror heater operation. (1) Check the resistance between terminals 1 and 5 of the connector. Resistance: 4.0 − 5.4 Ω (2) Check that the mirror is heated up when connecting the battery positive (+) to terminal 4 and the battery negative (−) to terminal 5 of the connector. 7. (a) B31263 INSPECT OUTER REAR VIEW MIRROR ASSY RH (W/ OUTER MIRROR HEATER, TMMK MADE) Inspect the mirror motor operation. Standard: Battery connection Mirror position Positive (+) − 6 Negative (−) − 2 Turn upward Positive (+) − 2 Negative (−) − 6 Turn downward Positive (+) − 3 Negative (−) − 2 Turn left Positive (+) − 2 Negative (−) − 3 Turn right If the continuity is not as specified, replace the outer rear view mirror assy RH. (b) Check the mirror heater operation. (1) Check the resistance between terminals 1 and 4 of the connector. Resistance: 4.0 − 5.4 Ω (2) Check that the mirror is heated up when connecting the battery positive (+) to terminal 4 and the battery negative (−) to terminal 5 of the connector. WhereEverybodyKnowsYourName 70−29 WINDSHIELD/WINDOWGLASS/MIRROR − INNER REAR VIEW MIRROR ASSY INNER REAR VIEW MIRROR ASSY 700LA−01 REPLACEMENT HINT: The installation is in the reverse order of the removal. 1. REMOVE INNER REAR VIEW MIRROR ASSY (a) Remove the screw. (b) w/ Erector chromic inner mirror: Remove the inner rear view mirror cover. (c) w/ Erector chromic inner mirror: Disconnect the connector. (d) Remove the rear view inner mirror assembly. WhereEverybodyKnowsYourName 70−30 WINDSHIELD/WINDOWGLASS/MIRROR − INNER REAR VIEW MIRROR ASSY 700B5−02 PRE−CHECK 1. (a) 2. (a) 3. (a) 4. (a) 5. SELECTING COMPASS DISPLAY MODE The comp switch allows you to select a Display or Non−display mode of the compass. SETTING ZONE Deviation between the ”magnetic north” and ”actual north” differs depending on the location. Therefore, adjustment of the magnetism is required. Since the magnetic condition differs depending on the area where the vehicle is used, it is necessary for each user to set the zone. (Refer to ”Compass Zone Map”). The zone setting can be changed using the comp switch of the inner mirror. PERFORMING CALIBRATION Since each vehicle has its own magnetic field, calibration should be performed for each vehicle. This compass function is used when storing the record of the magnetic field of the vehicle. WHEN COMPASS MAGNETIZED: A compass could be magnetized during shipping by vessels or freight cars. Before delivery, therefore, make sure to perform calibration and ensure that calibration is done properly. If it cannot be done (cannot be complete in spite of driving around several times), it may be caused by magnetization. Demagnetize the vehicle using a demagnetizer and perform calibration again. SETTING COMPASS Comp Switch On Duration Normal Mode Ignition switch ON. Pressed Compass Non−display Mode Pressed for 3 sec. 6. Zone Setting Mode Pressed for 6 sec. Comp Switch ON Zone area +1 7. Calibration Mode Leaving it untouched for a while Normal Mode WhereEverybodyKnowsYourName 70−31 WINDSHIELD/WINDOWGLASS/MIRROR − 6. (a) INNER REAR VIEW MIRROR ASSY ZONE SETTING MODE Press the comp switch for 3 seconds. In the normal mode, the zone setting mode will activate. A number (1−15) is displayed on the compass display. HINT: In the initial status, ”8” is displayed. (b) The displayed number increases +1 every time the comp switch is pressed. Referring to the map, check the number for the area where the vehicle will be used and set the zone number. (c) Leave it untouched for several seconds after setting and check that the compass display shows an azimuthal direction (N, NE, E, SE, S, SW, W or NW) or ”C”. 7. CALIBRATION SETTING MODE (a) Press the comp switch for 6 seconds. in the normal mode, this mode will also activate. (b) Drive the vehicle at a slow speed of 8 km/h (5 MPH) or less in the circular direction. (c) Driving around the circle 1 to 3 times will display the azimuthal direction on the display, completing the calibration. HINT: Once calibration is completed, it is not necessary to perform the above procedures unless the magnetic field strength is drastically changed. If this happens, the azimuthal display will be changed to ”C”. B57087 WhereEverybodyKnowsYourName 70−32 WINDSHIELD/WINDOWGLASS/MIRROR − INNER REAR VIEW MIRROR ASSY 700B4−02 INSPECTION 1 1. (a) INSPECT INNER REAR VIEW MIRROR ASSY Inspect operation of the elector chromic inner mirror. (1) Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2. (2) Attach a black colored tape to the forward sensor to prevent it from sensing. (3) Light up the mirror with an electric light, and check that the mirror surface changes from ”bright” to ”dark”. If operation is not as specified, replace the inner mirror. 2 B57086 WhereEverybodyKnowsYourName 70−33 WINDSHIELD/WINDOWGLASS/MIRROR − OUTER REAR VIEW MIRROR SUB−ASSY LH OUTER REAR VIEW MIRROR SUB−ASSY LH 700BF−02 REPLACEMENT HINT: On the RH side, use the same procedures as on the LH side. 1. REMOVE OUTER REAR VIEW MIRROR SUB−ASSY LH(TMC made) Clip (a) Tape the lower part of outer mirror body with protection tape. (b) Using a roof−moulding remover, disengage the clips placed in the lower part of the mirror. (c) Pull out the outer rear view mirror. Clip B57654 2. Down (a) Clip (b) (c) REMOVE OUTER REAR VIEW MIRROR SUB−ASSY LH(TMMK made) Tape the upper part of outer mirror body with protection tape. Using a roof−mouding remover, disengage the clips placed in the upper part of the mirror. Pull out the outer rear view mirror. Up B56620 3. (a) (b) (c) 4. B57655 (a) (b) (c) INSTALL OUTER REAR VIEW MIRROR SUB−ASSY LH(TMC made) Insert the claws placed in the upper part of backside of the mirror into the actuator hole. Set the mirror in the actuator. Insert the lower portion of the mirror to engage the 2 clips securely. INSTALL OUTER REAR VIEW MIRROR SUB−ASSY LH(TMMK made) Insert the claws placed in the lower part of backside of the mirror into the actuator hole. Set the mirror in the actuator. Insert the upper portion of the mirror to engage the 2 clips securely. WhereEverybodyKnowsYourName 70−6 WINDSHIELD/WINDOWGLASS/MIRROR − WINDSHIELD GLASS WINDSHIELD GLASS 700AZ−03 COMPONENTS w/ Sliding Roof: Sun Roof Opening Trim Moulding Assist Grip Sub−assy Assist Grip Cover Roof Headlining Assy (Partial) Visor Assy RH Visor Holder Visor Bracket Cover Roof Console Box w/ Electrochromic Inner Mirror: Inner Rear View Mirror Cover Inner Rear View Mirror Assy Front Pillar Garnish RH 1.75 (17.9, 15.5 in.⋅lbf) Front Door Opening Trim Weatherstrip RH (Partial) Visor Holder Assist Grip Sub−assy Visor Assy LH Visor Bracket Cover
Windshield Moulding OUT UPR
Window Glass Adhesive Dam
Windshield Glass Stopper No. 2*1
Windshield Glass Stopper No. 2*2
Windshield Glass Stopper No. 1*2
Window Glass Adhesive Dam w/ Curtain Shield Airbag: Front Pillar Garnish Cover
Windshield Glass Retainer Front Door Opening Trim Weatherstrip LH (Partial) Windshield Glass 20 (204, 15) FR Wiper Arm RH 20 (204, 15) Front Pillar Garnish LH
Windshield Glass Retainer FR Wiper Arm LH N⋅m (kgf⋅cm ft⋅lbf) : Specified torque Cowl Top Ventilator Louver Sub−assy
Non−reusable part *1: 1−piece *2: 2−piece type type B56396 WhereEverybodyKnowsYourName 70−7 WINDSHIELD/WINDOWGLASS/MIRROR − WINDSHIELD GLASS 700YB−01 REPLACEMENT HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is a standard bolt (See page 03−2). REMOVE FR WIPER ARM RH (See page 66−6) REMOVE FR WIPER ARM LH (See page 66−6) REMOVE COWL TOP VENTILATOR LOUVER SUB−ASSY (See page 66−6) REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 66−6) REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page 66−6) REMOVE FRONT PILLAR GARNISH RH (w/o CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE FRONT PILLAR GARNISH LH (w/o CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE FRONT PILLAR GARNISH RH (w/ CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE FRONT PILLAR GARNISH LH (w/ CURTAIN SHIELD AIR BAG) (See page 76−22) REMOVE ROOF CONSOLE BOX ASSY (See page 76−22) REMOVE RH VISOR ASSY (See page 76−22) REMOVE LH VISOR ASSY (See page 76−22) REMOVE VISOR HOLDER (See page 76−22) REMOVE ROOF HEADLINING ASSY (See page 76−22) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step 17. 15. REMOVE INNER REAR VIEW MIRROR ASSY (See page 70−29) Windshield Glass Cut Vehicle Body Cut Moulding B51018 16. (a) REMOVE WINDSHIELD MOULDING OUTER UPPER Using a knife, cut off the moulding, as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (b) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. 17. REMOVE WINDSHIELD GLASS HINT: In some cases, 1−piece type and 2−piece type stoppers are installed in the same vehicle. 2−piece Type Stopper 1−piece Type Stopper B56902 WhereEverybodyKnowsYourName 70−8 WINDSHIELD/WINDOWGLASS/MIRROR − (a) (b) Stopper Piano Wire WINDSHIELD GLASS From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends. Retainer B56906 Plastic Sheet Protective Tape B63724 B73128 HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE:
w/ Curtain shield airbag: When working around the curtain shield airbag, be careful not to damage the airbag.
When separating the glass from the vehicle, be careful not to damage the vehicle’s paint or interior / exterior ornaments.
To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad. (c) Cut through the adhesive by pulling the piano wire around the glass. (d) Disengage the stoppers. (e) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. 18. CLEAN WINDSHIELD GLASS (a) Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gasoline. NOTICE:
Do not touch the glass after cleaning it.
Even if using new glass, clean the glass with white gasoline. WhereEverybodyKnowsYourName 70−9 WINDSHIELD/WINDOWGLASS/MIRROR − Adhesive Backside 19. (a) Adhesive Vehicle Body WINDSHIELD GLASS B73084 Stopper Ceramic Line A B B56903 CLEAN VEHICLE BODY Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. 20. INSTALL WINDSHIELD GLASS STOPPER NO.2 (a) Coat the installation part of the stopper with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install 2 new stoppers onto the glass, as shown in the illustration. Specification: Area Measurement A 7.7 mm (0.303 in.) B 40.0 mm (1.575 in.) 21. (a) INSTALL WINDSHIELD GLASS STOPPER NO.1 Install 2 new stoppers to the vehicle body, as shown in the illustration. 22. (a) INSTALL WINDSHIELD GLASS RETAINER Install 2 new retainers onto the glass, as shown in the illustration. Stopper Vehicle Body B63758 Backside Ceramic Line Retainer B56907 WhereEverybodyKnowsYourName 70−10 WINDSHIELD/WINDOWGLASS/MIRROR − 23. (a) INSTALL WINDOW GLASS ADHESIVE DAM Coat the installation part of the windshield glass adhesive dam with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much primer. (b) Install a new dam, as shown in the illustration. Specification: Backside A A B WINDSHIELD GLASS B Dam C C A − A, B − B Area Measurement a 7.0 mm (0.276 in.) b 35.0 mm (1.378 in.) a b C−C B56904 24. (a) Mark B73129 INSTALL WINDSHIELD GLASS Position the glass. (1) Using a suction cup, place the glass in the correct position. (2) Check that the whole contact surface of the glass rim is perfectly even. (3) Place reference marks between the glass and vehicle body. NOTICE: Check that the stoppers are attached to the vehicle body correctly. HINT: When reusing the glass, check and correct the reference mark’s positions. (4) Using a suction cup, remove the glass. WhereEverybodyKnowsYourName 70−11 WINDSHIELD/WINDOWGLASS/MIRROR − WINDSHIELD GLASS (b) Primer M CORRECT Primer M Adhesive WRONG Primer M B67819 (d) Backside A A B Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not coat the adhesive with Primer M.
Throw away any leftover Primer M.
Do not apply too much Primer M. (c) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. Apply adhesive. Adhesive: Part No. 08850−00801 or equivalent (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe: B C C A − A,B − B b Usage Timeframe 35C (95F) 15 minutes 20C (68F) 1 hour 40 minutes 5C (41F) 8 hours (2) (3) Load the sealer gun with the cartridge. Coat the glass with adhesive, as shown in the illustration. Specification: a b Temperature C−C b a a B56908 Area Measurement a 8.0 mm (0.315 in.) b 12.0 mm (0.472 in.) WhereEverybodyKnowsYourName 70−12 WINDSHIELD/WINDOWGLASS/MIRROR − WINDSHIELD GLASS (e) Mark B73132 Install the glass. (1) Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Check that the stoppers are attached to the vehicle body correctly.
Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive on the glass rim. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time: Adhesive B73131 Temperature Minimum time prior to driving vehicle 35C (95F) 1 hour 30 minutes 20C (68F) 5 hours 5C (41F) 24 hours 25. INSTALL WINDSHIELD MOULDING OUTER UPPER (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install the moulding. 26. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. WhereEverybodyKnowsYourName 10−1 ENGINE CONTROL SYSTEM − SFI SYSTEM (2AZ−FE) SFI SYSTEM (2AZ−FE) 10068−06 ON−VEHICLE INSPECTION 1. (a) CHECK THROTTLE BODY Listen to the throttle control motor operating sounds. (1) Turn the ignition switch ON. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure no friction noise comes from the motor. If friction noise exists, replace the throttle body. (b) Check the throttle position sensor. (1) Connect the hand−held tester or OBD II scan tool to the DLC3. (2) Turn the ignition switch ON. (3) Check that the check engine warning light does not light up. (4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be within the standard value range below. Standard throttle valve opening percentage: 60% or more If the percentage is less than 60%, replace the throttle body. NOTICE: When checking the standard throttle valve opening percentage, the transmission should be in the neutral position. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR (a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should be within the standard value range below. Standard: 0.6 to 1.0 V If the result is not as specified, replace the accelerator pedal position sensor. 3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Connect the hand−held tester or OBD II scan tool to the DLC3. (b) Turn the ignition switch ON. (c) Start the engine and warmed it up. (d) Select the VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the hand−held tester. Standard: Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled If the result is not as specified, replace the OCV assy. WhereEverybodyKnowsYourName 10−1−1 ENGINE CONTROL SYSTEM Hand−held Tester DLC3 A59675 − SFI SYSTEM (2AZ−FE) 4. CHECK MASS AIR FLOW METER (MAF meter) NOTICE:
Perform the MAF meter inspection by following the procedures below.
Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. (a) Perform confirmation driving pattern. (1) Connect the hand−held tester to the DLC3. (2) Turn the ignition switch ON. (3) Turn the tester on. (4) Clear the DTCs (see page 05−41). (5) Start the engine and warm it up with all accessory switches off (until the engine coolant temperature is 75C (167F) or more). (6) Drive the vehicle at 31 mph (50 km/h) or more for 3 to 5 minutes. *1 (7) Allow the engine to idle for 2 minutes. *2 (8) Perform steps *1 and *2 at least 3 times. (Vehicle Speed) *1 *1 *1 31 mph (50 km/h) Idling Ignition switch OFF *2 *2 Warming up WhereEverybodyKnowsYourName *2 *1: 3 to 5 minutes *2: 2 minutes cmc0324 10−1−2 ENGINE CONTROL SYSTEM − SFI SYSTEM (2AZ−FE) (b) Read value using the hand−held tester (LONG FT#1). (1) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / LONG FT#1. (2) Read the values displayed on the tester. Standard value: Within −15 to +15 % If the result is not within the specified range, perform the inspection below. (c) Read value using the hand−held tester (MAF). NOTICE:
Turn off the engine.
Perform the inspection with the vehicle indoors and on a level surface.
Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle).
During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn off the engine (do not run the engine). (2) Turn the ignition switch ON. (3) Turn the tester on. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / PRIMARY / MAF. (5) Wait 30 seconds, and read the values on the hand− held tester. Standard condition: Less than 0.54 g/s
If the result is not as specified, replace the MAF meter.
If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (see page 05−138). WhereEverybodyKnowsYourName 10−11 ENGINE CONTROL SYSTEM − ACCELERATOR PEDAL ASSY (2AZ−FE) ACCELERATOR PEDAL ASSY (2AZ−FE) 100JY−02 REPLACEMENT (a) (b) 1. (a) (b) REMOVE ACCELERATOR PEDAL ASSY Disconnect the accelerator position sensor connector. Remove the 2 bolts and the accelerator pedal. 2. (a) (b) INSTALL ACCELERATOR PEDAL ASSY Connect the accelerator position sensor connector. Install the accelerator pedal with the 2 bolts. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (b) B75316 (a) (b) (b) B75316 WhereEverybodyKnowsYourName 10−12 ENGINE CONTROL SYSTEM − SFI SYSTEM (1MZ−FE/3MZ−FE) SFI SYSTEM (1MZ−FE/3MZ−FE) 100FS−05 ON−VEHICLE INSPECTION 1. (a) CHECK THROTTLE BODY Listen to the throttle control motor operating sounds. (1) Turn the ignition switch ON. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure no friction noise comes from the motor. If friction noise exists, replace the throttle body. (b) Inspect the throttle position sensor. (1) Connect the hand−held tester or OBD II scan tool to the DLC3. (2) Turn the ignition switch ON. (3) Check that the MIL is off. (4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be within the standard value range below. Standard throttle valve opening percentage: 60% or more If the percentage is less than 60%, replace the throttle body. NOTICE: When checking the standard throttle valve opening percentage, the transmission should be in the neutral position. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR (a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should be within the standard value range below. Standard: 0.6 to 1.0 V If the result is not as specified, replace the accelerator pedal position sensor. 3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Connect the hand−held tester or OBD II scan tool to the DLC3. (b) Turn the ignition switch ON. (c) Start the engine and warm it up. (d) Select the VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the hand−held tester. Standard: Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled If the result is not as specified, replace the OCV assy. WhereEverybodyKnowsYourName 10−12−1 ENGINE CONTROL SYSTEM Hand−held Tester DLC3 A59675 − SFI SYSTEM (1MZ−FE/3MZ−FE) 4. CHECK MASS AIR FLOW METER (MAF meter) NOTICE:
Perform the MAF meter inspection by following the procedures below.
Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. (a) Perform confirmation driving pattern. (1) Connect the hand−held tester to the DLC3. (2) Turn the ignition switch ON. (3) Turn the tester on. (4) Clear the DTCs (see page 05−531). (5) Start the engine and warm it up with all accessory switches off (until the engine coolant temperature is 75C (167F) or more). (6) Drive the vehicle at 31 mph (50 km/h) or more for 3 to 5 minutes. *1 (7) Allow the engine to idle for 2 minutes. *2 (8) Perform steps *1 and *2 at least 3 times. (Vehicle Speed) *1 *1 *1 31 mph (50 km/h) Idling Ignition switch OFF *2 *2 Warming up WhereEverybodyKnowsYourName *2 *1: 3 to 5 minutes *2: 2 minutes cmc0324 10−12−2 ENGINE CONTROL SYSTEM − SFI SYSTEM (1MZ−FE/3MZ−FE) (b) Read value using the hand−held tester (LONG FT#1). (1) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / LONG FT#1. (2) Read the values displayed on the tester. Standard value: Within −15 to +15 % If the result is not within the specified range, perform the inspection below. (c) Read value using the hand−held tester (MAF). NOTICE:
Turn off the engine.
Perform the inspection with the vehicle indoors and on a level surface.
Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle).
During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn off the engine (do not run the engine). (2) Turn the ignition switch ON. (3) Turn the tester on. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / PRIMARY / MAF. (5) Wait 30 seconds, and read the values on the hand− held tester. Standard condition: Less than 0.54 g/s
If the result is not as specified, replace the MAF meter.
If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (see page 05−632). WhereEverybodyKnowsYourName 10−13 ENGINE CONTROL SYSTEM − SFI SYSTEM (1MZ−FE/3MZ−FE) 100JZ−02 INSPECTION 1. (a) Air E2 VG +B THA E2G 5 4 3 2 1 (b) 30 20 Resistance kΩ 10 INSPECT MASS AIR FLOW METER Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (−) tester probe to terminal E2G. (3) Blow air into the MAF meter, and check that the voltage fluctuates. Measure the resistance between terminals 4 (THA) and 5 (E2). Standard: Condition Specified Condition 5 −20
C (−4
F) 13.6 to 18.4 kΩ 3 2 20
C (68
F) 2.21 to 2.69 kΩ 60
C (140
F) 0.493 to 0.667 kΩ 1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68) (104)(140) (176) (212) Temperature
C (
F) If the result is not as specified, replace the MAF meter. 2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Measure the resistance between the terminals. Standard: 6.9 to 7.9 Ω at 20
C (68
F) If the result is not as specified, replace the OCV assy. A91319 1 (b) 2 Valve A50377 Connect the battery’s positive (+) lead to terminal 1 and negative (−) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not become stuck in any position. If necessary, replace the OCV assy. HINT: If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC will be output. WhereEverybodyKnowsYourName 10−14 ENGINE CONTROL SYSTEM 3. (a) VPA2 EP2 EP1 VCP1 VCP2 VPA1 A60812 5 4 3 2 SFI SYSTEM (1MZ−FE/3MZ−FE) INSPECT ACCELERATOR PEDAL ASSY Measure the resistance between the terminals. Standard: Tester Connection Specified Condition 2 (VPA2) − 3 (EP1) 5.0 kΩ or less 5 (VPA1) − 1 (EP2) 5.0 kΩ or less 6 (VCP1) − 3 (EP1) 2.25 to 4.75 kΩ 4 (VCP2) − 1 (EP2) 2.25 to 4.75 kΩ If the result is not as specified, replace the pedal assy. 4. (a) 6 − 1 INSPECT THROTTLE BODY ASSY Measure the resistance between the terminals. Standard: Tester Connection Condition Specified Condition 2 (M+) − 1 (M−) 20
C (68
F) 0.3 to 100 Ω 5 (VC) − 3 (E2) 20
C (68
F) 2.0 to 4.0 kΩ If the result is not as specified, replace the throttle body assy. VTA VC VTA2 E2 M+ M− A75258 5. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between each terminal. Standard: Condition 2.32 to 2.59 kΩ Approx. 80
C (176
F) 0.310 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: If checking the engine coolant temperature sensor in the water, keep the terminals dry. After the check, wipe the sensor dry. 30 20 Resistance kΩ Specified Condition Approx. 20
C (68
F) 10 5 3 2 1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68)(104) (140) (176) (212) Temperature
C (
F) A91320 6. (a) INSPECT KNOCK SENSOR (1MZ−FE ENGINE TYPE) Using an ohmmeter, measure the resistance between the terminal and body. Standard: 10 kΩ or higher HINT: If the result is not as specified, replace the sensor. P01630 WhereEverybodyKnowsYourName 10−15 ENGINE CONTROL SYSTEM 7. (a) − SFI SYSTEM (1MZ−FE/3MZ−FE) INSPECT KNOCK SENSOR (3MZ−FE ENGINE TYPE) Using an ohmmeter, measure the resistance between the terminals. Standard: 120 to 280 kΩ at 20
C (68
F) HINT: If the result is not as specified, replace the sensor. A65174 1 3 2 5 5 2 1 3 8. (a) INSPECT RELAY (Marking: EFI, C/OPN) Using an ohmmeter, measure the resistance of the relay. Standard: Tester Connection Specified Condition 3−5 10 kΩ or higher 3−5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. A91031 WhereEverybodyKnowsYourName 10−16 ENGINE CONTROL SYSTEM − THROTTLE BODY ASSY (1MZ−FE/3MZ−FE) THROTTLE BODY ASSY (1MZ−FE/3MZ−FE) 100IU−04 COMPONENTS 80 (815, 59) x2 Spacer 7.9 (81, 70 in.⋅lbf) w/ Performance Rod: Front Suspension Upper Brace Center x3 80 (815, 59) x2 V−Bank Cover Sub−assy Spacer Ventilation Hose No. 2 Fuel Vapor Feed Hose Assy MAF Meter Connector VSV Connector Vacuum Hose Vacuum Hose Air Cleaner Cap Sub−assy 5.0 (51, 44 in.⋅lbf) Emission Tube, No. 1 Fuel Hose Air Cleaner Filter Element Sub−assy N·m (kgf·cm, ft·lbf) : Specified torque A79542 WhereEverybodyKnowsYourName 10−17 ENGINE CONTROL SYSTEM − THROTTLE BODY ASSY (1MZ−FE/3MZ−FE)
Gasket Throttle Body Assy Throttle Control Motor & Throttle Position Sensor Connector Water Bypass Hose No. 2 11 (112, 8) Water Bypass Hose No. 3 N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A79466 WhereEverybodyKnowsYourName 10−18 ENGINE CONTROL SYSTEM − THROTTLE BODY ASSY (1MZ−FE/3MZ−FE) 100K0−02 REPLACEMENT 1. 2. (a) DRAIN ENGINE COOLANT (See page 16−27) w/ Perfomance rod: REMOVE FRONT SUSPENSION UPPER BRACE CENTER Remove the 2 nuts and upper brace. 3. (a) (b) REMOVE V−BANK COVER SUB−ASSY Using a socket hexagon wrench 5, remove the 3 nuts. Remove the V−bank cover. A88625 4. (a) (b) (c) (d) (e) (f) (g) REMOVE AIR CLEANER CAP SUB−ASSY Disconnet the MAF meter connector. Disconnect the VSV connector. Remove the ventilation hose No. 2. Disconnect the emission tube No. 1 fuel hose. Disconnec the vacuum hoses. Remove the fuel vapor feed hose from the 2 hose clamps. Loosen the air cleaner hose clamp bolt, and then remove the intake air resonator. 5. (a) (a) (b) (b) (c) REMOVE THROTTLE BODY ASSY Disconnect the throttle control motor & throttle position sensor connector. Disconnect the water bypass hose No. 2. Disconnect the water bypass hose No. 3. (d) (e) Remove the 2 bolts, 2 nuts and throttle body. Remove the gasket. (c) A81197 A81198 WhereEverybodyKnowsYourName 10−19 ENGINE CONTROL SYSTEM 6. (a) (b) (c) (d) (e) 7. (a) (b) (c) (d) (e) (f) (g) (h) 8. 9. 10. (a) (b) 11. (a) − THROTTLE BODY ASSY (1MZ−FE/3MZ−FE) INSTALL THROTTLE BODY ASSY Install a new gasket to the intake air connector. Install the throttle body with the 2 bolts and 2 nuts. Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) Connect the water bypass hose No. 3. Connect the water bypass hose No. 2. Connect the throttle control motor & throttle position sensor connector. INSTALL AIR CLEANER CAP SUB−ASSY Install the air cleaner hose (w/ air cleaner cap) to the throttle body. Tighten the air cleaner hose clamp bolt. Install the fuel vapor feed hose to the 2 hose clamps. Connect the vacuum hoses. Connect the emission tube No. 1 fuel hose. Install the ventilation hose No. 2. Connect the VSV connector. Connect the MAF meter connector. ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) INSTALL V−BANK COVER SUB−ASSY Fit the 2 retainers and install the V−bank cover. Using a socket hexagon wrench 5, tighten the 3 nuts. Torque: 7.9 N⋅m (81 kgf⋅cm, 70 in.⋅lbf) w/ Performance Rod: INSTALL FRONT SUSPENSION UPPER BRACE CENTER Install the upper brace with the 2 nuts. Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) WhereEverybodyKnowsYourName 10−2 ENGINE CONTROL SYSTEM − SFI SYSTEM (2AZ−FE) 100IO−04 INSPECTION 1. (a) Air E2 VG +B THA E2G 5 4 3 2 1 (b) 30 20 Resistance kΩ 10 INSPECT MASS AIR FLOW METER Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (−) tester probe to terminal E2G. (3) Blow air into the MAF meter, and check that the voltage fluctuates. Measure the resistance between terminals 4 (THA) and 5 (E2). Standard: Condition Specified Condition 5 −20
C (−4
F) 13.6 to 18.4 kΩ 3 2 20
C (68
F) 2.21 to 2.69 kΩ 60
C (140
F) 0.493 to 0.667 kΩ 1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68) (104)(140) (176) (212) Temperature
C (
F) If the result is not as specified, replace the MAF meter. 2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Measure the resistance between the terminals. Standard: 6.9 to 7.9 Ω at 20
C (68
F) If the result is not as specified, replace the OCV assy. A91319 1 (b) 2 Valve A50377 Connect the battery’s positive (+) lead to terminal 1 and negative (−) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not become stuck in any position. If necessary, replace the OCV assy. HINT: If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC will be output. WhereEverybodyKnowsYourName 10−3 ENGINE CONTROL SYSTEM 3. (a) VPA2 EP2 EP1 VCP1 VCP2 VPA1 A60812 5 4 3 2 SFI SYSTEM (2AZ−FE) INSPECT ACCELERATOR PEDAL ASSY Measure the resistance between the terminals. Standard: Tester Connection Specified Condition 2 (VPA2) − 3 (EP1) 5.0 kΩ or less 5 (VPA1) − 1 (EP2) 5.0 kΩ or less 6 (VCP1) − 3 (EP1) 2.25 to 4.75 kΩ 4 (VCP2) − 1 (EP2) 2.25 to 4.75 kΩ If the result is not as specified, replace the pedal assy. 4. (a) 6 − 1 INSPECT THROTTLE BODY ASSY Measure the resistance between the terminals. Standard: Tester Connection Condition Specified Condition 2 (M+) − 1 (M−) 20
C (68
F) 0.3 to 100 Ω 5 (VC) − 3 (E2) 20
C (68
F) 1.2 to 3.2 kΩ If the result is not as specified, replace the throttle body assy. VTA VC VTA2 E2 M+ M− A75258 5. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between terminals 1 and 2. Standard: Condition 2.32 to 2.59 kΩ Approx. 80
C (176
F) 0.310 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: If checking the engine coolant temperature sensor in the water, keep the terminals dry. After the check, wipe the sensor dry. 30 20 Resistance kΩ Specified Condition Approx. 20
C (68
F) 10 5 3 2 1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68)(104) (140) (176) (212) Temperature
C (
F) A91320 6. (a) INSPECT KNOCK SENSOR Using an ohmmeter, measure the resistance between the terminals. Standard: 120 to 280 kΩ at 20
C (68
F) HINT: If the result is not as specified, replace the sensor. A65174 WhereEverybodyKnowsYourName 10−4 ENGINE CONTROL SYSTEM 1 3 2 5 5 2 1 3 7. (a) − SFI SYSTEM (2AZ−FE) INSPECT RELAY (Marking: EFI, C/OPN) Using an ohmmeter, measure the resistance of the relay. Standard: Tester Connection Specified Condition 3−5 10 kΩ or higher 3−5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. A91031 WhereEverybodyKnowsYourName 10−20 ENGINE CONTROL SYSTEM − KNOCK SENSOR (1MZ−FE/3MZ−FE) KNOCK SENSOR (1MZ−FE/3MZ−FE) 100K1−02 REPLACEMENT 1. 2. 3. 4. 5. 6. DISCHARGE FUEL SYSTEM PRESSURE (See page11−26 ) DRAIN ENGINE COOLANT (See page 16−27) REMOVE V−BANK COVER SUB−ASSY (See page 10−18) REMOVE AIR CLEANER CAP SUB−ASSY (See page 10−18) REMOVE EMISSION CONTROL VALVE SET (See page 11−38) REMOVE INTAKE AIR SURGE TANK (See page 11−38) Fuel Pipe Clamp 7. (a) Pinch Pinch REMOVE INTAKE MANIFOLD Disconnect the fuel pipe No. 1. (1) Remove the fuel pipe clamp. (2) Pinch the tube connector and then pull out the fuel pipe No. 1. A81199 Nylon Tube Tube Connector O−ring Pipe A75650 NOTICE:
Check the connector for dirt, mud or other contamination. Clean if necessary.
Be sure to keep the tube connector, pipe and O−ring clean. They can become contaminated easily.
Do not use tools when disconnecting the fuel pipe.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and the connector are stuck, push and pull the connector to release it. Then pull the connector out carefully. (b) (c) Lock the hose clamp, as shown in the illustration. Disconnect the heater inlet water hose. (c) (b) A79759 WhereEverybodyKnowsYourName 10−21 ENGINE CONTROL SYSTEM (e) (d) (d) (e) (e) (e) (e) − KNOCK SENSOR (1MZ−FE/3MZ−FE) Remove the nut and disconnect the ground cable. Disconnect the 6 fuel injector connectors. (e) (e) A81200 (f) Loosen and remove the intake manifold’s 9 bolts and 2 nuts little by little in the numerical order shown in the illustration. (g) Remove the intake manifold. NOTICE: Fully removing each bolt and nut one by one may damage the intake manifold, bolts and nuts. 10 4 2 6 8 3 11 5 9 7 1 A81201 8. (a) (a) REMOVE WATER OUTLET Disconnect the radiator hose inlet. A81202 WhereEverybodyKnowsYourName 10−22 ENGINE CONTROL SYSTEM (b) (c) (d) (e) (e) (b) (f) − KNOCK SENSOR (1MZ−FE/3MZ−FE) Disconnect the ECT sensor connector. Remove the clamp. Remove the 2 bolts, 2 nuts and 2 washers. Lock the hose clamp as shown in the illustration. Then remove the water outlet together with the water bypass hose No. 1. Remove the 2 gaskets from the 2 cylinder heads. (c) A81203 9. (a) (b) REMOVE KNOCK SENSOR (1MZ−FE ENGINE TYPE) Disconnect the 2 knock sensor connectors. Using SST, remove the 2 knock sensors. SST 09249−63010, 09816−30010 10. (a) (b) REMOVE KNOCK SENSOR (3MZ−FE ENGINE TYPE) Disconnect the 2 knock sensor connectors. Remove the 2 nuts and 2 knock sensors. SST A82416 A79749 WhereEverybodyKnowsYourName 10−23 ENGINE CONTROL SYSTEM 11. (a) (b) SST − KNOCK SENSOR (1MZ−FE/3MZ−FE) INSTALL KNOCK SENSOR (1MZ−FE ENGINE TYPE) Using SST, install the 2 knock sensors. SST 09249−63010, 09816−30010 Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) Connect the 2 knock sensors. A82416 12. (a) Upper 0 to 5
(b) 13. (a) (b) Engine Front A79750 (c) (d) (e) (f) INSTALL KNOCK SENSOR (3MZ−FE ENGINE TYPE) Install the 2 knock sensors with the 2 nuts, as shown in the illustration. Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) Connect the 2 knock sensor connectors. INSTALL WATER OUTLET Install 2 new gaskets to the 2 cylinder heads. Install the water outlet together with the water bypass hose No. 1 and unlock the hose clamp. Tighten the 2 bolts, 2 nuts and 2 washers. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the clamp. Connect the ECT sensor connector. Connect the radiator hose inlet. 14. (a) 2 8 10 6 4 9 1 5 INSTALL INTAKE MANIFOLD Tighten the intake manifolds’s 9 bolts and 2 nuts little by little in the numerical order shown in the illustration. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) NOTICE: In this case, fully tightening one of these bolts or nuts without partially tightening the other bolts or nuts in the group may damage the intake manifold, bolts and nuts. (b) Retighten the water outlet mounting bolts and nuts. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) (c) Install the ground cable with the nut. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) (d) Connect the heater inlet water hose. 7 3 11 A81201 WhereEverybodyKnowsYourName 10−24 ENGINE CONTROL SYSTEM − KNOCK SENSOR (1MZ−FE/3MZ−FE) (e) Push A81204 15. 16. 17. 18. 19. 20. 21. 22. Connect the fuel pipe No. 1. (1) Push the quick connector into the pipe until it makes ”click” sound. NOTICE:
Check if there is any damage or contamination on the connected part.
After connecting, confirm that the connector and pipe are securely connected by trying to pull them apart. (2) Install the fuel pipe clamp. INSTALL INTAKE AIR SURGE TANK (See page 11−38) INSTALL EMISSION CONTROL VALVE SET (See page 11−38) INSTALL AIR CLEANER CAP SUB−ASSY (See page 10−18) CHECK CONNECTION OF VACUUM HOSE ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) CHECK FOR FUEL LEAKS (See page 11−29) INSTALL V−BANK COVER SUB−ASSY (See page 10−18) WhereEverybodyKnowsYourName 10−25 ENGINE CONTROL SYSTEM − ECM (1MZ−FE/3MZ−FE) ECM (1MZ−FE/3MZ−FE) 100K2−02 REPLACEMENT 1. 2. 3. 4. 5. DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE FRONT DOOR SCUFF PLATE RH (See page 76−22) REMOVE COWL SIDE TRIM SUB−ASSY RH (See page 76−22) REMOVE INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) REMOVE INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) 6. (a) (b) (c) REMOVE ECM Remove the 2 wire harness clamps. Disconnect the 5 ECM connectors. Remove the 2 nuts and ECM. 7. (a) REMOVE ECM BRACKET Remove the 2 screws and ECM bracket. 8. (a) REMOVE ECM BRACKET NO.2 Remove the 2 screws and ECM bracket. 9. (a) INSTALL ECM BRACKET NO.2 Install the ECM bracket with the 2 screws. A91032 A91033 A91034 A91034 WhereEverybodyKnowsYourName 10−26 ENGINE CONTROL SYSTEM − ECM (1MZ−FE/3MZ−FE) 10. (a) INSTALL ECM BRACKET Install the ECM bracket with the 2 screws. 11. (a) (b) (c) INSTALL ECM Install the 2 wire harness clamps. Connect the 5 ECM connectors. Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) A91033 A91032 12. 13. 14. 15. 16. INSTALL INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) INSTALL INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) INSTALL COWL SIDE TRIM SUB−ASSY RH (See page 76−22) INSTALL FRONT DOOR SCUFF PLATE RH (See page 76−22) CONNECT BATTERY NEGATIVE TERMINAL WhereEverybodyKnowsYourName 10−27 ENGINE CONTROL SYSTEM − ACCELERATOR PEDAL ASSY (1MZ−FE/3MZ−FE) ACCELERATOR PEDAL ASSY (1MZ−FE/3MZ−FE) 100K3−02 REPLACEMENT (a) (b) 1. (a) (b) REMOVE ACCELERATOR PEDAL ASSY Disconnect the accelerator position sensor connector. Remove the 2 bolts and the accelerator pedal. 2. (a) (b) INSTALL ACCELERATOR PEDAL ASSY Connect the accelerator position sensor connector. Install the accelerator pedal with the 2 bolts. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (b) B75316 (a) (b) (b) B75316 WhereEverybodyKnowsYourName 10−5 ENGINE CONTROL SYSTEM − THROTTLE BODY ASSY (2AZ−FE) THROTTLE BODY ASSY (2AZ−FE) 1006A−06 COMPONENTS Fuel Vapor Feed Hose VSV Connector MAF Meter Connector Emission Tube, No.1 Fuel Hose Air Cleaner Cap Sub−assy 30 (306, 22) Fuel Pipe Support Throttle Body Assy Water Bypass Hose Water Bypass Hose No.2
Gasket Throttle Control Motor & Throttle Position Sensor Connector N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part G34896 WhereEverybodyKnowsYourName 10−6 ENGINE CONTROL SYSTEM − THROTTLE BODY ASSY (2AZ−FE) 1006B−06 REPLACEMENT 1. 2. DRAIN ENGINE COOLANT (See page 16−6) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 3. REMOVE THROTTLE BODY ASSY (a) Disconnect the throttle control motor & throttle position sensor connector. (b) Disconnect the 2 vacuum hoses from the throttle body. (c) Disconnect the 2 water bypass hoses. (d) (e) Remove the 4 bolts, fuel pipe support and throttle body. Remove the gasket. 4. (a) INSTALL THROTTLE BODY ASSY Install a new gasket on the intake manifold, as shown in the illustration. (b) Install the throttle body and fuel pipe support with the 4 bolts. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Connect the 2 water bypass hoses to the throttle body. Connect the 2 vacuum hoses to the throttle body. Connect the throttle control motor & throttle position sensor connector. G34897 B09649 (c) (d) (e) G34897 5. 6. 7. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName 10−7 ENGINE CONTROL SYSTEM − KNOCK SENSOR (2AZ−FE) KNOCK SENSOR (2AZ−FE) 100IP−04 REPLACEMENT 1. 2. 3. DRAIN ENGINE COOLANT (See page 16−6) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE REMOVE THROTTLE BODY ASSY (See page 10−6) 4. (a) REMOVE INTAKE MANIFOLD Remove the 5 bolts, 2 nuts, intake manifold and gasket. 5. (a) (b) REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut and knock sensor. 6. (a) INSTALL KNOCK SENSOR Install the knock sensor with the nut. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Connect the knock sensor connector. A61987 A85381 (b) A85381 7. (a) INSTALL INTAKE MANIFOLD Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A61987 WhereEverybodyKnowsYourName 10−8 ENGINE CONTROL SYSTEM 8. 9. 10. 11. 12. − KNOCK SENSOR (2AZ−FE) INSTALL THROTTLE BODY ASSY (See page 10−6) INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE CHECK CONNECTION OF VACUUM HOSE ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName 10−9 ENGINE CONTROL SYSTEM − ECM (2AZ−FE) ECM (2AZ−FE) 100JX−02 REPLACEMENT 1. 2. 3. 4. 5. DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE FRONT DOOR SCUFF PLATE RH (See page 76−22) REMOVE COWL SIDE TRIM SUB−ASSY RH (See page 76−22) REMOVE INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) REMOVE INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) 6. (a) (b) (c) REMOVE ECM Remove the 2 wire harness clamps. Disconnect the 5 ECM connectors. Remove the 2 nuts and ECM. 7. (a) REMOVE ECM BRACKET Remove the 2 screws and ECM bracket. 8. (a) REMOVE ECM BRACKET NO.2 Remove the 2 screws and ECM bracket. 9. (a) INSTALL ECM BRACKET NO.2 Install the ECM bracket with the 2 screws. A91032 A91033 A91034 A91034 WhereEverybodyKnowsYourName 10−10 ENGINE CONTROL SYSTEM − ECM (2AZ−FE) 10. (a) INSTALL ECM BRACKET Install the ECM bracket with the 2 screws. 11. (a) (b) (c) INSTALL ECM Install the 2 wire harness clamps. Connect the 5 ECM connectors. Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) A91033 A91032 12. 13. 14. 15. 16. INSTALL INSTRUMENT PANEL SUB−ASSY LOWER (See page 71−16) INSTALL INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 (See page 71−16) INSTALL COWL SIDE TRIM SUB−ASSY RH (See page 76−22) INSTALL FRONT DOOR SCUFF PLATE RH (See page 76−22) CONNECT BATTERY NEGATIVE TERMINAL WhereEverybodyKnowsYourName 32−1 BRAKE − BRAKE SYSTEM BRAKE SYSTEM 32038−12 PRECAUTION


Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. WhereEverybodyKnowsYourName 32−10 BRAKE − BRAKE PEDAL SUPPORT ASSY 321BW−01 COMPONENTS Normal type: 20 (204, 15) Brake Pedal Support Sub−assy Stop Lamp Switch Assy 37 (375, 27) Lock Nut 26 (265, 19) 13 (130, 9) 13 (130, 9)
Brake Pedal Bush Stop Lamp Switch Cushion
Brake Pedal Bush Brake Pedal Sub−assy Brake Pedal Return Spring Clip Push Rod Pin Brake Pedal Pad M/T models: Brake Pedal Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Lithium soap base glycol grease WhereEverybodyKnowsYourName F41014 32−11 BRAKE − BRAKE PEDAL SUPPORT ASSY Link type: Push Rod Pin Stop Lamp Switch Assy Lock Nut 26 (265, 19) Stop Lamp Switch Cushion Brake Pedal Return Spring 13 (130, 9) Clip Brake Pedal Support Sub−Assy M/T models: Brake Pedal Pad Brake Pedal Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Lithium soap base glycol grease WhereEverybodyKnowsYourName F42751 32−12 BRAKE − BRAKE PEDAL SUPPORT ASSY 321BX−02 OVERHAUL 1. 2. 3. (a) 4. (a) (b) (c) REMOVE INSTRUMENT PANEL REINFORCEMENT (See page 55−34) REMOVE BRAKE PEDAL RETURN SPRING REMOVE PUSH ROD PIN Remove the clip and push rod pin. REMOVE BRAKE PEDAL SUPPORT ASSY Disconnect the stop lamp switch connector. Normal type: Remove the bolt, 4 nuts and brake pedal support assy. Link type: Remove the 4 nuts and brake pedal support assy. REMOVE STOP LAMP SWITCH ASSY Loosen the lock nut and remove the stop lamp switch. REMOVE BRAKE PEDAL SUB−ASSY (NORMAL TYPE BRAKE PEDAL) Remove the nut, bolt and brake pedal sub−assy from brake pedal support sub−assy. REMOVE BRAKE PEDAL PAD REMOVE BRAKE PEDAL BUSH (NORMAL TYPE BRAKE PEDAL) Remove the 2 brake pedal bushes from brake pedal sub−assy. REMOVE STOP LAMP SWITCH CUSHION INSTALL STOP LAMP SWITCH CUSHION INSTALL BRAKE PEDAL BUSH (NORMAL TYPE BRAKE PEDAL) Install the new 2 brake pedal bushes to brake pedal sub−assy. 5. (a) 6. (a) 7. 8. (a) 9. 10. 11. (a) HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows (See page 32−10). 12. INSTALL BRAKE PEDAL PAD 13. INSTALL BRAKE PEDAL SUB−ASSY (NORMAL TYPE BRAKE PEDAL) (a) Install the brake pedal sub−assy with the bolt and nut. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) 14. INSTALL STOP LAMP SWITCH ASSY (a) Install the stop lamp switch with the lock nut. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 15. INSTALL BRAKE PEDAL SUPPORT ASSY (a) Normal type: Install the brake pedal support assy with the bolt and 4 nuts. Torque: Bolt: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Nut: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) (b) Link type: Install the brake pedal support assy with the 4 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) 16. INSTALL PUSH ROD PIN (a) Install the push rod pin and clip. HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows (See page 32−10). 17. INSTALL BRAKE PEDAL RETURN SPRING 18. INSTALL INSTRUMENT PANEL REINFORCEMENT (See page 55−34) 19. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32−8) 20. CHECK PEDAL FREE PLAY (See page 32−8) WhereEverybodyKnowsYourName 32−13 BRAKE 21. − BRAKE PEDAL SUPPORT ASSY CHECK PEDAL RESERVE DISTANCE (See page 32−8) WhereEverybodyKnowsYourName 32−14 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY ACCELERATOR & BRAKE PEDAL ASSY 320MZ−03 ADJUSTMENT Stop Lamp Switch Assy 1. (a) (b) Push Rod Pedal Height F42717 CHECK AND ADJUST BRAKE PEDAL HEIGHT Inspect brake pedal height. Pedal height from asphalt sheet: 144.1 − 154.1 mm (5.673 − 6.067 in.) Adjust brake pedal height. (1) Remove the instrument panel finish panel sub− assy lower and instrument panel insert sub−assy lower LH. (2) Disconnect the connector from the stop lamp switch assy. (3) Loosen the stop lamp switch lock nut and remove the stop lamp switch assy. (4) Loosen the clevis lock nut. (5) Adjust the pedal height by turning the pedal push rod. (6) Tighten the push rod lock nut. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) (7) Install the stop lamp switch assy. (8) Connect the connector to the stop lamp switch assy. (9) Push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off. (10) After installation, push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), check that stop lamp lights up. (11) Install the instrument panel insert sub−assy lower LH and instrument panel finish panel sub−assy lower. WhereEverybodyKnowsYourName 32−15 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 2. (a) CHECK PEDAL FREE PLAY Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown. Pedal free play: 1 − 6 mm (0.04 − 0.24 in.) If incorrect, check the stop lamp switch assy clearance. If the clearance is OK, then troubleshoot the brake system. Stop lamp switch clearance: 0.5 − 2.5 mm (0.020 − 0.098 in.) Pedal Free Play F42718 3. (a) CHECK PEDAL RESERVE DISTANCE Release the parking brake pedal. With engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 63 mm (2.48 in.) If incorrect, troubleshoot the brake system. Pedal Reserve Distance R00934 WhereEverybodyKnowsYourName 32−16 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 320N0−03 COMPONENTS 3 Spoke Steering Wheel: Steerig Wheel Assy Steering Wheel Cover Lower No.2 Instrument Cluster Finish Panel Horn Button Assy Steering Column Cover 50 (510, 37) 20.6 (210, 15) Steering Column Assy Steering Wheel Cover Lower No.3 4 Spoke Steering Wheel: Steerig Wheel Assy Steering Wheel Cover Lower No.2 Horn Button Assy 8.8 (90, 78 in.⋅lbf) Steering Intermediate Shaft Sub−assy 20.6 (210, 15) w/o Steering Pad Switch: 50 (510, 37) Steering Wheel Cover Lower No.3 w/ Steering Wheel Pad Switch: Connector Cover Steering Column Cover Heater to Foot Duct No.3 Instrument PNL Insert Sub−assy LWR LH Instrument Panel Sub−assy Upper Instrument Panel Junction Block Assy Cowl Side Trim Sub−assy LH Clip Front Door Scuff Plate LH Instrument Coin Box Sub−assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F16903 WhereEverybodyKnowsYourName 32−17 BRAKE Push Rod Pin − ACCELERATOR & BRAKE PEDAL ASSY Stop Lamp Switch Connector Stop Lamp Switch Assy 26 (265, 19) Brake Pedal Support Assy 19.1 (194, 14) Clip Stop Lamp Switch Cushion Accelerator Pedal Assy Brake Pedal Return Spring Accel Position Sensor Connector Brake Pedal Pad 12 (122, 8.8) 13 (130, 9) Accelerator Pedal Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Lithium soap base glycol grease WhereEverybodyKnowsYourName F16916 32−18 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 320N1−07 OVERHAUL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. PRECAUTION (See page 60−1) DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE STEERING WHEEL COVER LOWER NO.2 REMOVE STEERING WHEEL COVER LOWER NO.2 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) REMOVE POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50−6) REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) (See page 50−6) INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE HORN BUTTON ASSY (See page 60−25) REMOVE STEERING WHEEL ASSY (See page 50−9) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page 71−16) REMOVE STEERING COLUMN COVER (See page 50−9) DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (See page 50−9) REMOVE FRONT DOOR SCUFF PLATE LH (See page 71−16) REMOVE COWL SIDE TRIM SUB−ASSY LH (See page 71−16) REMOVE INSTRUMENT PANEL COIN BOX SUB−ASSY (See page 71−16) REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH (See page 71−16) REMOVE DUCT, FR VENTILATOR, LH (See page 71−16) DISCONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY (See page 50−9) REMOVE STEERING COLUMN ASSY (See page 50−9) 21. (a) REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSY Remove the 3 nuts and junction block assy, then disconnect the connector. F16911 22. REMOVE BRAKE PEDAL RETURN SPRING F16914 WhereEverybodyKnowsYourName 32−19 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 23. (a) REMOVE PUSH ROD PIN Remove the clip and push rod pin. 24. (a) REMOVE ACCELERATOR & BRAKE PEDAL ASSY Disconnect the stop lamp switch connector. (b) Disconnect the accel position sensor connector. (c) Remove the 4 bolts, 4 nuts and accelerator & brake pedal assy. 25. (a) REMOVE STOP LAMP SWITCH ASSY Loosen the nut and remove the stop lamp switch assy. F16908 F16906 F16910 F16907 F16909 WhereEverybodyKnowsYourName 32−20 BRAKE 26. − ACCELERATOR & BRAKE PEDAL ASSY REMOVE BRAKE PEDAL PAD 27. REMOVE STOP LAMP SWITCH CUSHION 28. (a) REMOVE ACCELERATOR PEDAL ASSY Remove the bolt, nut and accelerator pedal assy. 29. (a) INSTALL ACCELERATOR PEDAL ASSY Install the accelerator pedal assy with nut and bolt. Torque: 12 N⋅m (122 kgf⋅cm, 8.8 ft⋅lbf) 30. INSTALL STOP LAMP SWITCH CUSHION F16905 F16904 F16904 F16905 31. INSTALL BRAKE PEDAL PAD WhereEverybodyKnowsYourName 32−21 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 32. (a) INSTALL STOP LAMP SWITCH ASSY Install the stop lamp switch assy with a nut. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 33. (a) INSTALL ACCELERATOR & BRAKE PEDAL ASSY Install the accelerator & brake pedal assy with the 4 nuts and 4 bolts. Torque: Nut: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) Bolt: 19.1 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (b) Connect the accel position sensor connector. (c) Connect the stop lamp switch connector. F16909 F16907 F16910 F16906 34. INSTALL PUSH ROD PIN (a) Install the push rod pin and clip. HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows (See page 32−16). F16908 WhereEverybodyKnowsYourName 32−22 BRAKE − ACCELERATOR & BRAKE PEDAL ASSY 35. INSTALL BRAKE PEDAL RETURN SPRING 36. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY Install the junction block assy with the 3 nuts, then connect the each connector. F16914 (a) F16911 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. INSTALL STEERING COLUMN ASSY (See page 50−9) CONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY (See page 50−9) PLACE FRONT WHEELS FACING STRAIGHT AHEAD CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (See page 50−9) CHECK KEY INTERLOCK OPERATION INSTALL STEERING COLUMN COVER (See page 50−9) INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page 71−16) INSTALL DUCT, FR VENTILATOR, LH (See page 71−16) INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH (See page 71−16) INSTALL INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) INSTALL INSTRUMENT PANEL COIN BOX SUB−ASSY (See page 71−16) INSTALL COWL SIDE TRIM SUB−ASSY LH (See page 71−16) INSTALL FRONT DOOR SCUFF PLATE LH (See page 71−16) CENTER SPIRAL CABLE (See page 60−34) INSTALL STEERING WHEEL ASSY (See page 50−9) INSPECT HORN BUTTON ASSY (See page 60−25) INSTALL HORN BUTTON ASSY (See page 60−25) INSTALL STEERING WHEEL COVER LOWER NO.2 INSTALL STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) INSTALL POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) INSTALL STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT (See page 05−1464) WhereEverybodyKnowsYourName 32−2 BRAKE − BRAKE SYSTEM 32039−17 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area 1. Fluid leaks for brake system 2. Air in brake system 3. Piston seals (Worn or damaged) Low pedal or spongy pedal 4. Rear brake shoe clearance (Out of adjustment) 5. Master cylinder (Fauly) 6. Booster push rod (Out of adjustment) 1. Brake pedal freeplay (Minimal) 2. Parking brake pedal travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Rear brake shoe clearance (Out of adjustment) 5. Parking brake shoe clearance (Out of adjustment) 6. Pad or lining (Cracked or distorted) Brake drag 7. Piston (Stuck) 8. Piston (Frozen) 9. Anchor, tension or return spring (Faulty) 10.Booster push rod (Out adjustment) 11.Master cylinder (Faulty) 1. Piston (Stuck) 2. Pad or lining (Oily) Brake pull 3. Piston (Frozen) 4. Disc (Scored) 5. Pad or lining (Cracked or distorted) WhereEverybodyKnowsYourName See page − 32−4 32−35 32−44 32−50 32−23 32−23 32−8 32−14 33−19 33−10 33−14 33−17 32−50 33−19 32−35 32−44 32−50 32−35 32−44 32−35 32−44 33−19 32−50 32−23 32−23 32−35 32−44 32−35 32−44 32−50 32−35 32−44 32−35 32−44 32−35 32−44 32−50 32−3 BRAKE − BRAKE SYSTEM 1. Fluid leaks for brake system 2. Air in brake system 3. Pad or lining (Worn) 4. Pad or lining (Cracked or distorted) Hard pedal but brake inefficient 5. Rear brake shoe clearance (Out of adjustment) 6. Pad or lining (Oily) 7. Pad or lining (Glanzed) 8. Disc (Scored) 9. Booster push rod (Out of adjustment) 1. Pad on lining (Cracked or distorted) 2. Installation bolt (Loose) 3. Disc (Scored) 4. Pad support plate (Loose) 5. Sliding pin (Worn) Noise from brakes 6. Pad or lining (dirty) 7. Pad or lining (Glanzed) 8. Anchor, tension or return spring (Faulty) 9. Anti−squeal shim (Damaged) 10.Shoe hold−down spring (Damaged) WhereEverybodyKnowsYourName − 32−4 32−35 32−44 32−50 32−35 32−44 32−50 32−50 32−35 32−44 32−50 32−35 32−44 32−50 32−35 32−44 32−23 32−35 32−44 32−50 32−35 32−44 32−35 32−44 32−35 32−44 32−35 32−44 32−35 32−44 32−50 32−35 32−44 32−50 32−50 33−19 32−35 32−44 32−50 33−19 32−23 BRAKE − BRAKE MASTER CYLINDER SUB−ASSY BRAKE MASTER CYLINDER SUB−ASSY 321BY−02 OVERHAUL 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 2. REMOVE AIR CLEANER ASSY w/o ABS: 3. (a) (b) REMOVE BRAKE MASTER CYLINDER SUB−ASSY Disconnect the level warning switch connector. w/o ABS: Using SST, disconnect the 5 brake tubes from the brake master cylinder. SST 09023−00101 (c) w/ ABS: Using SST, disconnect the 6 brake tubes from the brake master cylinder. SST 09023−00101 (d) w/o ABS: Remove the 2 nuts, pull out the 3−way and brake master cylinder sub−assy. w/ ABS: Remove the 2 nuts, pull out the 2−way and brake master cylinder sub−assy. F41024 w/ ABS: F40991 (e) F40992 4. (a) 5. (a) 6. (a) 7. (a) REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY Pull out the master cylinder reservoir filler cap assy. REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER Pull out the master cylinder reservoir strainer. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB−ASSY Remove the screw and pull out the master cylinder reservoir sub−assy. REMOVE MASTER CYLINDER RESERVOIR GROMMET Remove the 2 master cylinder reservoir grommets. WhereEverybodyKnowsYourName 32−24 BRAKE 8. (a) (b) (c) − BRAKE MASTER CYLINDER SUB−ASSY REMOVE BRAKE MASTER CYLINDER KIT (W/O VSC) Place master cylinder in vise. Remove the O−ring. Push in the piston and remove the snap ring with snap ring pliers. F40004 (d) Push in the piston and remove the piston stopper bolt and gasket. (e) Remove the No.1 piston sub−assy, pulling straight out not at an angle. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. C69097 (f) (A) R12236 Place a waste cloth and 2 wooden blocks on the work table and lightly edges until the No.2 piston sub−assy drops out of the cylinder. HINT: Make sure the distance (A) from the rag the top of the blocks is at least 100 mm (3.94 in.). NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. 9. (a) (b) (c) REMOVE BRAKE MASTER CYLINDER KIT (W/ VSC) Place master cylinder in vise. Remove the O−ring. Push in the piston and remove the snap ring with snap ring pliers. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. F41707 (d) Push in the piston with a screwdriver, and remove the straight pin by turning over the cylinder body. HINT: Tape the screwdriver tip before use. (e) Remove the No.1 and No.2 piston sub−assy and 2 springs by hand, pulling straight out, not at an angle. F09717 WhereEverybodyKnowsYourName 32−25 BRAKE 10. (a) − BRAKE MASTER CYLINDER SUB−ASSY INSPECT MASTER CYLINDER BODY Check the cylinder bore for rust or scoring. 11. (a) (b) INSTALL BRAKE MASTER CYLINDER KIT (W/O VSC) Place master cylinder in vise. Apply the lithium soap base grycol grease on new No.1 and No.2 piston sub−assy. (c) Install the No.2 and No.1 piston sub−assy. NOTICE:
If the piston is inserted at an angle, there is a possibility that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pistons. (d) Push in the piston and install a new gasket and a new piston stopper bolt. Torque: 10 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) C69097 (e) (f) Push in the piston and install the snap ring with snap ring pliers. Apply the lithium soap base grycol grease on a new O− ring and install the O−ring to the master cylinder. F40004 12. (a) (b) INSTALL BRAKE MASTER CYLINDER KIT (W/ VSC) Place master cylinder in vise. Apply the lithium soap base glycol grease on new No.1 and No.2 piston sub−assy. (c) Install the No.2 and No.1 piston sub−assy. NOTICE:
If the piston is inserted at an angle, there is a possibility that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pistons. WhereEverybodyKnowsYourName 32−26 BRAKE − BRAKE MASTER CYLINDER SUB−ASSY (d) Install the straight pin. HINT: Insert the No.2 piston with the groove positioning horizontally. F09718 (e) (f) Push in the piston and install the snap ring with snap ring pliers. Apply the lithium soap base glycol grease on a new O− ring and install the O−ring to the master cylinder. F41707 13. (a) (b) 14. (a) 15. (a) 16. (a) INSTALL MASTER CYLINDER RESERVOIR GROMMET Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets. Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub−assy. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB−ASSY Install the master cylinder reservoir sub−assy to the master cylinder with the screw. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER Install the brake master cylinder reservoir strainer. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY Install the brake master cylinder reservoir filler cap assy. 17. SST (a) (b) (c) (d) F42650 INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD Apply SST to the master cylinder. SST 09737−00013 Set SST, on the master cylinder, lower the pin of the SST until it slightly touches the piston. Apply the chalk to the flat surfaced tip of the SST pin. Turn SST upside down and place it clearance between the brake booster and SST. Clearance: 0 mm (0 in.) HINT:

If there is a clearance between the SST main body and the booster shell. It means that the specified value, and no chalk attachment on the booster push rod means that it is more than the specified value. Brake booster push rod clearance before shipment is adjusted to be
0.105 mm (
0.004 in.). WhereEverybodyKnowsYourName 32−27 BRAKE − BRAKE MASTER CYLINDER SUB−ASSY (e) Using SST, adjust the booster push rod length until the push rod lightly touches the pin head. SST 09737−00020 18. (a) INSTALL BRAKE MASTER CYLINDER SUB−ASSY w/o ABS: Install the master cylinder sub−assy and 3−way with the 2 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) w/ ABS: Install the master cylinder sub−assy and 2−way with the 2 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) SST F40006 (b) F40992 w/o ABS: (c) w/o ABS: Using SST and connect the 5 brake tubes to the master cylinder sub−assy. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) (d) w/ ABS: Using SST and connect the 6 brake tubes to the master cylinder sub−assy. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) Connect the level warning switch connector. F41024 w/ ABS: (e) F40991 19. 20. 21. 22. 23. 24. FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32−4) SST 09023−00101 BLEED BRAKE LINE (See page 32−4) INSTALL AIR CLEANER ASSY CHECK FLUID LEVEL IN RESERVOIR (See page 32−4) CHECK BRAKE FLUID LEAKAGE WhereEverybodyKnowsYourName 32−28 BRAKE GOOD − BRAKE BOOSTER ASSY BRAKE BOOSTER ASSY NO GOOD 320CU−06 ON−VEHICLE INSPECTION 1. (a) 1st 2nd 3rd BR2238 BR2237 INSPECT BRAKE BOOSTER Air tightness check. (1) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. HINT: If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. HINT: If there is no change in the pedal reserve distance after holding the pedal for 30 seconds, the booster is air−tight. (b) Operating check. (1) Depress the brake pedal several times with the ignition switch OFF and check that there is no change in the pedal reserve distance. (2) Depress the brake pedal and start the engine. HINT: If the pedal goes down slightly, operation is normal. 2. INSPECT VACUUM CHECK VALVE (a) Check vacuum check valve. (1) Slide the clip and disconnect the vacuum hose. (2) Remove the vacuum check valve. (3) Ventilation (4) Check that there is ventilation from the booster to engine, and no ventilation from the engine to the booster. If any fault is found, replace the vacuum check valve. No Ventilation C16481 WhereEverybodyKnowsYourName 32−29 BRAKE − BRAKE BOOSTER ASSY 320CV−06 COMPONENTS w/o ABS: Vacuum Hose Assy Vacuum Hose Bracket 5.4 (55, 48 in.⋅lbf) Front Brake Tube No.1 Clip 15 (155, 11) Push Rod Pin 15 (155, 11) Brake Master Cylinder Sub−Assy
Gasket Push Rod Clevis 3−way 13 (130, 9) Clip 13 (130, 9) Brake Booster 13 (130, 9) Front Brake Tube Frame No.1 15 (155, 11) Front Brake Tube No.5 15 (155, 11) w/ ABS: Front Brake Tube No.2 15 (155, 11) Front Brake Tube No.3 2−way 15 (155, 11) 13 (130, 9) 15 (155, 11) Front Brake Tube No.5 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Lithium soap base glycol grease F40997 F46214 WhereEverybodyKnowsYourName 32−30 BRAKE − BRAKE BOOSTER ASSY 3211T−05 REPLACEMENT HINT: COMPONENTS: See page 32−29 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 2. REMOVE AIR CLEANER ASSY 3. REMOVE BRAKE MASTER CYLINDER SUB−ASSY (See page 32−23) SST 09023−00101 4. (a) (b) DISCONNECT VACUUM HOSE ASSY Remove the bolt and separate the vacuum hose from the vacuum hose bracket. Slide the clip and disconnect the vacuum hose from the brake booster. F40995 5. 6. 7. 8. (a) 9. (a) REMOVE FRONT DOOR SCUFF PLATE LH (See page 71−16) REMOVE COWL SIDE TRIM SUB−ASSY LH (See page 71−16) REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) REMOVE PUSH ROD PIN Remove the clip and push rod pin. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS Loosen the lock nut and remove the push rod clevis. 10. (a) REMOVE FRONT BRAKE TUBE NO.5 Using SST and remove the front brake tube No.5. SST 09023−00101 11. (a) (b) REMOVE BRAKE BOOSTER ASSY Remove the 4 nuts. Pull out the brake booster assy. F40996 BR3753 WhereEverybodyKnowsYourName 32−31 BRAKE 12. 13. (a) − BRAKE BOOSTER ASSY REMOVE BRAKE BOOSTER GASKET INSTALL BRAKE BOOSTER GASKET Install a new brake booster gasket to the brake booster. 14. (a) INSTALL BRAKE BOOSTER ASSY Install the brake booster with the 4 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) 15. (a) INSTALL FRONT BRAKE TUBE NO.5 Using SST and install the front brake tube No.5. Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) SST 09023−00101 BR3753 F40996 16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (a) Install the push rod clevis and lock nut. 17. INSTALL PUSH ROD PIN (a) Install the push rod pin and clip. HINT: Apply the lithium soap base glycol grease to the part indicate by arrow (See page 32−29). 18. INSTALL INSTRUMENT PANEL SUB−ASSY UPPER (See page 71−16) 19. INSTALL COWL SIDE TRIM SUB−ASSY LH (See page 71−16) 20. INSTALL FRONT DOOR SCUFF PLATE LH (See page 71−16) 21. (a) (b) INSTALL VACUUM HOSE ASSY Install the vacuum hose and vacuum hose bracket to the body with a bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Connect the vacuum hose to the brake booster with the clip. F40995 22. 23. 24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD SST 09737−00013, 09737−00020 INSTALL BRAKE MASTER CYLINDER SUB−ASSY (See page 32−23) SST 09023−00101 INSTALL AIR CLEANER ASSY WhereEverybodyKnowsYourName 32−32 BRAKE 25. 26. 27. 28. 29. 30. − BRAKE BOOSTER ASSY FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32−4) SST 09023−00101 BLEED BRAKE LINE (See page 32−4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32−8 or 32−14) WhereEverybodyKnowsYourName 32−33 BRAKE − FRONT BRAKE FRONT BRAKE 321BZ−01 COMPONENTS MZ Series (SE, XLE Grade): Front Disc 34 (350, 25) Union Bolt 29 (300, 22) Front Flexible Hose LH Front Disc Brake Bleeder Plug 8.3 (85, 74 in.⋅lbf) Front Disc Brake Cylinder Slide Pin (No.1)
Gasket
Gasket
Piston Seal
Front Disc Brake Bush Dust Boot
Gasket TMC Made: Front Disc Brake Cylinder Mounting LH Front Disc Brake Bleeder Plug Cap
Set Ring 107 (1,090, 79) 34 (350, 25) Front Disc Brake Cylinder Sub−assy 107 (1,090, 79 ) Front Disc Brake Piston
Cylinder Boot Front Disc Brake Cylinder Slide Pin (No.2)
Front Disc Brake Cylinder Slide Bush
Front Disc Brake Bush Dust Boot Pad Wear Indicator Plate Front Disc Brake Pad Support Plate (No.2) Anti−squeal Shim Front Disc Brake Pad Support Plate (No.1) Front Disc Brake Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Anti−squeal Shim
Non−reusable part Lithium soap base glycol grease Disc brake grease WhereEverybodyKnowsYourName F50335 32−34 BRAKE − FRONT BRAKE Except MZ Series (SE, XLE Grade): Front Disc Brake Bleeder Pulg Cap Front Disc Front Disc Brake Bleeder Plug Front Flexible Hose LH 8.3 (85, 74 in.⋅lbf) Front Disc Brake Cylinder Slide Pin (No.1) 34 (350, 25) Union Bolt Front Disc Brake Cylinder Sub−assy 29 (300, 22)
Front Disc Brake Bush Dust Boot
Gasket 107 (1,090, 79)
Gasket
Gasket Front Disc Brake Pad Support Plate (No.1) TMC Made: 34 (350, 25)
Piston Seal Front Disc Brake Piston Front Disc Brake Cylinder Slide Pin (No.2)
Cylinder Boot
Set Ring
Front Disc Brake Cylinder Slide Bush Anti−squeal Shim No.2
Front Disc Brake Bush Dust Boot 107 (1,090, 79) Front Disc Brake Cylinder Mounting LH Pad Wear Indicator Plate Front Disc Brake Pad Support Plate (No.2) Anti−squeal Shim No.1 Anti−squeal Shim No.1 Front Disc Brake Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Anti−squeal Shim No.2
Non−reusable part Lithium soap base glycol grease Disc brake grease WhereEverybodyKnowsYourName F50749 32−35 BRAKE − FRONT BRAKE 321C0−03 OVERHAUL HINT:

Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 3. DISCONNECT FRONT FLEXIBLE HOSE (a) Remove the union bolt and the gasket(s) from the disc brake cylinder sub−assy, then disconnect the flexible hose. HINT: Gasket has 2 types: 2−piece type and 1−piece type. 4. Hold (a) Turn REMOVE FRONT DISC BRAKE CYLINDER SUB−ASSY Hold the front disc brake cylinder slide pin (No.1) and slide pin (No.2), and remove the 2 bolts. C97868 5. (a) REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) Remove the 2 disc brake pads with anti−squeal shims from the front disc brake cylinder mounting LH. 6. (a) (b) (c) REMOVE ANTI SQUEAL SHIM KIT FRONT MZ Series (SE, XLE Grade): Remove the 2 anti−squeal shims from each pad. Except MZ Series (SE, XLE Grade): Remove the 4 anti−squeal shims from each pad. Using a screwdriver, remove the pad wear indicator plates from each pad. F41535 7. (a) REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE Remove the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) from the front disc brake cylinder mounting LH. WhereEverybodyKnowsYourName 32−36 BRAKE 8. (a) No.1 − FRONT BRAKE REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN Remove the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2) from the front disc brake cylinder mounting LH. No.2 F45565 9. Cylinder Slide Bush Pin (No.2) REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH (a) Using a screwdriver, remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin (No.2). NOTICE: Do not damage the front disc brake cylinder slide pin (No.2). F45566 10. (a) REMOVE FRONT DISC BRAKE CYLINDER MOUNTING Remove the 2 bolts and front disc brake cylinder mounting LH. F45344 11. (a) (b) REMOVE FRONT DISC BRAKE BUSH DUST BOOT Hold the front disc brake cylinder mounting LH in the vise through the soft jaws. Using a screwdriver and a hammer, remove the 2 front disc brake bush dust boots from the front disc brake cylinder mounting LH. C68791 12. (a) REMOVE CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot. NOTICE: Do not damage the piston groove and cylinder groove. R09298 WhereEverybodyKnowsYourName 32−37 BRAKE − FRONT BRAKE 13. (a) Shop Rag C97869 REMOVE FRONT DISC BRAKE PISTON Place a shop rag between the front disc brake piston and the disc brake cylinder sub−assy. (b) Use compressed air to remove the front disc brake piston from the disc brake cylinder sub−assy. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid. 14. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the front disc brake cylinder sub−assy. NOTICE: Do not damage the inner cylinder and cylinder groove. G23223 15. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 16. REMOVE FRONT DISC BRAKE BLEEDER PLUG 17. INSPECT BRAKE CYLINDER AND PISTON (a) Check the brake cylinder bore and front disc brake piston for rust or scoring. If necessary, replace the brake cylinder and piston. 18. INSPECT PAD LINING THICKNESS Ruler (a) Using a ruler, measure the pad lining thickness. Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad. R02951 19. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE (a) Inspect the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2). HINT: Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt is cleaned off. If necessary, replace the brake pad support plate. WhereEverybodyKnowsYourName 32−38 BRAKE − FRONT BRAKE 20. (a) INSPECT DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) If the disc thickness is less than the minimum, replace the disc. Micrometer F42895 21. REMOVE FRONT DISC (a) Put matchmarks on the front disc and the axle hub. (b) Remove the front disc. 22. INSTALL FRONT DISC (a) Aligning the matchmarks, install the front disc. HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout. Matchmarks F41543 23. (a) 24. 25. 26. (a) (b) INSPECT DISC RUNOUT Check the bearing play in the axial direction and check for the axle hub runout (see page 30−2). (b) Temporarily fasten the front disc together with the hub nuts. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) (c) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the front disc. Dial Indicator Maximum disc runout: 0.05 mm (0.0020 in.) C97900 If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP INSTALL PISTON SEAL Apply lithium soap base glycol grease to a new piston seal. Install the piston seal to the front disc brake cylinder sub−assy. 27. (a) Lithium soap base glycol grease F45277 INSTALL FRONT DISC BRAKE PISTON Apply lithium soap base glycol grease to the front disc brake piston and new cylinder boot. (b) Install the cylinder boot to the front disc brake piston. (c) Install the front disc brake piston to the front disc brake cylinder sub−assy. NOTICE: Do not install the piston forcibly in the front disc brake cylinder sub−assy. WhereEverybodyKnowsYourName 32−39 BRAKE Cylinder Boot − FRONT BRAKE 28. (a) Front Disc Brake Piston Set Ring F42832 INSTALL CYLINDER BOOT Install the cylinder boot to the front disc brake cylinder sub−assy. NOTICE: Install the boot securely to the grooves of the cylinder and piston. (b) Using a screwdriver, install the set ring. NOTICE: Do not damage the cylinder boot. 29. (a) 30. (a) (b) INSTALL FRONT DISC BRAKE BUSH DUST BOOT Hold the front disc brake cylinder mounting LH in the vise through the soft jaws. (b) Place the front disc brake cylinder mounting LH in the vise. (c) Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots (see page 32−33). (d) Using a socket wrench (19 mm) and a hammer, drive the C68792 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH Apply lithium soap base glycol grease to a new front disc brake cylinder slide bush (see page 32−33). Install the cylinder slide bush to the bottom side of the front disc brake cylinder slide pin (No.2). 31. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING (a) Install the front disc brake cylinder mounting with the 2 bolts. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) F45344 No.1 32. (a) No.2 (b) Lithium soap base glycol grease INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN Apply lithium soap base glycol grease to the sliding part and the sealing surface of the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2). Install the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2) to the front disc brake cylinder mounting LH. F45565 33. (a) INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE Install the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) to the front disc brake cylinder mounting LH. NOTICE: Install the pad support plates in the correct position and direction. WhereEverybodyKnowsYourName 32−40 BRAKE MZ Series (SE, XLE Grade): Indicator Plate Shim Brake Pad FRONT BRAKE 34. INSTALL ANTI SQUEAL SHIM KIT FRONT NOTICE:
When replacing worn pads, the anti−squeal shims must be replaced together with the pads.
Install the shims and pad wear indicator plates in the correct position and direction. (a) Apply disc brake grease to the anti−squeal shims as shown in the illustration. (b) Install the anti−squeal shims on each pad as shown in the illustration. (c) Install the pad wear indicator plates to each pad. Shim Except MZ Series (SE, XLE Grade): Shim No.2 − Indicator Plate Shim No.2 Shim No.1 Brake Pad Shim No.1 Disc brake grease F50334 35. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Install the disc brake pad kit front to the front disc brake cylinder mounting LH. NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
Brake pads are installed with indicator plates facing upward. 36. INSTALL FRONT DISC BRAKE CYLINDER SUB−ASSY (a) Install the front disc brake cylinder sub−assy with the 2 Hold bolts. Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) Turn C97868 37. (a) INSTALL FRONT FLEXIBLE HOSE Install new gasket(s) and flexible hose with the union bolt. Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf) NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder. HINT: Gasket has 2 types: 2−piece type and 1−piece type. 38. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32−4) 39. BLEED MASTER CYLINDER (SEE PAGE 32−4) SST 09023−00101 WhereEverybodyKnowsYourName 32−41 BRAKE 40. 41. 42. 43. − FRONT BRAKE BLEED BRAKE LINE (SEE PAGE 32−4) CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32−4) CHECK FOR BRAKE FLUID LEAKAGE INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 32−4 BRAKE − BRAKE FLUID BRAKE FLUID 3211S−02 BLEEDING HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 1. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS No. 116 DOT3 F41694 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Remove the air cleaner assembly with hose. (b) Disconnect the brake lines from the master cylinder. SST 09023−00101 (c) Slowly depress the brake pedal and hold it. F41695 (d) (e) (f) Block off the outer holes with your fingers, and release the brake pedal. Repeat (c) and (d) 3 or 4 times. Install the air cleaner assembly with hose. F41696 3. (a) (b) (c) (d) C80826 (e) BLEED BRAKE LINE Connect the vinyl tube to the brake caliper. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Repeat (b) and (c) until all the air in the fluid has been bled out. Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 74 in.⋅lbf) WhereEverybodyKnowsYourName 32−5 BRAKE − BRAKE FLUID (f) Hand−held Tester DLC3 G23361 Repeat the above procedure to bleed the air out of the brake line for each wheel. 4. BLEED BRAKE ACTUATOR ASSY (W/ VSC) NOTICE: After performing the usual air bleeding in the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding in the BRAKE actuator assy with a hand−held tester by following procedures below. (a) Depress the brake pedal more than 20 times with the engine off. (b) Connect the hand−held tester to the DLC3, then turn the ignition switch to the ON position. NOTICE: Do not start the engine. (c) Select ”AIR BLEEDING” on the hand−held tester. HINT: Please refer to the Hand−Held Tester Operator’s Manual for further details. (d) Bleed the air out of the regular brake line in ”Step1: Increase” on the hand−held tester display. NOTICE:
Perform the air bleeding by following the steps displayed on the hand−held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. (1) Connect the vinyl tube to either one of the bleeder plugs. (2) C80826 Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed. (3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (4) Repeat (2) and (3) until all air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (6) Repeat the above procedure to bleed the air out of the brake line for each wheel. (e) Bleed the air out of the suction line in ”Step2: Inhalation” on the hand−held tester display. NOTICE:
Perform the air bleeding by following the steps displayed on the hand−held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. WhereEverybodyKnowsYourName 32−6 BRAKE (1) (2) − BRAKE FLUID Connect the vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug. Operate the BRAKE actuator assy using the hand− held tester to bleed the air. NOTICE:
The operation stops automatically in 4 seconds.
At this time, be sure to release the brake pedal. (3) Check that the operation has stopped, by referring to the hand−held tester display. (4) Repeat (2) and (3) until all the air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (6) For the rest of the wheels, bleed the air in the same way as stated in the above procedure. (f) Bleed the air out of the pressure reduction line in ”Step3: Decrease” on the hand−held tester display. NOTICE:
Perform air bleeding by following the steps displayed on the hand−held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. (1) Connect a vinyl tube to either one of the bleeder plugs. (2) Loosen the bleeder plug. (3) Using the hand−held tester, operate the BRAKE actuator assy using hand−held tester, completely depress the brake pedal and keep it. NOTICE:
The operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required.
When the operation is completed, the brake pedal slightly goes down. This is a normal phenomenon caused when the solenoid opens.
During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.
Be sure to keep depressing the brake pedal. Never depress and release the pedal repeatedly. (4) Tighten the bleeder plug, then release the brake pedal. (5) Repeat (2) to (4) until all the air in the fluid is completely bled out. (6) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (7) Repeat the above procedure to bleed the air out of the brake line for each wheel. WhereEverybodyKnowsYourName 32−7 BRAKE − BRAKE FLUID (g) Bleed the air out of the regular brake line again in ”Step4: Increase” on the hand−held tester display. NOTICE:
Perform air bleeding by following the steps displayed on the hand−held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. (1) Connect the vinyl tube to either one of the bleeder plug. (2) Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed. (3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (4) Repeat (2) and (3) until all the air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (6) Repeat the above procedure to bleed the air out of the brake line for each wheel. C80826 5. (a) CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 F41007 WhereEverybodyKnowsYourName 32−42 BRAKE − REAR DISC BRAKE REAR DISC BRAKE 320D2−03 COMPONENTS TMC made: Rear Disc Brake Cylinder Slide Pin Union Bolt 29.4 (300, 22) 34.3 (350, 25) Rear LH Flexible Hose Rear Disc Brake Bleeder Plug Cap Rear Disc Brake Bleeder Plug
Rear Disc Brake Cylinder Slide Bush 8.3 (85, 74 in.⋅lbf)
Gasket Disc Brake Cylinder Assy Rear LH
Piston Seal Rear Disc Brake Disc Brake Piston
Set Ring Anti Squeal Shim No.1
Rear Disc Brake Bush Dust Boot Rear Disc Brake Cylinder Slide Pin Anti Squeal Shim No.2
Cylinder Boot 39.2 (400, 29) Rear Disc Brake Pad Rear Disc Brake Pad Support Plate No.1 Rear Disc Brake Pad Support Plate No.2 Pad Wear Indicator Plate Rear Disc Brake Pad 61.8 (630, 46) Rear Disc Rear Disc Brake Cylinder Mounting LH 61.8 (630, 46) Pad Wear Indicator Plate Parking Brake Shoe Adjusting Hole Plug Anti Squeal Shim No.2 Anti Squeal Shim No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Lithium soap base glycol grease Disc brake grease WhereEverybodyKnowsYourName F41546 32−43 BRAKE − REAR DISC BRAKE Rear Disc Brake Cylinder Slide Pin TMMK made: 43 (440, 32) Union Bolt 29.4 (300, 22)
Gasket 47 (475, 34) Cylinder Slide Bush Rear Disc Rear Disc Brake Cylinder Assembly LH Parking Brake Shoe Adjusting Hole Plug Rear Disc Brake Bleeder Plug Cap Rear Disc Brake Cylinder Slide Pin 8.3 (85, 74 in.⋅lbf) Rear Disc Brake Cylinder LH
Piston Seal
Rear Disc Brake Bush Dust Boot Rear Disc Brake Disc Brake Piston
Cylinder Boot Rear Disc Brake Pad
Set Ring Anti−Squeal Shim No.3 Anti−Squeal Shim No.4 Rear Disc Brake Pad Support Plate No.1 Pad Wear Indicator Plate Rear Disc Brake Pad Anti−Squeal Shim No.1 Rear Disc Brake Cylinder Mounting LH Rear Disc Brake Pad Support Plate No.2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Lithium soap base glycol grease Disc brake grease WhereEverybodyKnowsYourName Anti−Squeal Shim No.2 F41706 32−44 BRAKE − REAR DISC BRAKE 320D3−05 OVERHAUL HINT:


COMPONENTS: See page 32−42 Overhaul the RH side by the same procedures with LH side. Two types of brake pad exist; one is with slit and the other without slit. 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 3. DISCONNECT REAR LH FLEXIBLE HOSE (a) Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder. HINT: Gasket has 2 types: 2−piece type and 1−piece type. 4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN (a) TMC made: Remove the cylinder slide pin. (b) TMMK made: Remove the cylinder slide pin and cylinder slide bush. 5. REMOVE REAR DISC BRAKE CYLINDER ASSY LH (a) TMC made: Lift up the disc brake cylinder and remove the disc brake cylinder. (b) TMMK made: Remove the cylinder slide pin and disc brake cylinder. 6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY) (a) Remove the 2 brake pads with the anti−squeal shim. 7. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT (a) Remove the 2 anti−squeal shims and pad wear indicator from each of 2 brake pads. (b) TMC made: Remove the 2 pad wear indicator plates from each of 2 brake pads. (c) TMMK made: Remove the pad wear indicator plate from inner pad. 8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the rear disc brake pad support plate No.1. 9. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the rear disc brake pad support plate No.2. 10. REMOVE REAR DISC BRAKE BUSH DUST BOOT (a) TMC made: Remove the rear disc brake bush dust boot. (b) TMMK made: Remove the 2 rear disc brake bush dust boots. 11. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH (a) TMC made: Using a hexagon wrench (φ8 mm), remove the cylinder slide pin. (b) Remove the 2 bolts and cylinder mounting LH. 12. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the set ring and disc cylinder boot. WhereEverybodyKnowsYourName 32−45 BRAKE − REAR DISC BRAKE 13. (a) C82872 REMOVE REAR DISC BRAKE PISTON Place a piece of cloth or similar, between the piston and the disc brake cylinder. (b) Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid. 14. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the brake cylinder. NOTICE: Do not damage the inner cylinder and the cylinder groove. 15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP 16. REMOVE REAR DISC BRAKE BLEEDER PLUG 17. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. 18. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) 19. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE (a) Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt cleaned off. 20. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE (a) Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt and cleaned off. 21. (a) INSPECT DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 10.5 mm (0.413 in.) F41554 22. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG 23. REMOVE REAR DISC (a) Put matchmarks on the disc and the axle hub. (b) Remove the disc. 24. INSTALL REAR DISC (a) Aligning the matchmarks, install the rear disc. HINT: When replacing the disc with new one, select the installation position where the disc has the minimum runout. 25. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG WhereEverybodyKnowsYourName 32−46 BRAKE − REAR DISC BRAKE 26. (a) INSPECT DISC RUNOUT Temporarily fasten the disc with hub nuts. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) (b) Using dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.15 mm (0.0059 in.) (c) If the disc’s runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. (See page 30−2)If the bearing play and axle hub F41556 runout are not abnormal, adjust the disc runout or grind it on a ”On−car” brake lathe. 27. ADJUST PARKING BRAKE SHOE CLEARANCE (See page 33−19) 28. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG (a) Temporarily tighten the bleeder plug to the disc brake cylinder. 29. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP 30. INSTALL PISTON SEAL (a) Apply the lithium soap base glycol grease on a new piston seal. (b) Install the piston seal to the disc brake cylinder. 31. INSTALL REAR DISC BRAKE PISTON (a) Apply the lithium soap base glycol grease on the piston. (b) Install the piston to the disc brake cylinder. NOTICE: Do not screw the piston forcedly in the disc brake cylinder. 32. INSTALL CYLINDER BOOT (a) Apply the lithium soap base glycol grease on a new cylinder boot. (b) Install the cylinder boot to the disc brake cylinder. HINT: Install the boot securely to the grooves of the cylinder and piston. (c) Using a screwdriver, install a new set ring. NOTICE: Do not damage the cylinder boot. 33. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH (a) Install the cylinder mounting LH with the 2 bolts. Torque: TMC made: 61.8 N⋅m (630 kgf⋅cm, 46 ft⋅lbf) TMMK made: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf) 34. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN (a) TMC made: Using a hexagon wrench (8 mm), install the cylinder slide pin. Torque: 39.2 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (b) TMMK made: Install the cylinder slide pin with the cylinder slide bush. Torque: 43 N⋅m (440 kgf⋅cm, 32 ft⋅lbf) WhereEverybodyKnowsYourName 32−47 BRAKE Cylinder Mounting Cylinder Slide Pin 35. (a) (b) − REAR DISC BRAKE INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH (TMC MADE) Apply the lithium soap base glycol grease on a new cylinder slide bush. Install the cylinder slide bush to the disc brake cylinder assy. C88526 F41966 INSTALL REAR DISC BRAKE BUSH DUST BOOT TMC made: Install the rear disc brake bush dust boot. (1) Apply the lithium soap base glycol grease to seal surface of a new bush dust boot. (2) Install the bush dust boot to the cylinder slide pin. (b) TMMK made: Install the rear disc brake bush dust boot. Cylinder Mounting (1) Apply the lithium soap base glycol grease to seal F41562 surface of a 2 new bush dust boots. (2) Install the 2 bush dust boots to the each cylinder slide pin. 37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the rear disc brake pad support plate No.1. 38. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the rear disc brake pad support plate No.2. 39. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT (a) Coat the both sides of No.1 anti−squeal shim with pad grease all over, and install the shim together with No.2 anti−squeal shim to each pad. (b) TMC made: Install the 2 pad wear indicator plates to the each of 2 brake pads. NOTICE: When replacing worn pads, the anti−squeal shims must be replaced together with the pads. (c) TMMK made: Install the pad wear indicator plate to the inner pad. NOTICE: When replacing worn pads, the anti−squeal shims must be replaced together with the pads. 40. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY) (a) Install the 2 brake pads with the anti−squeal shim. NOTICE: There should be no oil or grease on to the friction surface of the pads and the disc. 41. INSTALL REAR DISC BRAKE CYLINDER ASSY LH (TMC MADE) (a) Apply the lithium soap base glycol grease to the cylinder slide pin. (b) Install the disc brake cylinder assembly rear LH to the cylinder slide pin. 42. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN (a) Apply the lithium soap base glycol grease to the cylinder slide pin. (b) Install and torque the cylinder slide pin to the disc brake cylinder assembly. Torque: TMC made: 34.3 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) TMMK made: 43 N⋅m (440 kgf⋅cm, 32 ft⋅lbf) TMC made: Cylinder Slide Pin 36. (a) WhereEverybodyKnowsYourName 32−48 BRAKE 43. (a) 44. 45. 46. 47. 48. 49. − REAR DISC BRAKE CONNECT REAR LH FLEXIBLE HOSE Connect a new gasket and flexible hose with the union bolt. Torque: 29.4 N⋅m (300 kgf⋅cm, 22 ft⋅lbf) FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32−4) SST 09023−00101 BLEED BRAKE LINE (See page 32−4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 32−49 BRAKE − REAR DRUM BRAKE REAR DRUM BRAKE 320D4−03 COMPONENTS Parking Brake Shoe Strut Set LH Rear Disc Brake Bleeder Plug Rear Disc Brake Bleeder Plug Cap 8.3 (85, 74 in.·lbf) Cylinder Dust Boot Wheel Cylinder 10 (100, 7) Parking Brake Shoe Lever Compression Spring
C−washer Automatic Adjusting Lever LH 15.2 (155, 11)
Cup Piston Plug E−ring Adjusting Lever Spring Parking Brake Shoe Strut Set LH Inspection Hole Plug Shoe Hold−down Spring Rear Brake Shoe Pin Tension Spring Front Brake Shoe Cup N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part Lithium soap base glycol grease High temperature grease Rear Brake Drum Sub−assy WhereEverybodyKnowsYourName F41708 32−57 BRAKE − BRAKE ACTUATOR ASSY (W/O VSC) BRAKE ACTUATOR ASSY (W/O VSC) 3203J−10 ON−VEHICLE INSPECTION 1. CONNECT HAND−HELD TESTER: (a) Connect the hand−held tester to the DLC3. (b) Start the engine and run it at idle. (c) Select the ACTIVE TEST mode on the hand−held tester. HINT: Please refer to the hand−held tester operator’s manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay ON, check the actuator motor operation noise. (b) Turn the motor relay OFF. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d) With the motor relay ON, check that the pedal does not pulsate. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Never turn ON the solenoid which is not described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay ON, and check that the pedal returns. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 4. INSPECT OTHER WHEEL OPERATION (a) As in the same procedure, check the solenoids of other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR WhereEverybodyKnowsYourName 32−58 BRAKE − BRAKE ACTUATOR ASSY (W/O VSC) 320CQ−05 REPLACEMENT 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluied immediately if it comes into contact with a painted surface. 2. (a) DENSO made: REMOVE BRAKE ACTUATOR WITH BRACKET Using SST, disconnect the 6 brake lines from the actuator. SST 09023−00101 BOSCH made: F40998 F45684 F46202 WhereEverybodyKnowsYourName 32−59 BRAKE DENSO made: (b) To RL W/C To FR W/C (c) (d) From M/C 2nd From M/C 1st − BRAKE ACTUATOR ASSY (W/O VSC) Use tags or make a memo to identify the place to reconnect. Disconnect the brake actuator connector. Remove the 3 nuts and brake actuator with bracket. To FL W/C To RR W/C BOSCH made: From M/C 2nd To FL W/C To RR W/C To RL W/C From M/C 1st To FR W/C C84798 F45685 3. (a) 4. (a) F46203 REMOVE BRAKE ACTUATOR ASSY Remove the 2 nuts and brake actuator from the bracket. INSTALL BRAKE ACTUATOR ASSY Install the brake actuator to the bracket with the 2 nuts. Torque: DENSO made: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) BOSCH made: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) WhereEverybodyKnowsYourName 32−60 BRAKE 5. (a) DENSO made: (b) − BRAKE ACTUATOR ASSY (W/O VSC) INSTALL BRAKE ACTUATOR WITH BRACKET Install the brake actuator with the 3 nuts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Connect the brake actuator connector. BOSCH made: F46133 F46204 F46215 DENSO made: (c) To RL W/C To FR W/C From M/C 2nd From M/C 1st Using SST, connect the each brake line to the correct position of brake actuator, as shown in the illustration. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) To FL W/C To RR W/C BOSCH made: From M/C 2nd To FL W/C To RR W/C To RL W/C From M/C 1st To FR W/C C84798 F45685 F46203 WhereEverybodyKnowsYourName 32−61 BRAKE 6. 7. 8. 9. 10. 11. − BRAKE ACTUATOR ASSY (W/O VSC) FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32−4) SST 09023−00101 BLEED BRAKE LINE (See page 32−4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE CHECK OPERATION OF BRAKE ACTUATOR (See page 32−4) WhereEverybodyKnowsYourName 32−62 BRAKE − BRAKE ACTUATOR ASSY (W/ VSC) BRAKE ACTUATOR ASSY (W/ VSC) 3203L−07 ON−VEHICLE INSPECTION 1. CONNECT HAND−HELD TESTER: (a) Connect the hand−held tester to the DLC3. (b) Start the engine and run it at idle. (c) Select the ACTIVE TEST mode on the hand−held tester. HINT: Please refer to the hand−held tester operator’s manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay ON, check the actuator motor operation noise. (b) Turn the motor relay OFF. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d) With the motor relay ON, check that the pedal does not pulsate. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Never turn ON the solenoid which is not described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay ON, and check that the pedal returns. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 4. INSPECT OTHER WHEEL OPERATION (a) As in the same procedure, check the solenoids of other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR WhereEverybodyKnowsYourName 32−63 BRAKE − BRAKE ACTUATOR ASSY (W/ VSC) 3211U−04 REPLACEMENT 1. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluied immediately if it comes into contact with a painted surface. 2. REMOVE BRAKE ACTUATOR WITH BRACKET (a) Using SST, disconnect the 6 brake lines from the actuator. SST 09023−00101 (b) Use tags or make a memo to identify the place to reconnect. (c) Disconnect the actuator connector. F45680 From M/C 1st From M/C 2nd To FR W/C To FL W/C To RR W/C To RL W/C F45681 F45682 WhereEverybodyKnowsYourName 32−64 BRAKE (d) − BRAKE ACTUATOR ASSY (W/ VSC) Remove the 3 nuts and brake actuator with bracket. F45683 3. (a) 4. (a) REMOVE BRAKE ACTUATOR ASSY Remove the 2 nuts and BRAKE actuator from the bracket. INSTALL BRAKE ACTUATOR ASSY Install the BRAKE actuator to the bracket with the 2 nuts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 5. (a) (b) INSTALL BRAKE ACTUATOR WITH BRACKET Install the brake actuator with the 3 nuts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Connect the brake actuator connector. F45683 (c) From M/C 1st From M/C 2nd Using SST, connect the each brake line to the correct position of brake actuator, as shown in the illustration. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) To FR W/C To FL W/C To RR W/C To RL W/C F45681 6. 7. 8. FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32−4) SST 09023−00101 BLEED BRAKE LINE (See page 32−4) WhereEverybodyKnowsYourName 32−65 BRAKE 9. 10. 11. 12. − BRAKE ACTUATOR ASSY (W/ VSC) BLEED BRAKE ACTUATOR ASSY (See page 32−4) SST 09992−00242, 09992−00350 CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE CHECK OPERATION OF BRAKE ACTUATOR (See page 32−28) WhereEverybodyKnowsYourName 32−66 BRAKE − SPEED SENSOR FRONT LH SPEED SENSOR FRONT LH 3203N−12 REPLACEMENT HINT: Replace the RH side by the same procedures with LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT FENDER LINER LH 3. (a) REMOVE SPEED SENSOR FRONT LH Disconnect the speed sensor connector and clamp. (b) Remove the 2 clamp bolts holding the sensor harness and clamp from the body and shock absorber. F41016 F41018 F41017 (c) Remove the bolt and speed sensor FR LH. NOTICE: Do not stick and foreign matter on the sensor tip. C84803 WhereEverybodyKnowsYourName 32−67 BRAKE − SPEED SENSOR FRONT LH 4. (a) INSTALL SPEED SENSOR FRONT LH Install the speed sensor FR LH with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Make sure the sensor tip is clean. C84803 (b) A (c) Install the sensor harness clamps with the 2 bolts ”A” and ”B” to the body and shock absorber. Torque: Bolt A: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Bolt B: 18.8 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) Connect the clamp to the knuckle. (d) Connect the speed sensor connector and clamp. B F41018 F41017 F41016 5. 6. 7. INSTALL FRONT FENDER LINER LH INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) CHECK ABS SPEED SENSOR SIGNAL (See page 05−873, 05−933 or 05−990) WhereEverybodyKnowsYourName 32−68 BRAKE − SKID CONTROL SENSOR SKID CONTROL SENSOR 320CS−06 REPLACEMENT HINT: Replace the RH side by the same procedure with LH side. 1. REMOVE REAR WHEEL 2. (a) DISCONNECT SKID CONTROL SENSOR WIRE Disconnect the connector from the skid control sensor. F40301 3. 4. REMOVE REAR DISC BRAKE CALIPER ASSY LH (See page 32−44) REMOVE REAR DISC 5. (a) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and rear axle hub & bearing assy. C83035 WhereEverybodyKnowsYourName 32−69 BRAKE − SKID CONTROL SENSOR 6. REMOVE SKID CONTROL SENSOR (a) Mount the rear axle hub in a soft jaw vise. NOTICE: Replace the axle hub assembly if it is dropped or a strong shock is given to it. (b) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. (c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the rear axle hub. SST 09520−00031 (09520−00040), 09521−00020, 09950−00020 NOTICE:
If a damage is inflicted to the sensor rotor, replace the axle hub assembly.
Do not scratch the contacting surface of axle hub and speed sensor. 7. INSTALL SKID CONTROL SENSOR (a) Clean the contacting surface of the axle hub and a new skid control sensor. NOTICE: Make sure the sensor rotor is clean. SST Bolt SST F40303 (b) LH RH Place the speed sensor on the axle hub so that the connector is positioned, as shown in the illustration. F40302 (c) SST F40304 Using SST and a press, install the skid control sensor to the axle hub. SST 09830−36010, 09950−60010 (09951−00650), 09950−70010 (09951−07100) NOTICE:
Do not tap the skid control sensor with a hammer directly.
Check that the skid control sensor detection part is clean.
Press in the skid control sensor straight and slowly. WhereEverybodyKnowsYourName 32−70 BRAKE 8. (a) − SKID CONTROL SENSOR INSTALL REAR AXLE HUB & BEARING ASSY LH Install the rear axle hub & bearing assy with the 4 bolts. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) C83035 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. INSTALL REAR DISC INSTALL REAR DISC BRAKE CALIPER ASSY LH (See page 32−44) CONNECT SKID CONTROL SENSOR WIRE INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT TIRE (See page 28−1) MEASURE VEHICLE HEIGHT (See page 26−5) INSPECT SIDE SLIP (See page 27−3) INSPECT CAMBER (See page 27−3) INSPECT TOE−IN (See page 27−3) ADJUST CAMBER AND TOE−IN (See page 27−3) CHECK ABS SPEED SENSOR SIGNAL (See page 05−873, 05−938 or 05−1002) WhereEverybodyKnowsYourName 32−71 BRAKE − YAWRATE SENSOR YAWRATE SENSOR 320D6−07 REPLACEMENT NOTICE: Do not separate the sensor from the bracket. 1. REMOVE CONSOLE PANEL UPPER REAR (See page 71−16) 2. REMOVE RR CONSOLE BOX (See page 71−16) 3. (a) (b) REMOVE YAWRATE SENSOR Disconnect the yawrate sensor connector. Remove the 2 bolts and yawrate sensor. 4. (a) INSTALL YAWRATE SENSOR Install the yawrate sensor with the 2 bolts. Torque: 12.5 N⋅m (127 kgf⋅cm, 9 ft⋅lbf) Connect the yawrate sensor connector. F45687 (b) F45687 5. 6. 7. INSTALL RR CONSOLE BOX (See page 71−16) INSTALL CONSOLE PANEL UPPER REAR (See page 71−16) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05−987) WhereEverybodyKnowsYourName 32−72 BRAKE − STEERING SENSOR STEERING SENSOR 3203S−10 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. (a) 15. 16. 17. 18. 19. 20. 21. PRECAUTION (See page 60−1) SEPARATE BATTERY NEGATIVE TERMINAL PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL COVER LOWER NO.2 REMOVE STEERING WHEEL COVER LOWER NO.2 (4 SPOKE STEERING WHEEL ASSY) REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) REMOVE HORN BUTTON ASSY (See page 60−25) REMOVE STEERING WHEEL ASSY (See page 50−9 or 50−21) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page 71−16) REMOVE STEERING COLUMN COVER (See page 50−9) REMOVE SPIRAL CABLE SUB−ASSY (See page 60−34) REMOVE STEERING SENSOR INSTALL STEERING SENSOR INSPECT SPIRAL CABLE SUB−ASSY If the following condition is identified, replace the spiral cable sub−assy with new one. Condition: Scratches or cracks on the connector Cracks, dents or chipping of the spiral cable sub−assy PLACE FRONT WHEELS FACING STRAIGHT AHEAD INSTALL SPIRAL CABLE SUB−ASSY (See page 60−34) CENTER SPIRAL CABLE (See page 60−34) INSTALL STEERING WHEEL ASSY (See page 50−9) INSTALL HORN BUTTON ASSY (See page 60−25) INSPECT HORN BUTTON ASSY (See page 60−25) INSPECT SRS WARNING LIGHT (See page 05−1464) WhereEverybodyKnowsYourName 32−73 BRAKE − ADJUSTABLE PEDAL SWITCH ADJUSTABLE PEDAL SWITCH 320N2−03 INSPECTION 1. (a) REMOVE ADJUSTABLE PEDAL SWITCH Using a screwdriver, remove the adjustable pedal switch, then disconnect the connector. 2. INSPECT ADJUSTABLE PEDAL SWITCH F16912 Switch position Tester connection Specified condition OFF 1−2−3 Continuity 1−3 FRONT 4 3 2 1 REAR F42753 3. (a) (b) 2−4 1−2 3−4 Continuity Continuity INSTALL ADJUSTABLE PEDAL SWITCH Connect the connector. Install the adjustable pedal switch. WhereEverybodyKnowsYourName 32−74 BRAKE − ADJUSTABLE PEDAL RELAY ADJUSTABLE PEDAL RELAY 320N3−03 INSPECTION Engine Room J/B: Adjustable Pedal Relay 1. (a) REMOVE ADJUSTABLE PEDAL RELAY Remove the adjustable pedal relay from the engine room J/B. 2. INSPECT ADJUSTABLE PEDAL RELAY F42754 Condition 3 Constant Apply +B between terminals 1 and 2 5 2 1 3. (a) Tester condition Specified condition 1−2 Continuity 3−5 No continuity 3−5 continuity INSTALL ADJUSTABLE PEDAL RELAY Install the adjustable pedal relay to the engine room J/B. F42755 WhereEverybodyKnowsYourName 32−8 BRAKE − BRAKE PEDAL SUPPORT ASSY BRAKE PEDAL SUPPORT ASSY 321BV−01 ADJUSTMENT 1. (a) Normal type: (b) Push Rod Stop Lamp Switch Assy Pedal Height F41697 Link type: Stop Lamp Switch Assy CHECK AND ADJUST BRAKE PEDAL HEIGHT Inspect brake pedal height. Pedal height from asphalt sheet: 144.1 − 154.1 mm (5.673 − 6.067 in.) Adjust brake pedal height. (1) Remove the instrument panel finish panel sub− assy lower and instrument panel insert sub−assy lower LH. (2) Disconnect the connector from the stop lamp switch assy. (3) Loosen the stop lamp switch lock nut and remove the stop lamp switch assy. (4) Loosen the clevis lock nut. (5) Adjust the pedal height by turning the pedal push rod. (6) Tighten the push rod lock nut. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) (7) Install the stop lamp switch assy. (8) Connect the connector to the stop lamp switch assy. (9) Push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off. (10) After installation, push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), check that stop lamp lights up. (11) Install the instrument panel insert sub−assy lower LH and instrument panel finish panel sub−assy lower. Push Rod Pedal Height F42749 WhereEverybodyKnowsYourName 32−9 BRAKE − BRAKE PEDAL SUPPORT ASSY 2. (a) CHECK PEDAL FREE PLAY Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown. Pedal free play: 1 − 6 mm (0.04 − 0.24 in.) If incorrect, check the stop lamp switch assy clearance. If the clearance is OK, then troubleshoot the brake system. Stop lamp switch clearance: 0.5 − 2.5 mm (0.020 − 0.098 in.) Normal type: Pedal Free Play F41698 Link type: Pedal Free Play F42750 3. (a) CHECK PEDAL RESERVE DISTANCE Release the parking brake pedal. With engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 63 mm (2.48 in.) If incorrect, troubleshoot the brake system. Pedal Reserve Distance R00934 WhereEverybodyKnowsYourName 51−1 POWER STEERING − POWER STEERING SYSTEM POWER STEERING SYSTEM 5105K−03 PRECAUTION 1. (a) HANDLING PRECAUTIONS ON STEERING SYSTEM Care must be taken to when replacing parts. Incorrect replacement could affect the performance of the steering system and result in a driving hazard. (b) 1MZ−FE/3MZ−FE engine has 2 types of vane pump assy. HINT: TYPE A VANE PUMP: Vane pump pulley can be removed from the vane pump shaft (See page 51−15). TYPE B VANE PUMP: Vane pump pulley cannot be removed from the vane pump shaft (See page 51−15). TYPE A VANE PUMP: Pulley TYPE B VANE PUMP: Pulley F41916 2. (a) HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page 60−1). WhereEverybodyKnowsYourName 51−15 POWER STEERING − VANE PUMP ASSY (1MZ−FE/3MZ−FE) VANE PUMP ASSY (1MZ−FE/3MZ−FE) 5105P−02 COMPONENTS TYPE A VANE PUMP: Pressure Port Union Vane Pump Housing Rear Sport Grade: 83 (846, 61) Flow Control Valve
O−Ring Vane Pump Bracket Rear Except Sport Grade: Flow Control Valve Flow Control Valve Compression Spring
O−Ring 13 (133, 10)
O−Ring Power Steering Suction Port Union 43 (438, 32)
Gasket Vane Pump Housing Front 43 (438, 32) 24 (245, 18) Pump Bracket Front 24 (245, 18) Wave Washer Vane Pump Rotor Vane Pump Shaft Vane Pump Side Plate Rear 44 (449, 32) X10 Vane Pump Cam Ring Vane Pump Plate
Vane Pump Housing Oil Seal
Vane Pump Shaft Snap Ring Vane Pump Pulley N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Power steering fluid F41917 F41597 WhereEverybodyKnowsYourName 51−16 POWER STEERING − VANE PUMP ASSY (1MZ−FE/3MZ−FE) TYPE B VANE PUMP: Vane Pump Housing Rear Pressure Port Union 83 (846, 61) Sport Grade:
O−Ring Flow Control Valve Except Sport Grade: Flow Control Valve 44 (449, 32) Flow Control Valve Compression Spring 13 (133, 10) Vane Pump Bracket Rear
O−Ring
Gasket 44 (449, 32) Power Steering Suction Port Union
O−Ring Vane Pump Housing Front 44 (449, 32) 24 (245, 18) 24 (245, 18) Pump Bracket Front Vane Pump Rotor Wave Washer
Vane Pump Housing Oil Seal Vane Pump Side Plate Rear X10 Vane Pump Cam Ring Vane Pump Plate W/Pulley Shaft Sub−assy
Vane Pump Shaft Snap Ring N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Power steering fluid F41488 WhereEverybodyKnowsYourName 51−17 POWER STEERING − VANE PUMP ASSY (1MZ−FE/3MZ−FE) 5105Q−02 OVERHAUL NOTICE:
When using a vise, do not over tighten.
When installing, coat the parts indicated by the arrows with power steering fluid (See page 51−15). 1. REMOVE FRONT WHEEL RH 2. DRAIN POWER STEERING FLUID 3. REMOVE FRONT FENDER LINER RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Remove the clip and disconnect the oil reservoir to pump hose No.1. NOTICE: Take care not to spill fluid on the V belt. 6. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the power steering oil pressure switch from the union bolt. NOTICE: Be careful not to drop the power steering oil pressure switch. If the power steering oil pressure switch is dropped or strongly damaged, replace it with a new one. 7. DISCONNECT PRESSURE FEED HOSE (a) Using a spanner (24 mm) to hold the pressure port union, remove the union bolt and gasket. 8. (a) 9. (a) REMOVE VANE PUMP V BELT Loosen the 2 bolts and remove the vane pump V belt. REMOVE VANE PUMP ASSY Remove the 2 bolts and vane pump assy. 10. (a) REMOVE VANE PUMP PULLEY (TYPE A VANE PUMP) Using SST, stop the vane pump pulley rotation and loosen the nut. SST 09960−10010 (09962−01000, 09963−01000) Remove the nut and vane pump pulley from the vane pump shaft. F41598 F41599 SST (b) F41600 WhereEverybodyKnowsYourName 51−18 POWER STEERING 11. (a) (b) 12. (a) (b) 13. 14. 15. (a) 16. (a) 17. (a) (b) (c) 18. (a) (b) 19. − VANE PUMP ASSY (1MZ−FE/3MZ−FE) REMOVE POWER STEERING SUCTION PORT UNION Remove the bolt and power steering suction port union. Remove the O−ring from the power steering suction port union. REMOVE PRESSURE PORT UNION Remove the pressure port union. Remove the O−ring from the pressure port union. REMOVE FLOW CONTROL VALVE REMOVE FLOW CONTROL VALVE COMPRESSION SPRING REMOVE VANE PUMP BRACKET REAR (TYPE A VANE PUMP) Remove the 2 bolts, vane pump bracket rear from the vane pump assy. REMOVE VANE PUMP BRACKET REAR (TYPE B VANE PUMP) Remove the 2 bolts and 2 nuts, vane pump bracket rear from the vane pump assy. REMOVE VANE PUMP HOUSING REAR Remove the 4 bolts and vane pump housing rear from the vane pump housing front. Remove the gasket. Remove the 2 O−rings from the vane pump housing rear. REMOVE VANE PUMP SIDE PLATE REAR Remove the wave washer from the vane pump side plate rear. Remove the vane pump side plate rear. REMOVE VANE PUMP CAM RING 20. REMOVE VANE PUMP ROTOR (a) Remove the 10 vane pump plates from the vane pump rotor. (b) Using a screwdriver, remove the vane pump shaft snap ring from the vane pump shaft. (c) Remove the vane pump rotor. C65312 21. 22. 23. (a) REMOVE VANE PUMP SHAFT (TYPE A VANE PUMP) REMOVE W/PULLEY SHAFT SUB−ASSY (TYPE B VANE PUMP) REMOVE PUMP BRACKET FRONT Remove the bolt, pump bracket front from the vane pump housing front. 24. (a) REMOVE VANE PUMP HOUSING OIL SEAL Using SST and a hammer, tap out the vane pump housing oil seal from the vane pump housing front. SST 09631−10030 NOTICE: Be careful not to damage the bushing of the vane pump housing front. SST F41486 WhereEverybodyKnowsYourName 51−19 POWER STEERING − VANE PUMP ASSY (1MZ−FE/3MZ−FE) 25. (a) INSPECT OIL CLEARANCE Using a micrometer and a caliper gauge, measure the oil clearance. Standard clearance: 0.027 − 0.054 mm (0.00106 − 0.00213 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the vane pump assy. Caliper Gauge Micrometer TYPE A VANE PUMP Vane Pump Shaft Bushing Vane pump Housing Front TYPE B VANE PUMP Bushing W/Pulley Shaft Sub−assy Vane pump Housing Front F41618 26. Thickness (a) Height INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES Using a micrometer, measure the height, thickness and length of the vane pump plates. Minimum height: 8.7 mm (0.343 in.) Minimum thickness: 1.4 mm (0.055 in.) Minimum length: 14.991 mm (0.59020 in.) Length N00372 (b) Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane pump plate. Maximum clearance: 0.03 mm (0.0012 in.) If it is more than the maximum, replace the vane pump assy. Feeler Gauge R10282 WhereEverybodyKnowsYourName 51−20 POWER STEERING 27. (a) Sport Grade: − VANE PUMP ASSY (1MZ−FE/3MZ−FE) INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. Except Sport Grade: R11288 F41490 F41529 (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 − 490 kPa (4 − 5 kgf/cm2, 57 − 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes. If necessary, replace the vane pump assy. Sport Grade: Compressed Air Except Sport Grade: Compressed Air F41623 28. Vernier Calipers INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the flow control valve compression spring. Minimum free length: 32.24 mm (1.2693 in.) If it is not within the specification, replace the vane pump assy. R08702 WhereEverybodyKnowsYourName 51−21 POWER STEERING − VANE PUMP ASSY (1MZ−FE/3MZ−FE) 29. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assy. 30. (a) Press SST W03541 31. (a) Oil Seal F41624 INSTALL VANE PUMP HOUSING OIL SEAL Coat a new vane pump housing oil seal lip with power steering fluid. (b) Using SST and a press, install the new vane pump housing oil seal. SST 09950−60010 (09951−00330), 09950−70010 (09951−07100) NOTICE: Make sure that the vane pump housing oil seal is installed facing the correct direction. INSTALL PUMP BRACKET FRONT Install the pump bracket front with the bolt. Torque: Type A Vane Pump: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) Type B Vane Pump: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) 32. INSTALL VANE PUMP SHAFT (TYPE A VANE PUMP) Power Steering Fluid (a) Coat inside bushing surface of the vane pump housing front with power steering fluid. (b) Gradually insert the vane pump shaft from the pulley side. NOTICE: Do not damage the vane pump housing oil seal lip in the vane pump housing front. F40339 33. Power Steering Fluid F40339 INSTALL W/PULLEY SHAFT SUB−ASSY (TYPE B VANE PUMP) (a) Coat inside bushing surface of the vane pump housing front with power steering fluid. (b) Gradually insert the w/pulley shaft sub−assy from the pulley side. NOTICE: Do not damage the vane pump housing oil seal lip in the vane pump housing front. 34. (a) (b) INSTALL VANE PUMP ROTOR Install the vane pump rotor. Using a shaft snap ring expander, install a new vane pump shaft snap ring to the vane pump shaft. F40340 WhereEverybodyKnowsYourName 51−22 POWER STEERING Inscribed Mark − VANE PUMP ASSY (1MZ−FE/3MZ−FE) 35. (a) INSTALL VANE PUMP CAM RING Align the holes of the vane pump cam ring with 2 straight pins, and install the vane pump cam ring with inscribed mark facing outward. (b) (c) Coat 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. Install a new gasket. F40341 Round End Gasket (d) F04644 36. (a) (b) Set INSTALL VANE PUMP SIDE PLATE REAR Coat a new O−ring with power steering fluid and install it to the vane pump side plate rear. Align the groove of the vane pump cam ring with that of the vane pump side plate rear, install the vane pump side plate rear. F41480 (c) Install the wave washer so that its protrusions fit into the slots in the vane pump side plate rear. R11292 37. (a) (b) INSTALL VANE PUMP HOUSING REAR Coat a new O−ring with power steering fluid and install it to the vane pump housing rear. Install the vane pump housing rear with the 4 bolts. Torque: 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) WhereEverybodyKnowsYourName 51−23 POWER STEERING 38. (a) (b) (c) F41573 − VANE PUMP ASSY (1MZ−FE/3MZ−FE) MEASURE VANE PUMP ROTATION TORQUE (TYPE A VANE PUMP) Check that the vane pump rotates smoothly without abnormal noise. Temporarily install the pulley set nut. Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.27 N⋅m (2.8 kgf⋅cm, 2.4 in.⋅lbf) or less 39. 40. (a) 41. (a) 42. (a) 43. (a) (b) 44. (a) (b) 45. (a) (b) MEASURE VANE PUMP ROTATION TORQUE (TYPE B VANE PUMP) (a) Check that the vane pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.) F41492 (c) Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.27 N⋅m (2.8 kgf⋅cm, 2.4 in.⋅lbf) or less INSTALL VANE PUMP BRACKET REAR (TYPE A VANE PUMP) Install the vane pump bracket rear with the 2 bolts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSTALL VANE PUMP BRACKET REAR (TYPE B VANE PUMP) Install the vane pump bracket rear with the 2 bolts and 2 nuts. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) INSTALL FLOW CONTROL VALVE COMPRESSION SPRING Coat the flow control valve compression spring with power steering fluid and install it. INSTALL FLOW CONTROL VALVE Coat the flow control valve with power steering fluid. Install the flow control valve. INSTALL PRESSURE PORT UNION Coat a new O−ring with power steering fluid and install it to the pressure port union. Install the pressure port union. Torque: 83 N⋅m (846 kgf⋅cm, 61 ft⋅lbf) INSTALL POWER STEERING SUCTION PORT UNION Coat a new O−ring with power steering fluid and install it to the power steering suction port union. Install the power steering suction port union with the bolt. Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) WhereEverybodyKnowsYourName 51−24 POWER STEERING SST − VANE PUMP ASSY (1MZ−FE/3MZ−FE) 46. (a) (b) INSTALL VANE PUMP PULLEY (TYPE A VANE PUMP) Install the vane pump pulley to the vane pump shaft. Using SST, stop the vane pump pulley rotation and install the nut. SST 09960−10010 (09962−01000, 09963−01000) Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) 47. (a) INSTALL VANE PUMP ASSY Temporarily install the vane pump assy with the 2 (A and B) bolts. INSTALL VANE PUMP V BELT Install the vane pump V belt and adjust the V belt tension (See page 14−136). Torque the bolt A. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) Torque the bolt B. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) CONNECT PRESSURE FEED HOSE F41600 A 48. (a) (b) B F41599 Pressure Feed Tube Stopper (c) 49. (a) Using a spanner (24 mm) to hold the pressure port union, connect the pressure feed tube assy with the union bolt and a new gasket. Torque: 51.5 N⋅m (525 kgf⋅cm, 38 ft⋅lbf) HINT: Make sure the stopper of the pressure feed tube touches the W03441 front bracket as shown in the illustration, then install the union F41567 bolt. 50. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install the power steering oil pressure switch to the union bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) NOTICE: Be careful not to prevent oil from being attached to the connector. (b) Connect the connector. 51. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Connect the oil reservoir to pump hose No.1. (b) Install the clip. 52. INSTALL FRONT FENDER APRON SEAL RH 53. INSTALL FRONT FENDER LINER RH 54. INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 55. BLEED POWER STEERING FLUID (See page 51−3) 56. INSPECT FLUID LEAK WhereEverybodyKnowsYourName 51−2 POWER STEERING − POWER STEERING SYSTEM 5105L−09 PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. Symptom Suspect Area 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) See page 9. Power steering gear 28−1 51−3 14−5 14−140 26−5 − 26−19 − 51−8 51−17 51−28 Poor return 1. 2. 3. 4. Tires (Improperly inflated) Front wheel alignment (Incorrect) Steering column (Binding) Power steering gear 28−1 26−5 − 51−28 Excessive play 1. 2. 3. 4. 5. Steering system joints (Worn) Suspension arm ball joints (Worn) Intermediate shaft, Sliding yoke (Worn) Front wheel bearing (Worn) Power steering gear − 26−19 − 30−23 51−28 Hard steering Abnormal noise 4. 5. 6. 7. 8. Front wheel alignment (Incorrect) Steering system joints (Worn) Suspension arm ball joints (Worn) Steering column (Binding) Power steering vane pump 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 4. Power steering gear WhereEverybodyKnowsYourName 51−3 − 51−8 51−17 51−28 51−25 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY RACK & PINION POWER STEERING GEAR ASSY 5105R−03 COMPONENTS 24.5 (250, 18) *22.5 (229, 17) 9.8 (100, 86 in.⋅lbf) 9.8 (100, 86 in.⋅lbf) 35.3 (360, 26) Pressure Feed Tube Return Tube Assy Clamp  O−Ring 24.5 (250, 18) *22.5 (229, 17) Return Tube Assy 1MZ−FE: Power Steering Rack Housing Heat Insulator 49 (500, 36)  Cotter Pin 70 (714, 52) Rack & Pinion Power Steering Gear Assy Front Stabilizer Bracket No.1 RH 19 (194, 14) 49 (500, 36) 19 (194, 14) Front Stabilizer Bar Bush No.1  Cotter Pin Front Stabilizer Bracket No.1 LH Front Stabilizer Bar Front Stabilizer Bar Bush No.1 74 (755, 55) 74 (755, 55) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part * For use with SST F41605 WhereEverybodyKnowsYourName 51−26 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY RACK & PINION POWER STEERING GEAR ASSY: 21 (214, 15) 12.5 (127, 9) *11.5 (117, 8) Right Turn Pressure Tube 12.5 (127, 9) *11.5 (117, 8) Dust Cover   O−Ring 12.5 (127, 9) *11.5 (117, 8)   Control Valve Housing  Power Steering Control Valve Upper Oil Seal Left Turn Pressure Tube  Control Valve Upper Bearing Control Valve  Control Valve Ring  Oil Seal  Gasket Compression Spring
Rack Guide Spring Cap Nut 68.5 (699, 51) *48 (489, 35)
Rack Guide Spring Cap Rack Guide Rack Housing  24.5 (250, 18)
Rack Housing Cap N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque 58.5 (597, 43)  Non−reusable part
Precoated part Molybdenum disulfide lithium base grease Power steering fluid MP grease * For use with SST F41889 WhereEverybodyKnowsYourName 51−27 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY RACK & PINION GEAR POWER STEERING GEAR ASSY:  Steering Rack Boot No.1 Clamp Steering Rack Boot No.1 Lock Nut 74 (755, 55) Tie Rod Assy LH Steering Rack Boot Clip Rack Housing Steering Rack End Sub−assy 83.5 (851, 62) *58.5 (597, 43)  Claw Washer Power Steering Rack  O−Ring  Rack Steering Piston Ring Steering Rack End Sub−assy 83.5 (851, 62) *58.5 (597, 43)  Power Steering Cylinder Tube Oil Seal  Claw Washer Cylinder End Stopper  O−Ring  Wire Tie Rod Assy RH Lock Nut 74 (755, 55)  Rack Bush Oil Seal Power Steering Rack Bush Steering Rack Boot No.2 Steering Rack Boot Clip N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non−reusable part Molybdenum disulfide lithium base grease  Steering Rack Boot No.2 Clamp Power steering fluid * For use with SST F41890 WhereEverybodyKnowsYourName 51−28 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 5105S−06 OVERHAUL NOTICE: When installing , coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease (See page 51−25). 1. PRECAUTION(See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE HORN BUTTON ASSY(See page 50−9, 50−21) 4. REMOVE STEERING WHEEL ASSY(See page 50−9, 50−21) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) 5. REMOVE FRONT WHEEL 6. REMOVE SPIRAL CABLE SUB−ASSY(See page 50−9, 50−21) 7. (a) (b) SST DISCONNECT TIE ROD ASSY LH Remove the cotter pin and nut. Using SST, remove the tie rod assy LH from the steering knuckle. SST 09628−62011 F40531 8. DISCONNECT TIE ROD ASSY RH SST 09628−62011 HINT: Remove the RH side by the same procedures with LH side. 9. (a) (b) (c) DISCONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY Loosen the bolt and remove the clamp from the steering column hole cover No.1. Disconnect the steering column hole cover No.2 from the steering column hole cover No.1. Loosen the bolt. C92274 (d) Matchmarks (e) Place matchmarks on the steering intermediate shaft sub−assy and rack & pinion power steering gear assy. Remove the bolt and separate the steering intermediate shaft sub−assy. F41595 WhereEverybodyKnowsYourName 51−29 POWER STEERING 10. (a) − RACK & PINION POWER STEERING GEAR ASSY DISCONNECT FRONT STABILIZER LINK ASSY LH Remove the nut and disconnect the front stabilizer link assy from the absorber. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F41524 11. DISCONNECT FRONT STABILIZER LINK ASSY RH HINT: Remove the RH side by the same procedures with LH side. 12. REMOVE FRONT STABILIZER BRACKET NO.1 LH (a) Remove the 2 bolts and disconnect the front stabilizer bracket No.1 LH. F41523 13. REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Remove the RH side by the same procedures with LH side. SST SST 14. DISCONNECT PRESSURE FEED TUBE ASSY (a) Using SST, disconnect the return tube assy from the rack & pinion power steering gear assy. SST 09023−12701 (b) Using SST, disconnect the pressure feed tube assy from the rack & pinion power steering gear assy. SST 09023−12701 F41578 F42897 WhereEverybodyKnowsYourName 51−30 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY (c) Remove the nut and disconnect the return tube clamp. 15. REMOVE RACK & PINION POWER STEERING GEAR ASSY Remove the bolt and disconnect the tube clamp. F41602 (a) F41568 (b) Remove the 2 bolts, nuts and rack & pinion power steering gear assy. F41496 16. (a) REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR (1MZ−FE ENGINE TYPE) Remove the power steering rack housing heat insulator. 17. (a) SST (b) 18. (a) (b) REMOVE STEERING LEFT TURN PRESSURE TUBE Using SST, renove the left turn pressure tube. SST 09023−38201 Remove the 2 O−rings from the left turn pressure tube. REMOVE STEERING RIGHT TURN PRESSURE TUBE Using SST, renove the right turn pressure tube. SST 09023−38201 Remove the 2 O−rings from the right turn pressure tube. F41497 WhereEverybodyKnowsYourName 51−31 POWER STEERING 19. (a) SST − RACK & PINION POWER STEERING GEAR ASSY FIX RACK & PINION POWER STEERING GEAR ASSY Using SST, secure the rack & pinion power steering gear assy. SST 09612−00012 HINT: Tape the SST before use. F41498 20. (a) (b) REMOVE TIE ROD ASSY LH Place matchmarks on the tie rod assy LH and steering rack end sub−assy. Loosen the lock nut, and remove the tie rod assy LH and lock nut. Matchmarks F40050 21. REMOVE TIE ROD ASSY RH HINT: Remove the RH side by the same procedures with LH side. 22. (a) (b) (c) (d) ZK8184 INSPECT TIE ROD ASSY LH Secure the tie rod assy LH in a vise. Install the nut to the stud bolt. Flip the ball joint stud back and forth 5 times. Using a torque wrench, turn the nut continuously at a rate of 3 − 5 seconds per 1 turn and take the torque reading of the 5th turn. Turning torque: 0.83 − 3.43 N⋅m (8.5 − 35.0 kgf⋅cm, 7.3 − 30.4 in.⋅lbf) 23. INSPECT TIE ROD ASSY RH HINT: Remove the RH side by the same procedures with LH side. 24. REMOVE STEERING RACK BOOT CLIP (a) Remove the 2 steering rack boot clips. 25. REMOVE STEERING RACK BOOT NO.2 CLAMP (a) Using pliers, remove the steering rack boot No.2 clamp. NOTICE: Be careful not to damage the steering rack boot No.2. 26. REMOVE STEERING RACK BOOT NO.1 CLAMP HINT: Remove the steering rack boot No.1 clamp by the same procedures with the steering rack boot No.2 clamp. NOTICE: Be careful not to damage the steering rack boot No.1. WhereEverybodyKnowsYourName 51−32 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 27. REMOVE STEERING RACK BOOT NO.2 (a) Remove the steering rack boot No.2. 28. REMOVE STEERING RACK BOOT NO.1 HINT: Remove the steering rack boot No.1 by the same procedures with the steering rack boot No.2. 29. REMOVE STEERING RACK END SUB−ASSY Claw (a) Using a screwdriver and a hammer, unstake the claw Washer washer. NOTICE: Avoid any impact to the power steering rack. C83166 (b) Using 2 SSTs, remove the 2 steering rack ends sub−assy and 2 claw washers. SST 09922−10010 NOTICE:
Use SST 09922−10010 in the direction shown in the illustration.
Securely hold the power steering rack end with a SST. SST SST F41526 30. (a) REMOVE RACK GUIDE Using SST, remove the rack guide spring cap nut. SST 09922−10010 NOTICE: Use SST 09922−10010 in the direction shown in the illustration. SST F41500 WhereEverybodyKnowsYourName 51−33 POWER STEERING Rack Guide Spring Cap (b) (c) − RACK & PINION POWER STEERING GEAR ASSY Using SST, remove the rack guide spring cap. SST 09631−10021 Remove the compression spring and rack guide. SST F41501 31. (a) REMOVE POWER STEERING CONTROL VALVE Using a socket wrench (27 mm), remove the rack housing cap. (b) Using SST, hold the control valve and remove the nut. SST 09616−00011 (c) (d) Wind vinyl tape around the serrated part of the control valve. Remove the dust cover from the control valve housing. (e) (f) Remove the 2 bolts and control valve. Remove the gasket. F41502 SST F41503 Vinyl Tape F41504 F41505 WhereEverybodyKnowsYourName 51−34 POWER STEERING (g) Vinyl Tape (h) (i) − RACK & PINION POWER STEERING GEAR ASSY To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve. Using a plastic hammer, remove the control valve with oil seal from the control valve housing. Remove the oil seal from the control valve. F41506 (j) Using a screwdriver, remove the 4 control valve rings. NOTICE: Be careful not to damage the grooves for the control valve rings. Control Valve Ring R11572 32. (a) SST REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL Using SST and a press, remove the control valve upper bearing and power steering control valve upper oil seal from the control valve housing. SST 09950−70010 (09951−07150), 09950−60010 (09951−00250) F40911 33. (a) (b) REMOVE CYLINDER END STOPPER Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper. Cylinder End Stopper Wire C83179 WhereEverybodyKnowsYourName 51−35 POWER STEERING 34. − RACK & PINION POWER STEERING GEAR ASSY REMOVE POWER STEERING RACK 35. (a) SST (b) (c) REMOVE POWER STEERING RACK BUSH Remove the power steering rack bush from the power steering rack. Using SST, remove the rack bush oil seal. SST 09527−21011, 09612−24014 (09613−22011) Using a screwdriver, remove the O−ring from the power steering rack bush. F40542 36. (a) (b) INSPECT POWER STEERING RACK Using a dial indicator, check the power steering rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.012 in.) Check the back surface for wear and damage. ZX9355 37. SST (a) REMOVE POWER STEERING CYLINDER TUBE OIL SEAL Using SST and a press, remove the power steering cylinder tube oil seal. SST 09950−70010 (09951−07360), 09950−60010 (09951−00290) F40544 38. (a) REMOVE RACK STEERING PISTON RING Using a screwdriver, remove the rack steering piston ring and O−ring. NOTICE: Be careful not to damage the grooves for rack steering piston ring. R10955 WhereEverybodyKnowsYourName 51−36 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 39. (a) INSTALL RACK STEERING PISTON RING Coat a new O−ring with power steering fluid and install it to the power steering rack. (b) Expand a new rack steering piston ring with your fingers. NOTICE: Be careful not to over expand the rack steering piston ring. (c) Coat a new rack steering piston ring with power steering fluid. C03629 (d) Install the rack steering piston ring to the power steering rack, and settle it down with your fingers. N00401 40. SST SST F40545 INSTALL POWER STEERING CYLINDER TUBE OIL SEAL (a) Coat a new power steering cylinder tube oil seal lip with power steering fluid. SST 09950−60010 (09951−00420, 09951−00250, 09952−06010), 09950−70010 (09951−07360) (b) Using SST and a press, install the power steering cylinder tube oil seal. NOTICE:
Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
Take care so that the power steering cylinder tube oil seal will not be reversed as you install it. WhereEverybodyKnowsYourName 51−37 POWER STEERING 41. (a) − RACK & PINION POWER STEERING GEAR ASSY INSTALL POWER STEERING RACK Install SST to the power steering rack. SST 09631−33010 HINT: If necessary, scrape the burrs off the power steering rack teeth end and burnish. (b) Coat the SST with power steering fluid. (c) Install the power steering rack into the rack housing. (d) Remove the SST. Rack Teeth End SST W02101 42. (a) SST F40543 Vinyl Tape INSTALL POWER STEERING RACK BUSH Using SST and a press, install the rack bush oil seal to the power steering rack bush. SST 09950−60010 (09951−00400), 09950−70010 (09951−07100) NOTICE: Make sure that the rack bush oil seal is installed facing in the correct direction. (b) Coat a new O−ring with power steering fluid and install it to the power steering rack bush. (c) To prevent rack bush oil seal lip damage, wind vinyl tape around the power steering rack end, and apply power steering fluid. (d) Install the power steering rack bush to the power steering rack. Power Steering Rack Bush F05730 43. (a) Wire (b) (c) INSTALL CYLINDER END STOPPER Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. Install a new wire into the cylinder end stopper. Using a screwdriver, turn the cylinder end stopper clockwise by 450
50. Cylinder End Stopper F40546 WhereEverybodyKnowsYourName 51−38 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 44. (a) AIR TIGHTNESS TEST Install SST to the rack housing. SST 09631−12071 (09633−00010) (b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds. (c) Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals. SST F41507 45. (a) SST (b) SST F40912 (c) SST INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL Coat a control valve upper bearing and a new power steering control valve upper oil seal with power steering fluid. Using SST and a press, install the power steering control valve upper oil seal. SST 09950−70010 (09951−07150), 09950−60010 (09951−00180, 09952−06010, 09951−00320) Using SST and a press, install the control valve upper bearing. SST 09950−70010 (09951−07150), 09950−60010 (09951−00180, 09952−06010, 09951−00340) F40913 46. INSTALL POWER STEERING CONTROL VALVE (a) Expand 4 new control valve rings with your fingers. NOTICE: Be careful not to over expand the control valve ring. (b) Coat the 4 control valve rings with power steering fluid. (c) Install the 4 control valve rings to the control valve, and settle them down with your fingers. C03629 (d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve. SST 09631−22081 NOTICE: Be careful not to damage the control valve rings. SST Valve Ring R11573 WhereEverybodyKnowsYourName 51−39 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY (e) Vinyl Tape F41508 To prevent power steering control valve upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve. (f) Coat the power steering control valve upper oil seal lip with power steering fluid. (g) Install the control valve to the control valve housing. NOTICE: Be careful not to damage the control valve ring and power steering control valve upper oil seal lip. (h) (i) Coat a new oil seal lip with power steering fluid. Using SST and a press, install the oil seal. SST 09612−22011 NOTICE: Make sure that the oil seal is installed facing in the correct direction. SST F41509 (j) (k) (l) (m) Apply grease to the needle bearing. Install a new gasket to the control valve housing. Wind vinyl tape around the serration part of the control valve. Install the control valve housing to the rack housing with the 2 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) F41512 (n) SST (o) Using SST, stop the control valve rotation and install a new lock nut. Torque: 24.5 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) SST 09616−00011 Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent F41513 (p) Using a socket wrench (27 mm), install the rack housing cap. Torque: 58.5 N⋅m (597 kgf⋅cm, 43 ft⋅lbf) F41502 WhereEverybodyKnowsYourName 51−40 POWER STEERING (q) − RACK & PINION POWER STEERING GEAR ASSY Using a punch and a hummer, stake the rack housing cap and rack housing. F41608 47. (a) (b) (c) (d) INSTALL RACK GUIDE Install the rack guide. Install the compression spring. Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap. 48. (a) (b) ADJUST TOTAL PRELOAD To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack ends sub−assy. Using SST, torque the rack guide spring cap. SST 09631−10021 Torque: 25 N⋅m (254 kgf⋅cm, 18 ft⋅lbf) SST F41514 (c) Using SST, loosen the rack guide spring cap. SST 09631−10021 (d) Using SST, turn the control valve to the right and left 1 or 2 times. SST 09616−00011 Using SST, loosen the rack guide spring cap until the compression spring is not functioning. SST 09631−10021 SST F41515 SST (e) F41516 WhereEverybodyKnowsYourName 51−41 POWER STEERING (f) SST Rack Guide Spring Cap SST (g) F41517 (h) − RACK & PINION POWER STEERING GEAR ASSY Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616−00011, 09631−10021 Preload (turning): 1.2 − 1.5 N⋅m (12.2 − 15.3 kgf⋅cm, 10.6 − 13.3 in.⋅lbf) Apply sealant to 2 or 3 threads of the rack guide spring cap nut. Sealant: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap nut. (i) Rack Guide Spring Cap Nut SST Fulcrum Length SST F41518 Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap nut. SST 09616−00011, 09922−10010 Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) NOTICE: Use SST 09922−10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (j) Precheck the total preload. Preload (turning): 1.2 − 1.5 N⋅m (12.2 − 15.3 kgf⋅cm, 10.6 − 13.3 in.⋅lbf) (k) Remove the RH and LH steering rack ends sub−assy. (l) Apply MP grease into the control valve, as shown in the illustration. (m) Wind vinyl tape around the serration part of the control valve. Install the dust cover to the control valve housing. MP Grease F40555 Vinyl Tape (n) F40538 WhereEverybodyKnowsYourName 51−42 POWER STEERING 49. (a) SST − RACK & PINION POWER STEERING GEAR ASSY INSTALL STEERING RACK END SUB−ASSY Install a new 2 claw washers, and temporarily install the 2 steering rack ends sub−assy. HINT: Align the claws of the claw washer with the power steering rack grooves. (b) Using 2 SSTs, install the 2 steering rack ends sub−assy. SST 09922−10010 Torque: 58.5 N⋅m (597 kgf⋅cm, 43 ft⋅lbf) NOTICE: Use SST 09922−10010 in the direction shown in the illustration. HINT:
Using SST, hold the power steering rack and install the steering rack end sub−assy.
Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Fulcrum Length SST Fulcrum Length F41576 (c) Using a brass bar and a hammer, stake the claw washer. NOTICE: Avoid any impact to the power steering rack. C35928 50. (a) INSPECT STEERING RACK END SUB−ASSY Ensure that the steering rack end sub−assy hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned. ZX9390 F41951 51. INSTALL STEERING RACK BOOT NO.2 (a) Install the steering rack boot No.2. 52. INSTALL STEERING RACK BOOT NO.1 HINT: Remove the steering rack boot No.1 by the same procedures with steering rack boot No.2. WhereEverybodyKnowsYourName 51−43 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 53. (a) 55. (a) 56. (a) INSTALL STEERING RACK BOOT NO.2 CLAMP Using SST, tighten the steering rack boot No.2 clamp, as SST shown in the illustration. SST 09521−24010 Clearance: 3.0 mm (0.118 in.) or less NOTICE: Be careful not to damage the boot No.2. 54. INSTALL STEERING RACK BOOT NO.1 CLAMP SST 09521−24010 F40556 NOTICE: Be careful not to damage the boot No.1. HINT: Install the steering rack boot No.1 clamp by the same procedures with steering rack boot No.2 clamp. INSTALL STEERING RACK BOOT CLIP Using pliers, install the 2 steering rack boot clips. INSTALL TIE ROD ASSY LH Screw the lock nut and tie rod assy LH onto the steering rack end sub−assy until the matchmarks are aligned. HINT: After adjusting toe−in, torque the lock nut. 57. INSTALL TIE ROD ASSY RH HINT: Install the RH side by the same procedures with LH side. 58. (a) Fulcrum Length (b) INSTALL STEERING LEFT TURN PRESSURE TUBE Coat 2 new O−rings with power steering fluid and install them to the left turn pressure tube. Using SST, install the left turn pressure tube to the rack & pinion power steering gear assy. SST 09023−38201 Torque: 11.5 N⋅m (117 kgf⋅cm, 8 ft⋅lbf) HINT: SST F41519

Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). This torque value is effective in the case that SST is parallel to a torque wrench. WhereEverybodyKnowsYourName 51−44 POWER STEERING 59. (a) Fulcrum Length (b) SST − RACK & PINION POWER STEERING GEAR ASSY INSTALL STEERING RIGHT TURN PRESSURE TUBE Coat 2 new O−rings with power steering fluid and install them to the right turn pressure tube. Using SST, install the right turn pressure tube to the rack & pinion power steering gear assy. SST 09023−38201 Torque: 11.5 N⋅m (117 kgf⋅cm, 8 ft⋅lbf) HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
This torque value is effective in the case that SST is parallel to a torque wrench. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR (1MZ−FE ENGINE TYPE) Install power steering rack housing heat insulator. F41613 60. (a) HINT: Install nut when installing the return tube clamp. 61. (a) INSTALL RACK & PINION POWER STEERING GEAR ASSY Install the rack & pinion power steering gear assy with the 2 bolts and nuts. Torque: 70 N⋅m (714 kgf⋅cm, 52 ft⋅lbf) F41496 (b) Connect the tube clamp with the bolt. Torque: 9.8 N⋅m (100 kgf⋅cm, 86 in.⋅lbf) F41568 WhereEverybodyKnowsYourName 51−45 POWER STEERING − RACK & PINION POWER STEERING GEAR ASSY 62. CONNECT PRESSURE FEED TUBE ASSY (a) Using SST, connect the pressure feed tube assy to the rack & pinion power steering gear assy. SST 09023−12701 Torque: 22.5 N⋅m (229 kgf⋅cm, 17 ft⋅lbf) Fulcrum Length HINT:
SST F41587
(b) Fulcrum Length Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective in the case that SST is parallel to a torque wrench. Using SST, connect the return tube assy to the rack & pinion power steering gear assy. SST 09023−12701 Torque: 22.5 N⋅m (229 kgf⋅cm, 17 ft⋅lbf) HINT:

SST F41586 Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective in the case that SST is parallel to a torque wrench. (c) Install the return tube clamp with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 86 in.⋅lbf) 63. INSTALL FRONT STABILIZER BRACKET NO.1 LH (a) Install the front stabilizer bracket No. 1 LH with the 2 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) F41602 F41523 64. INSTALL FRONT STABILIZER BRACKET NO.1 RH HINT: Install the RH side by the same procedures with LH side. WhereEverybodyKnowsYourName 51−46 POWER STEERING 65. (a) − RACK & PINION POWER STEERING GEAR ASSY CONNECT FRONT STABILIZER LINK ASSY LH Connect the stabilizer link assy LH to the stabilizer bar with the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F41570 66. CONNECT FRONT STABILIZER LINK ASSY RH HINT: Connect the RH side by the same procedures with LH side. 67. Matchmarks (a) (b) CONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY Align the matchmarks on the intermediate shaft sub−assy and rack & pinion power steering gear assy. Install the bolt. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) F41595 (c) (d) (e) Tighten the bolt. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Install the steering column hole cover No.2 to the steering hole cover No.1. Connect the clamp to the steering column hole cover No.1 and tighten the bolt. C92274 68. (a) CONNECT TIE ROD ASSY LH Connect the tie rod assy LH with the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. NOTICE: If the holes for a new cotter pin are not aligned, tighten the nut further up 60. 69. CONNECT TIE ROD ASSY RH HINT: Connect the RH side by the same procedures with LH side. 70. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 71. ADD POWER STEERING FLUID 72. BLEED POWER STEERING FLUID 73. CHECK POWER STEERING FLUID LEAKAGE 74. INSTALL SPIRAL CABLE SUB−ASSY(See page 50−9, 50−21) WhereEverybodyKnowsYourName 51−47 POWER STEERING 75. 76. 77. 78. 79. 80. − RACK & PINION POWER STEERING GEAR ASSY CENTER SPIRAL CABLE(See page 50−9, 50−21) INSTALL STEERING WHEEL ASSY(See page 50−9, 50−21) INSTALL HORN BUTTON ASSY(See page 50−9, 50−21) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26−5) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT WhereEverybodyKnowsYourName 51−3 POWER STEERING − POWER STEERING SYSTEM 5105M−05 ON−VEHICLE INSPECTION 1. (a) F40449 Normal Abnormal INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords, etc. If any defect is found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the belt, it should be replaced. 2. BLEED POWER STEERING SYSTEM (a) Check the fluid level. (b) Jack up the front of the vehicle and support it with the stands. (c) Turn the steering wheel. (1) With the engine stopped, turn the wheel slowly from lock to lock several times. (d) Lower the vehicle. (e) Start the engine. (1) Run the engine at idle for a few minutes. (f) Turn the steering wheel. (1) With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 − 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 − 3 seconds. (2) Repeat (1) several times. (g) Stop the engine. (h) Check for forming or emulsification. Especially, if the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system. (i) Check the fluid level. F40897 3. (a) (b) F40898 CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON® II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap. If the fluid is cold, check that it is within the COLD LEVEL range. WhereEverybodyKnowsYourName 51−4 POWER STEERING (c) (d) POWER STEERING SYSTEM Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 − 80°C (167 − 176°F) (e) Check for foaming or emulsification. If foaming or emulsification is identified, bleed the power steering system. Abnormal Normal − F40897 (f) 5 mm (0.20 in.) or less Engine Idling Engine Stopped R11786 With the engine idling, measure the fluid level in the oil reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed the power steering system. (i) Check the fluid level. 4. CHECK STEERING FLUID PRESSURE (a) Disconnect the pressure feed tube from the rack & pinion power steering gear assy (See page 51−28). (b) Connect SST, as shown in the illustration. SST 09640−10010 (09641−01010, 09641−01020, 09641−01030) NOTICE: Check that the valve of the SST is in the open position. (c) Bleed the power steering system. (d) Start the engine and run it at idle. (e) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 − 80 °C (167 − 176 °F) WhereEverybodyKnowsYourName 51−5 POWER STEERING Attachment − POWER STEERING SYSTEM Attachment SST IN OUT Pressure Feed Tube F41520 (f) Oil Reservoir PS Gear Closed PS Vane Pump SST With the engine idling, close the valve of the SST and observe the reading on the SST. Fluid pressure: 7,800 − 8,300 kPa (80 − 85 kgf/cm2, 1,138 − 1,209 psi) NOTICE:
Do not keep the valve closed for more than 10 seconds.
Do not let the fluid temperature become too high. Z15498 Oil Reservoir PS Gear Open PS Vane Pump SST (g) (h) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Fluid pressure difference: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Z15499 (i) Oil Reservoir Lock Position PS Gear Open PS Vane Pump SST With the engine idling and valve fully opened, turn the steering wheel to full lock position. Fluid pressure: 7,800 − 8,300 kPa (80 − 85 kgf/cm2, 1,138 − 1,209 psi) NOTICE:
Do not maintain lock position for more than 10 seconds.
Do not let the fluid temperature become too high. Z15500 WhereEverybodyKnowsYourName 51−6 POWER STEERING (j) (k) (l) 5. (a) (b) (c) (d) F41590 − POWER STEERING SYSTEM Disconnect the SST. SST 09640−10010 (09641−01010, 09641−01020, 09641−01030) Connect the pressure feed tube to the rack & pinion power steering gear assy (See page 51−28). Bleed the power steering system. CHECK STEERING EFFORT Center the steering wheel assy. Remove the horn button assy (See page 50−9, 50−21). Start the engine and run it at idle. Using a torque wrench, measure the steering effort in both directions. Steering effort (Reference): 6 N·m (60 kgf·cm, 53 in.·lbf) or less HINT: Take the tire type, pressure and contact surface into consideration before making your diagnosis. (e) Install the steering wheel assy set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) (f) Install the horn button assy (See page 50−9, 50−21). WhereEverybodyKnowsYourName 51−7 POWER STEERING − VANE PUMP ASSY (2AZ−FE) VANE PUMP ASSY (2AZ−FE) 5105N−02 COMPONENTS Pressure Port Union 69 (704, 51)
O−Ring Power Steering Oil Pressure Switch Flow Control Valve 21 (214, 15) Flow Control Valve Compression Spring Vane Pump Housing Front Power Steering Suction Port Union
O−Ring 12 (122, 9)
Vane Pump Housing Oil Seal Vane Pump Housing Rear W/Pulley Shaft Sub−assy
Vane Pump Shaft Snap Ring
O−Ring Vane Pump Side Plate Front
O−Ring X10 Vane Pump Rotor 22 (224, 16) Vane Pump Plate Vane Pump Cam Ring N⋅m (kgf⋅cm, ft⋅lbf) F41489 : Specified torque
Non−reusable part Power steering fluid WhereEverybodyKnowsYourName F41621 51−8 POWER STEERING − VANE PUMP ASSY (2AZ−FE) 5105O−02 OVERHAUL NOTICE:
When using a vise, do not over tighten.
When installing, coat the parts indicated by the arrows with power steering fluid (See page 51−7). 1. REMOVE FRONT WHEEL RH 2. DRAIN POWER STEERING FLUID 3. REMOVE FRONT FENDER LINER RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. REMOVE FAN AND GENERATOR V BELT(See page 14−5) SST 09249−63010 6. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Remove the clip and disconnect the oil reservoir to pump hose No.1. NOTICE: Take care not to spill fluid on the V belt. 7. (a) (b) DISCONNECT PRESSURE FEED TUBE ASSY Disconnect the connector from the power steering oil pressure switch. Using a spanner (27 mm) to hold the pressure port union, remove the union bolt and gasket. F40529 8. (a) (b) SST (c) A REMOVE VANE PUMP ASSY Disconnect the connector from the oil pressure switch. Using SST and a deep socket (14 mm), loosen the bolt A. SST 09249−63010 Remove the bolt B and vane pump assy. B F40342 9. (a) FIX VANE PUMP ASSY Using SST, hold the vane pump assy on the vise through the aluminum plate. SST 09630−00014 (09631−00132) HINT: As follow the necessity, remove and install SST for holding. SST F41481 WhereEverybodyKnowsYourName 51−9 POWER STEERING − VANE PUMP ASSY (2AZ−FE) 10. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and power steering suction port union. (b) Remove the O−ring from the power steering suction port union. 11. REMOVE PRESSURE PORT UNION (a) Using a socket wrench (27 mm), remove the pressure port union. (b) Remove the O−ring from the pressure port union. 12. REMOVE FLOW CONTROL VALVE 13. REMOVE FLOW CONTROL VALVE COMPRESSION SPRING 14. REMOVE POWER STEERING OIL PRESSURE SWITCH NOTICE: Be careful not to drop the power steering oil pressure switch. If the power steering oil pressure switch is dropped or strongly damaged, replace it with a new one. 15. REMOVE VANE PUMP HOUSING REAR (a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front. (b) Remove the O−ring from the vane pump housing rear. 16. REMOVE W/PULLEY SHAFT SUB−ASSY (a) Using a screwdriver, remove the vane pump shaft snap ring from the w/pulley shaft sub−assy. (b) Remove the w/pulley shaft sub−assy. 17. REMOVE VANE PUMP ROTOR (a) Remove the 10 vane pump plates. (b) Remove the vane pump rotor. 18. REMOVE VANE PUMP CAM RING 19. (a) (b) REMOVE VANE PUMP SIDE PLATE FRONT Remove the vane pump side plate front from the vane pump housing front. Remove the O−ring from the vane pump side plate front. (c) Remove the O−ring from the vane pump housing front. C65368 C65369 WhereEverybodyKnowsYourName 51−10 POWER STEERING − VANE PUMP ASSY (2AZ−FE) 20. (a) REMOVE VANE PUMP HOUSING OIL SEAL Using SST and a hammer, tap out the vane pump housing oil seal from the vane pump housing front. SST 09631−10030 NOTICE: Be careful not to damage the bushing of the vane pump housing front. SST F41482 21. (a) INSPECT OIL CLEARANCE Using a micrometer and a caliper gauge, measure the oil seal clearance. Standard clearance: 0.009 − 0.031 mm (0.00035 − 0.00122 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the vane pump assy. Bushing W/Pulley Shaft Sub−assy Vane Pump Housing Front F09875 Thickness Height 22. (a) INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES Using a micrometer, measure the height, thickness and length of the vane pump plates. Minimum height: 7.7 mm (0.303 in.) Minimum thickness: 1.408 mm (0.05543 in.) Minimum length: 11.993 mm (0.47216 in.) Length N00372 (b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane pump plate. Maximum clearance: 0.03 mm (0.0012 in.) If it is more than the maximum, replace the vane pump assy. Feeler Gauge R10282 23. (a) INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. F41493 WhereEverybodyKnowsYourName 51−11 POWER STEERING − VANE PUMP ASSY (2AZ−FE) (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 − 490 kPa (4 − 5 kgf/cm2, 57 − 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes. If necessary, replace the vane pump assy. Compressed Air F41491 F41622 24. Vernier Calipers INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the flow control valve compression spring. Minimum free length: 35.8 mm (1.409 in.) If it is not within the specification, replace the vane pump assy. F41483 25. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assy. 26. (a) (b) SST Oil Seal F08480 INSTALL VANE PUMP HOUSING OIL SEAL Coat a new oil seal lip with power steering fluid. Using SST and a press, install the new vane pump housing oil seal. SST 09950−60010 (09951−00280), 09950−70010 (09951−07100) NOTICE: Make sure that the vane pump housing oil seal is installed facing the correct direction. 27. (a) INSTALL VANE PUMP SIDE PLATE FRONT Coat a new O−ring with power steering fluid and install it to the vane pump housing front. C65369 WhereEverybodyKnowsYourName 51−12 POWER STEERING (b) − VANE PUMP ASSY (2AZ−FE) Coat a new O−ring with power steering fluid and install it to the vane pump side plate front. C65368 (c) Set Align the dent of the vane pump side plate front with that of the vane pump housing front, and install the vane pump side plate front. NOTICE: Make sure that the vane pump side plate front is installed facing in the correct direction. F41484 Inscribed Mark 28. (a) INSTALL VANE PUMP CAM RING Align the dent of the vane pump cam ring with that of the vane pump side plate front, and install the vane pump cam ring with the inscribed mark facing outward. Set F41485 29. INSTALL W/PULLEY SHAFT SUB−ASSY 30. (a) Inscribed Mark Round End (b) (c) INSTALL VANE PUMP ROTOR Install the vane pump rotor with the inscribed mark facing outward. Coat 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. F08484 WhereEverybodyKnowsYourName 51−13 POWER STEERING (d) − VANE PUMP ASSY (2AZ−FE) Using a snap ring expander, install a new vane pump shaft snap ring to the w/pulley shaft sub−assy. F40343 31. (a) (b) INSTALL VANE PUMP HOUSING REAR Coat a new O−ring with power steering fluid and install it to the vane pump housing rear. Align the straight pin of the vane pump housing rear with the dents of the vane pump cam ring, vane pump side plate front and vane pump housing front, and install the vane pump housing rear with the 4 bolts. Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) 32. (a) 33. (a) (b) 34. (a) 35. (a) 36. (a) (b) 37. (a) (b) MEASURE VANE PUMP ROTATION TORQUE Check that the vane pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.) (c) Using a torque wrench, check the vane pump rotating F11943 torque. Rotating torque: 0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less INSTALL POWER STEERING OIL PRESSURE SWITCH Coat a new O−ring with power steering fluid and install it to the power steering oil pressure switch. Install the power steering oil pressure switch to the vane pump assy. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL FLOW CONTROL VALVE COMPRESSION SPRING Coat the flow control valve compression spring with power steering fluid and install it. INSTALL FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and install it. INSTALL PRESSURE PORT UNION Coat a new O−ring with power steering fluid and install it to the pressure port union. Using a socket wrench (27 mm), install the pressure port union. Torque: 69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) INSTALL POWER STEERING SUCTION PORT UNION Coat a new O−ring with power steering fluid and install it to the power steering suction port union. Install the power steering suction port union with the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) WhereEverybodyKnowsYourName 51−14 POWER STEERING 38. (a) (b) A (c) SST B Fulcrum Length F40330
(d) Stopper F41596 40. (a) (b) 41. 42. 43. 44. 45. 46. VANE PUMP ASSY (2AZ−FE) INSTALL VANE PUMP ASSY Temporarily tighten the bolt A to the vane pump assy. Install the vane pump assy and bolt B. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) Using SST and a deep socket (14 mm), tighten the bolt A. SST 09249−63010 Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) HINT:
Pressure Feed Tube − 39. (a) Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). This torque value is effective in case that SST is parallel to a torque wrench. Connect the connector to the power steering oil pressure switch. CONNECT PRESSURE FEED TUBE ASSY Install the pressure feed tube assy and gasket to the vane pump assy with the union bolt. HINT: Make sure the stopper of the pressure feed tube touches the pump housing front as shown in the illustration. (b) Using a spanner (27 mm) to hold the pressure port union, torque the union bolt. Torque: 51.5 N⋅m (525 kgf⋅cm, 38 ft⋅lbf) CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 Connect the oil reservoir to pump hose No.1. Install the clip. INSTALL FAN AND GENERATOR V BELT(See page 14−5) SST 09249−63010 INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT FENDER LINER RH INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) BLEED POWER STEERING FLUID INSPECT FLUID LEAK WhereEverybodyKnowsYourName 80−1 VEHICLE CONTROL SYSTEM − IGNITION OR STARTER SWITCH ASSY IGNITION OR STARTER SWITCH ASSY 8001R−04 REPLACEMENT 1. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER(See page 71−16) 2. (a) (b) (c) REMOVE IGNITION OR STARTER SWITCH ASSY Disconnect the ignition switch connector and unlock warning switch connector. Remove the clamp. Remove the 2 screws and ignition switch. B56503 WhereEverybodyKnowsYourName 80−2 VEHICLE CONTROL SYSTEM − IGNITION OR STARTER SWITCH ASSY 8001S−02 INSPECTION 1. (a) ACC LOCK ON INSPECT IGNITION OR STARTER SWITCH ASSY Inspect the ignition switch continuity. Standard: Switch position START 4 3 2 1 8 7 6 5 B52423 Tester connection Specified condition LOCK − No continuity ACC 2⇔3 Continuity ON 2⇔3⇔4 6⇔7 Continuity START 1⇔2⇔4 6⇔7⇔8 Continuity If the continuity is not as specified, replace the switch. WhereEverybodyKnowsYourName 26−19 FRONT SUSPENSION − LOWER BALL JOINT ASSY FRONT LH LOWER BALL JOINT ASSY FRONT LH 2601I−10 REPLACEMENT HINT: COMPONENTS: See page 26−3. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT AXLE HUB LH NUT (See page 30−8) SST 09930−00010 3. DISCONNECT SPEED SENSOR FRONT LH (W/ ABS) (See page 30−8) 4. DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH (See page 30−23) 5. REMOVE FRONT DISC 6. DISCONNECT TIE ROD END SUB−ASSY LH (See page 30−8) SST 09628−62011 7. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (See page 30−8) 8. REMOVE FRONT AXLE ASSY LH (See page 30−23) 9. REMOVE LOWER BALL JOINT ASSY FRONT LH (See page 30−23) SST 09628−62011 10. (a) (b) INSPECT LOWER BALL JOINT ASSY FRONT LH As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nut continuously at a rate of 3 − 5 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 0.98 − 3.43 N·m (10 − 35 kgf·cm, 8.7 − 30 in.·lbf) ZX1712 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. INSTALL LOWER BALL JOINT ASSY FRONT LH (See page 30−23) INSTALL FRONT AXLE ASSY LH (See page 30−23) INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (See page 30−8) INSTALL TIE ROD END SUB−ASSY LH (See page 30−8) INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 30−23) INSTALL SPEED SENSOR FRONT LH (W/ ABS) (See page 30−8) INSTALL FRONT AXLE HUB LH NUT (See page 30−8) INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26−5) CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) w/ VSC (See page 05−1002) w/o VSC (BOSCH MADE) (See page 05−873) w/o VSC (DENSO MADE) (See page 05−938) WhereEverybodyKnowsYourName 26−1 FRONT SUSPENSION − FRONT SUSPENSION SYSTEM FRONT SUSPENSION SYSTEM 2601D−13 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page Bottoming 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn) − 26−11 26−11 Sways/pitches 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 3. Shock absorber (Worn) 28−1 26−20 26−11 1. 2. 3. 4. 28−1 28−1 26−11 26−5 27−3 26−19 30−2 − Front wheel shimmy Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) 5. Ball joint (Worn) 6. Hub bearing (Worn) 7. Steering linkage (Loose or worn) 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) Abnormal tire wear 3. Shock absorber (Worn) 4. Suspension parts (Worn) WhereEverybodyKnowsYourName 28−1 26−5 27−3 26−11 − 26−11 FRONT SUSPENSION − FRONT SHOCK ABSORBER WITH COIL SPRING FRONT SHOCK ABSORBER WITH COIL SPRING 2601F−11 OVERHAUL HINT: COMPONENTS: See page 26−3. 1. REMOVE FRONT WHEEL 2. (a) DISCONNECT FRONT STABILIZER LINK ASSY LH Remove the nut and disconnect the front stabilizer link assy LH from the shock absorber assy front LH. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40136 3. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (a) Loosen the lock nut. NOTICE:
Do not loosen except for the case with disassembling the shock absorber assy front LH with coil spring.
Do not remove the lock nut. F40137 (b) (c) w/ ABS: Remove the bolt, disconnect the front flexible hose No. 1 and speed sensor front LH. w/o ABS: Remove the bolt, disconnect the front flexible hose No. 1. C65925 (d) Remove the 2 nuts and 2 bolts on the lower side of front shock absorber with coil spring. NOTICE: When removing bolt, stop the bolt from rotating and loosen the nut. C93871 WhereEverybodyKnowsYourName 26−12 FRONT SUSPENSION − FRONT SHOCK ABSORBER WITH COIL SPRING (e) Remove the 3 nuts on the upper side of the front shock absorber with coil spring. (f) Remove the front shock absorber with the coil spring. NOTICE: Be careful not to drop the 2 washers in the case that there is front suspension upper brace center. F40140 SST 4. (a) FIX FRONT SHOCK ABSORBER WITH COIL SPRING Install 2 nuts and a bolt to the bracket at the lower side of the front shock absorber with coil spring and secure it in a vise. SST F03956 5. (a) REMOVE SHOCK ABSORBER ASSY FRONT LH Using SST, compress the front coil spring LH. SST 09727−30021 NOTICE: Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (b) Remove the front suspension support sub−assy LH, front suspension support bearing LH, front coil spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH and front coil spring insulator upper LH. 6. INSPECT SHOCK ABSORBER ASSY FRONT LH (a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber assy front LH with a new one. NOTICE: When disposing of the shock absorber assy front LH, see DISPOSAL on page 26−16. W03646 7. INSTALL SHOCK ABSORBER ASSY FRONT LH (a) Install the front coil spring insulator lower LH onto the shock absorber assy front LH. (b) Install the front spring bumper LH to the piston rod. WhereEverybodyKnowsYourName 26−13 FRONT SUSPENSION − FRONT SHOCK ABSORBER WITH COIL SPRING (c) SST SST F40160 Outside Using SST, compress the front coil spring LH. SST 09727−30021 NOTICE: Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (d) Install the front coil spring LH to the shock absorber assy front LH. HINT: Fit the lower end of the front coil spring LH into the gap of the spring lower seat. (e) Install the front coil spring insulator upper LH as shown in the illustration. (f) Install the front coil spring seat upper LH to the shock absorber assy front LH with the mark facing to the outside of the vehicle. (g) Install a new front suspension support bearing LH. Outside 5
5
F40168 Outside 5
5
F40161 F40162 WhereEverybodyKnowsYourName 26−14 FRONT SUSPENSION Outside Outside (h) (i) 8. (a) − FRONT SHOCK ABSORBER WITH COIL SPRING Install the front suspension support sub−assy LH with the mark facing to the outside of the vehicle. Temporarily tighten the new lock nut. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING Install the front shock absorber with coil spring as shown in the illustration. F40169 (b) F40140 Install the 3 nuts to the upper side of front shock absorber with coil spring. Torque: TMC Made: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) TMMK Made: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) NOTICE: Be careful not to drop the 2 washers in the case that there is front suspension upper brace center. (c) Install the 2 bolts and 2 nuts to the lower side of front shock absorber with coil spring. Torque: 210 N⋅m (2,141 kgf⋅cm, 155 ft⋅lbf) NOTICE: When installing bolt, stop the bolt from rotating and torque the nut. C93871 (d) Fully tighten the lock nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (e) w/ ABS: Install the front flexible hose No. 1 and speed sensor front LH with the bolt. Torque: 18.8 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) w/o ABS: Install the front flexible hose No. 1 with the bolt. Torque: 18.8 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) F40137 (f) C65925 WhereEverybodyKnowsYourName 26−15 FRONT SUSPENSION 9. (a) − FRONT SHOCK ABSORBER WITH COIL SPRING INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40136 10. 11. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26−5) WhereEverybodyKnowsYourName 26−16 FRONT SUSPENSION − FRONT SHOCK ABSORBER WITH COIL SPRING 2601G−16 DISPOSAL N00204 HINT: Dispose the RH side by the same procedures with the LH side. 1. DISPOSE OF SHOCK ABSORBER ASSY FRONT LH (a) Fully extend the shock absorber rod. (b) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION:
When drilling, chips may fly out, work carefully.
The gas is colorless, odorless and non−poisonous. WhereEverybodyKnowsYourName FRONT SUSPENSION − FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH 26−17 FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH 2601H−11 REPLACEMENT HINT: COMPONENTS: See page 26−3. 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (1MZ−FE ENGINE TYPE) (See page 14−164) 2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ−FE ENGINE TYPE) (See page 14−29) 3. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ−FE ENGINE TYPE) (See page 14−164) 4. (a) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (A/T TRANSAXLE) Remove the 3 nuts and the transverse engine engine mounting insulator. C83387 5. (a) (b) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (M/T TRANSAXLE) Remove the 3 nuts and the transverse engine engine mounting insulator. Remove the 4 bolts and bracket from the manual transmission. 6. (a) REMOVE FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Remove the 2 bolts on the front side of the front suspension arm sub−assy lower No. 1 LH. C91606 (b) (c) (d) Remove the bolt and nut on the rear side of the front suspension arm sub−assy lower No. 1 LH. Remove the front suspension arm sub−assy lower No. 1 LH. Remove the front lower arm bush stopper from the front suspension arm sub−assy lower No. 1 LH. F02227 WhereEverybodyKnowsYourName 26−18 FRONT SUSPENSION 7. (a) − FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Install the front lower arm bush stopper to the front suspension arm sub−assy lower No. 1 LH. (b) Install the front suspension arm sub−assy lower No. 1 LH with the 2 bolts to the front side. Torque: 200 N⋅m (2,039 kgf⋅cm, 148 ft⋅lbf) (c) Install the front suspension arm sub−assy lower No. 1 LH with the bolt and nut to the rear side. Torque: 206 N⋅m (2,101 kgf⋅cm, 152 ft⋅lbf) 8. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (A/T TRANSAXLE) Install the transverse engine engine mounting insulator with the 3 nuts. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) C91606 F02227 (a) C83387 9. (a) (b) 10. 11. 12. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (M/T TRANSAXLE) Install the bracket with the 4 bolts to the manual transmission. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) Install the transverse engine engine mounting insulator with the 3 nuts. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ−FE ENGINE TYPE) (See page 14−29) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1MZ−FE ENGINE TYPE) (See page 14−164) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ−FE ENGINE TYPE) (See page 14−164) WhereEverybodyKnowsYourName 26−2 FRONT SUSPENSION − FRONT SUSPENSION SYSTEM 2606O−07 REPAIR HINT: This is the repair procedure for vehicle pull. START * ROAD TEST Does the vehicle lead/pull? Preliminary Check  Tire pressure  Vehicle height  Brake dragging NO Is there steering off center? NO COMPLETE YES YES Adjust front tie rods. YES Are the tires uni−directional type? NO NO ROAD TEST Does the vehicle still lead/pull? Cross switch front tire & wheel assemblies (left & right). YES YES Does the vehicle lead/pull in same direction as before? NO Choose the position of front tire & wheel assemblies where there is least amount of pull. Check front wheel alignment. Is it within specification? YES NO Is the lead/pull stronger than before? YES NO Reverse the front left side tire and rebalance it. Adjust front wheel alignment. ROAD TEST Does the vehicle still lead/pull? YES NO ROAD TEST Does the vehicle still lead/pull? Does the vehicle lead/pull to the left? COMPLETE YES Increase right front camber and decrease left front camber until lead/pull is eliminated. NO NO NO YES NOTICE : Do not exceed 1° of cross camber. Do not exceed adjustment range. Increase left front camber and decrease right front camber until lead/pull is eliminated. ROAD TEST Does the vehicle still lead/pull? YES Contact your local retail tire distributor. *Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel. (1) The vehicle can keep straight but the steering wheel has some angle. STEERING OFF CENTER (See page 50−4) (2) The vehicle cannot keep straight. STEERING PULL WhereEverybodyKnowsYourName 26−20 FRONT SUSPENSION − STABILIZER BAR FRONT STABILIZER BAR FRONT 2601J−15 REPLACEMENT HINT: COMPONENTS: See page 26−3. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH (a) Remove the 2 nuts and front stabilizer link assy LH. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40143 3. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Remove the RH side following the same procedures as with the LH side. 4. (a) REMOVE FRONT STABILIZER BRACKET NO.1 LH Remove the 2 bolts and front stabilizer bracket No. 1 LH. C91607 5. REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Remove the RH side by the same procedures with the LH side. 6. DISCONNECT TIE ROD END SUB−ASSY LH (See page 30−8) SST 09628−62011 7. DISCONNECT TIE ROD END SUB−ASSY RH SST 09628−62011 HINT: Disconnect the RH side by the same procedures with the LH side. 8. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51−28) SST 09023−00100 9. DISCONNECT PRESSURE FEED TUBE ASSY (See page 51−28) SST 09023−00100 10. DISCONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY (See page 51−28) 11. REMOVE POWER STEERING GEAR ASSY (See page 51−28) WhereEverybodyKnowsYourName 26−21 FRONT SUSPENSION 12. (a) 13. (a) − STABILIZER BAR FRONT REMOVE STABILIZER BAR FRONT Remove the stabilizer bar front from the vehicle. REMOVE FRONT STABILIZER BAR BUSH NO.1 Remove the 2 bushes from the stabilizer. 14. (a) (b) INSPECT FRONT STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nut continuously at a rate of 2 to 4 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 0.05 to 1.96 N·m (0.5 to 20 kgf·cm, 0.4 to 17.4 in.·lbf) C66721 15. INSTALL FRONT STABILIZER BAR BUSH NO.1 HINT: Install the bush to the outer side of the bush stopper on the stabilizer bar. Outer side Rear side C96987 16. (a) 17. 18. 19. 20. G26610 INSTALL STABILIZER BAR FRONT Install the stabilizer bar front to the vehicle. INSTALL POWER STEERING GEAR ASSY (See page 51−28) INSTALL STEERING INTERMEDIATE SHAFT SUB−ASSY (See page 51−28) INSTALL PRESSURE FEED TUBE ASSY (See page 51−28) SST 09023−00100 INSTALL STEERING GEAR OUTLET RETURN TUBE (See page 51−28) SST 09023−00100 INSTALL TIE ROD END SUB−ASSY LH (See page 30−8) INSTALL TIE ROD END SUB−ASSY RH 21. 22. HINT: Install the RH side following the same procedures as with the LH side. 23. (a) INSTALL FRONT STABILIZER BRACKET NO.1 LH Install the front stabilizer bracket No. 1 LH with the 2 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) C91607 WhereEverybodyKnowsYourName 26−22 FRONT SUSPENSION − STABILIZER BAR FRONT 24. INSTALL FRONT STABILIZER BRACKET NO.1 RH HINT: Install the RH side following the same procedures as with the LH side. 25. (a) INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the 2 nuts. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40143 26. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Install the RH side following the same procedures as with the LH side. 27. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 28. BLEED POWER STEERING FLUID (See page 51−3) 29. CHECK POWER STEERING FLUID LEAKAGE 30. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26−5) WhereEverybodyKnowsYourName 26−3 FRONT SUSPENSION − FRONT SUSPENSION FRONT SUSPENSION 2601C−09 COMPONENTS
TMC Made: 80 (816, 59) 49 (500, 36) Front Suspension Support Sub−assy LH TMMK Made: 85 (867,63) SPORT: Front Suspension Upper Brace Center Front Suspension Support Bearing LH Washer Front Coil Spring Seat Upper LH Front Coil Spring Insulator Upper LH Front Stabilizer Link Assy LH Front Coil Spring LH 74 (755, 55) 210 (2,141, 155) Front Spring Bumper LH 18.8 (192, 14) w/ABS: Speed Sensor Front LH Front Flexible Hose No. 1 Front Coil Spring Insulator Lower LH Shock Absorber Assy Front LH Front Axle Assy LH N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName C90258 26−4 FRONT SUSPENSION 74 (755, 55) − FRONT SUSPENSION 19 (194, 14) Front Stabilizer Bracket No. 1 RH Front Stabilizer Link Assy RH Front Stabilizer Bar Bush No. 1 Stabilizer Bar Front 19 (194, 14) Front Stabilizer Bracket No. 1 LH Rack & Pinion Power Steering Gear Assy 74 (755, 55) Front Stabilizer Link Assy LH 70 (714, 52) MT: 143 (1,458, 105) 70 (714, 52) 95 (969, 70) Transverse Engine Engine Mounting Insulator w/ABS: Speed Sensor Front LH Front Frame Assy 8.0 (82, 71 in.⋅lbf) 74 (755, 55) 206 (2,101, 152) 87 (887, 64) 200 (2,039, 148) 106.9 (1,090, 79) Front Lower Arm Bush Stopper 200 (2,039, 148) 123 (1,254 91) Lower Ball Joint Assy Front LH
Cotter Pin 210 (2,141, 155) 106.9 (1,090, 79) Front Disc Front Axle Assy LH Front Suspension Arm Sub−assy Lower No. 1 LH
Front Brake Caliper Assy
Cotter Pin 75 (765, 55) N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName 294 (2,998, 217) 49 (500, 36) F46997 26−5 FRONT SUSPENSION − FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT 260L7−01 ADJUSTMENT 1. INSPECT TIRE (See page 28−1) 2. MEASURE VEHICLE HEIGHT Vehicle height: 2AZ−FE COMFORT: Front: A USA, Canada Mexico Front (A − B) 119 mm (4.69 in.) 106 mm (4.17 in.) Rear (D − C) 45 mm (1.77 in.) 33 mm (1.30 in.) 2AZ−FE PREMIUM: B C91608 Front (A − B) 120 mm (4.72 in.) Rear (D − C) 45 mm (1.77 in.) 2AZ−FE SPORT: Rear: Front (A − B) 120 mm (4.72 in.) Rear (D − C) 48 mm (1.89 in.) 1MZ−FE COMFORT: C Front (A − B) 120 mm (4.72 in.) Rear (D − C) 46 mm (1.81 in.) 1MZ−FE PREMIUM: D USA, Canada Mexico Front (A − B) 119 mm (4.69 in.) 106 mm (4.17 in.) Rear (D − C) 47 mm (1.85 in.) 33 mm (1.30 in.) C91609 3MZ−FE SPORT: Front (A − B) 121 mm (4.76 in.) Rear (D − C) 48 mm (1.89 in.) Measuring points: A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 set bolt center C: Ground clearance of strut rod set bolt center D: Ground clearance of rear wheel center NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. HINT: Bounce the vehicle at the corners up and down to stabilize the suspension and inspect the vehicle height. WhereEverybodyKnowsYourName 26−6 FRONT SUSPENSION B A D − FRONT WHEEL ALIGNMENT 3. INSPECT TOE−IN Toe−in: Front Toe−in (total) A + B: 0° ± 12’ (0° ± 0.2°) C − D: 0 ± 2 mm (0 ± 0.08 in.) HINT:

C SA3213 4. (a) (b) (c) Measure ”A + B” when ”C − D” can not be measured. If toe−in is not within the specified range, adjust it at the rack ends. ADJUST TOE−IN Remove the rack boot set clips. Loosen the tie rod end lock nuts. Turn the right and left rack ends by an equal amount to adjust the toe−in. HINT: Try to adjust the toe−in to the center of the specified range. (d) (e) Make sure that the lengths of the right and left rack ends are the same. Torque the tie rod end lock nuts. Torque: 74 N·m (755 kgf·cm, 55 ft·lbf) Place the boots on the seats and install the clips. (f) HINT: Make sure that the boots are not twisted. (g) Perform VSC system calibration. (See page 05−1002) F40165 5. (a) INSPECT WHEEL ANGLE Turn the steering wheel fully left and right, and measure the turning angle. Wheel turning angle: USA, Canada: Front A B B A Front A: Inside B: Outside F46953 15 inch 16 inch Inside wheel 39°04’ ± 2° (39.07° ± 2°) 36°39’ ± 2° (36.65° ± 2°) Outside wheel: Reference 33°44’ (33.73°) 32°11’ (32.18°) Mexico: 15 inch 16 inch Inside wheel 39°30’ ± 2° (39.50° ± 2°) 37°00’ ± 2° (37.00° ± 2°) Outside wheel: Reference 34°02’ (34.03°) 32°28’ (32.47°) If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. WhereEverybodyKnowsYourName 26−7 FRONT SUSPENSION − FRONT WHEEL ALIGNMENT 6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Put the front wheel on the center of the alignment tester. (b) Set the camber−caster−kingpin gauge at the center of the axle hub or drive shaft. Camber and steering axis inclination: Gauge Alignment Tester Camber Z03382 Right−left error Steering axis inclination Right−left error USA, Canada Mexico −0°43’ ± 45’ (−0.72° ± 0.75°) 45’ (0.75°) or less −0°33’ ± 45’ (−0.55° ± 0.75°) 45’ (0.75°) or less 11°27’ ± 45’ (11.45° ± 0.75°) 45’ (0.75°) or less 11°05’ ± 45’ (11.08° ± 0.75°) 45’ (0.75°) or less Caster 3MZ−FE: Caster Right−left error 2°40’ ± 45’ (2.67° ± 0.75°) 45’ (0.75°) or less 1MZ−FE: Caster Right−left error USA, Canada Mexico 2°37’ ± 45’ (2.62° ± 0.75°) 45’ (0.75°) or less 2°33’ ± 45’ (2.55° ± 0.75°) 45’ (0.75°) or less 2AZ−FE SPORT: Caster Right−left error 2°43’ ± 45’ (2.72° ± 0.75°) 45’ (0.75°) or less 2AZ−FE Except SPORT: Caster Right−left error USA, Canada Mexico 2°39’ ± 45’ (2.65° ± 0.75°) 45’ (0.75°) or less 2°36’ ± 45’ (2.60° ± 0.75°) 45’ (0.75°) or less If the caster and steering axis inclination are not within the specified ranges, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 7. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe−in. (a) Remove the front wheel. (b) (c) (d) Remove the 2 nuts on the lower side of the shock absorber assy front LH. Clean the installation surfaces of the shock absorber assy front LH and the steering knuckle. Temporarily install the 2 nuts. C93871 WhereEverybodyKnowsYourName 26−8 FRONT SUSPENSION (e) (f) (g) FRONT WHEEL ALIGNMENT Fully push or pull the front axle hub in the direction of the required adjustment. Tighten the nuts. Torque: 210 N⋅m (2,141 kgf⋅cm, 155 ft⋅lbf) Install the front wheel. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) F48834 C86746 (h) Check the camber. If the measured value is not within the specified range, calculate the required adjustment amount using the formula below. (Camber adjustment amount) = Center of the specified range − Measured value (i) Check installed bolts combination. Select appropriate bolts from the table below to adjust the camber within the specified range. 1 2 F02267 C86747 − C93935 Move the axle toward (+) in step (e) Refer to table (1) (Move the axle toward positive side) Move the axle toward (−) in step (e) Refer to table (2) (Move the axle toward negative side) WhereEverybodyKnowsYourName 26−9 FRONT SUSPENSION − FRONT WHEEL ALIGNMENT Table (1) (Move the axle toward positive side) Installed Bolt 1 90105−17008 90105−17008 90105−17008 90105−17008 90105−17009 90105−17010 90105−17011 Adjusting Value 2 90105−17008 90105−17009 90105−17010 90105−17011 90105−17011 90105−17011 90105−17011 G −130’ to −115’ −115’ to −100’ G A G A B G A B C G A B C D G A B C D E F −100’ to −045’ −045’ to −030’ −030’ to −015’ −015’ to 0 0 to 015’ A B C D E 015’ to 030 B C D E F 030’ to 045’ C D E F 045’ to 100’ D E F 100’ to 115’ E F 115’ to 130’ F Selected Bolt Combination A B C D E F G 1 90105−17008 90105−17008 90105−17008 90105−17009 90105−17010 90105−17011 90105−17008 2 90105−17009 90105−17010 90105−17011 90105−17011 90105−17011 90105−17011 90105−17008 F48751 90105−17008 17.0 mm 90105−17009 15.9 mm 90105−17010 15.0 mm 90105−17011 14.0 mm The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. NOTICE: Replace the nut with a new one when replacing the bolt. (j) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. HINT: Replace one bolt at a time when replacing 2 bolts. F48750 WhereEverybodyKnowsYourName 26−10 FRONT SUSPENSION − FRONT WHEEL ALIGNMENT Table (2) (Move the axle toward negative side) Installed Bolt 1 90105−17008 90105−17008 90105−17008 90105−17008 90105−17009 90105−17010 90105−17011 Adjusting Value 2 90105−17008 90105−17009 90105−17010 90105−17011 90105−17011 90105−17011 90105−17011 −130’ to −115’ F −115’ to −100’ E F −100’ to −045’ D E F −045’ to −030’ C D E F −030’ to −015’ B C D E F −015’ to 0 A B C D E F G A B C D E G A B C D G A B C G A B G A 0 to 015’ 015’ to 030 030’ to 045’ 045’ to 100’ 100’ to 115’ 115’ to 130’ G Selected Bolt Combination A B C D E F G 1 90105−17008 90105−17008 90105−17008 90105−17009 90105−17010 90105−17011 90105−17008 2 90105−17009 90105−17010 90105−17011 90105−17011 90105−17011 90105−17011 90105−17008 F48751 90105−17008 17.0 mm 90105−17009 15.9 mm 90105−17010 15.0 mm 90105−17011 14.0 mm The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. NOTICE: Replace the nut with a new one when replacing the bolt. (k) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. HINT: Replace one bolt at a time when replacing 2 bolts. F48750 WhereEverybodyKnowsYourName 76−1 EXTERIOR/INTERIOR TRIM − FRONT BUMPER FRONT BUMPER 761DL−01 COMPONENTS Front Bumper Reinforcement Extension RH TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 17.5 (178, 13) TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 17.5 (178, 13) TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 6.5 (66, 58 in.⋅lbf) TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 6.5 (66, 58 in.⋅lbf) Front Bumper Reinforcement Extension LH TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 6.5 (66, 58 in.⋅lbf) TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 6.5 (66, 58 in.⋅lbf) TMC Made: 8.5 (87, 75 in.⋅lbf) TMMK Made: 17.5 (178, 13) Front Bumper Reinforcement Sub−assy Upper w/o Fog Lamp: Front Bumper Hole Cover RH Front Fender Liner Retainer Pin Hold Clip TMC Made: 34 (347, 25) TMMK Made: 92 (938, 68) Front Bumper Energy Absorber TMMK Made: 6.5 (66, 58 in.⋅lbf) TMMK Made: Front Bumper Reinforcement Sub−assy TMC Made: 34 (347, 25) TMMK Made: 92 (938, 68) w/o Fog Lamp: Front Bumper Hole Cover LH 6.5 (66, 58 in.⋅lbf) Pin Hold Clip Front Fender Liner Retainer w/ Fog Lamp: Fog Lamp Assy RH Fog Lamp Assy LH Front Bumper Cover Front Bumper Extension Mounting Bracket N·m (kgf·cm, ft·lbf) : Specified torque B85304 WhereEverybodyKnowsYourName 76−11 EXTERIOR/INTERIOR TRIM − NAME PLATE NAME PLATE 760BZ−04 REPLACEMENT Luggage Door Line 89 (3.63) Garnish Luggage Compartment Door Outs End Garnish Luggage Compartment Door Outs End Luggage Door Line 233.8 (9.543) 59 (2.32) Luggage Door Line End 82.2 (3.355) Luggage Door Line End Garnish Luggage Compartment Door Outs End 22 (0.90) 13.2 (0.539) Luggage Door Line 236 (9.63) Luggage Door Line End mm (in.) WhereEverybodyKnowsYourName B75449 76−12 EXTERIOR/INTERIOR TRIM − FRONT DOOR BELT MOULDING ASSY LH FRONT DOOR BELT MOULDING ASSY LH 760CA−04 REPLACEMENT HINT:

1. 2. 3. 4. 5. The installation procedures are the removal procedures in reverse order. Use the same procedures for the RH side and LH side. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY (See page 75−8) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75−8) REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (See page 75−8) REMOVE FRONT DOOR TRIM BOARD SUB−ASSY LH (See page 75−8) REMOVE OUTER REAR VIEW MIRROR ASSY LH (See page 75−8) 6. (a) (b) REMOVE FRONT DOOR BELT MOULDING ASSY LH Put protective tape under the moulding. Using a moulding remover, pry out the moulding as shown in the illustration. HINT: Tape the remover tip before use. Protective Tape Moulding Remover Tape B73803 WhereEverybodyKnowsYourName 76−13 EXTERIOR/INTERIOR TRIM − REAR DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH 760CB−04 REPLACEMENT HINT:

1. 2. 3. The installation procedures are the removal procedures in reverse order. Use the same procedures for the RH side and LH side. REMOVE POWER WINDOW REGULATOR SWITCH ASSY (See page 75−16) REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page 75−16) REMOVE REAR DOOR TRIM BOARD SUB−ASSY LH (See page 75−16) 4. (a) (b) REMOVE REAR DOOR BELT MOULDING ASSY LH Put protective tape under the moulding. Using a moulding remover, pry out the moulding as shown in the illustration. HINT: Tape the remover tip before use. Protective Tape Moulding Remover Tape B73804 WhereEverybodyKnowsYourName 76−14 EXTERIOR/INTERIOR TRIM − ROOF DRIP SIDE FINISH MOULDING CENTER LH ROOF DRIP SIDE FINISH MOULDING CENTER LH 760BP−06 REPLACEMENT HINT:


Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. When replacing the moulding, heat the body and moulding using a heat light. Heating temperature: Item Temperature Body 40 to 60C (104 to 140F) Moulding 20 to 30C (68 to 86F) NOTICE: Do not heat the body and moulding excessively. 1. Clip Protective Tape B56185 Front Side Clip 2.5 mm (0.0098 in.) Rear Side Clip 1.7 mm (0.067 in.) REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER LH (a) Put protective tape around the edges of the moulding. (b) Using a moulding remover, disengage the moulding’s front and rear end clips from the vehicle. Remove the moulding. NOTICE:
Do not remove the clips from vehicle body.
If the clips are damaged or removed accidentally, replace them. 2. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NO.1 HINT: Use the following steps (a) to (c) replacing the clips with the clips. If not replacing the clips, they are not required. (a) Remove the tape that remains on the mounting surface of the body, and then clean the surface with white gasoline. (b) Heat the clip installation surfaces of the body and moulding. (c) Install new clips in the positions shown in the illustration. Press−fit the clips by hand. NOTICE: After press−fitting the clips, wait 30 minutes or more before installing the moulding. HINT:
Minimum hardening time: 30 minutes
Time needed for complete hardening: 24 hours B75450 WhereEverybodyKnowsYourName 76−15 EXTERIOR/INTERIOR TRIM − OUTSIDE MOULDING OUTSIDE MOULDING 7611R−02 REPLACEMENT HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. When replacing the moulding, heat the body and moulding using a heat light. Heating temperature:

Item Temperature Body 40 to 60C (104 to 140F) Moulding 20 to 30C (68 to 86F) NOTICE: Do not heat the body and moulding excessively. 1. (a) (b) Protective Tape B56187 2. (a) (b) (c) (d) REMOVE OUTSIDE MOULDING Using a heat light heat the moulding. Tie both piano wire ends to wooden block or similar object. (c) Scrape the double−sided tape off by pulling the piano wire as shown in the illustration. NOTICE:
If reusing the moulding, take care not to damage the moulding.
Do not damage the body. INSTALL OUTSIDE MOULDING Using a heat light, heat the body. Remove the protective tape from the body. Wipe off the stains with cleaner. Clean the moulding (if reusing the moulding). (1) Using a heat light, heat the moulding. (2) Remove the double−sided tape from the moulding. (3) Wipe off the stains with cleaner. WhereEverybodyKnowsYourName 76−16 EXTERIOR/INTERIOR TRIM (4) − OUTSIDE MOULDING Apply new bouble−sided tape to the moulding as shown in the illustration. Front Door Outside Moulding Rear Door Outside Moulding Double−sided Tape B56188 (e) (f) Using a heat light, heat the body and moulding. Remove the peeling paper from the face of the moulding and attach the moulding securely to the vehicle body. NOTICE: Be careful that dirt or foreign objects do not stick to adhesive part when removeing the peeling paper. (g) Push the moulding to the body. NOTICE: Do not apply excessive force onto the moulding. Instead, apply steady pressure with your thumbs. WhereEverybodyKnowsYourName 76−17 EXTERIOR/INTERIOR TRIM − ROCKER PANEL MOULDING LH ROCKER PANEL MOULDING LH 760BR−06 REPLACEMENT HINT:

The installation procedures are the removal procedures in reverse order. Use the same procedures for the RH side and LH side. 1. REMOVE ROCKER PANEL MOULDING LH (a) Remove the 6 screws. (b) Using a screwdriver, pry out the rocker panel moulding. HINT: Tape the screwdriver tip before use. Clip B56189 WhereEverybodyKnowsYourName 76−18 EXTERIOR/INTERIOR TRIM − LUGGAGE COMPARTMENT DOOR GARNISH SUB−ASSY OUTSIDE LUGGAGE COMPARTMENT DOOR GARNISH SUB−ASSY OUTSIDE 760BS−06 REPLACEMENT HINT:

1. (a) The installation procedures are the removal procedures in reverse order. A bolt without torque specification is a standard bolt (see page 03−2). REMOVE LUGGAGE COMPARTMENT DOOR COVER Remove the 15 screws and cover. 2. Clip REMOVE LUGGAGE COMPARTMENT GARNISH SUB−ASSY OUTSIDE Remove the 4 screws. Using a screwdriver, pry out the garnish. (a) (b) HINT: Tape the screwdriver tip before use. B56190 WhereEverybodyKnowsYourName DOOR 76−19 EXTERIOR/INTERIOR TRIM − FRONT FLOOR FOOTREST FRONT FLOOR FOOTREST 760BT−06 REPLACEMENT 1. (a) Clip B56191 REMOVE FRONT FLOOR FOOTREST Holding the floor mat, disengage the clips from the upper with a screwdriver to remove the front floor footrest. HINT: Tape the screwdriver tip before use. NOTICE: Warm the inside of the vehicle well before removal. (b) Disengage the foot rest clips, and then remove the 2 clips from the front floor footrest. 2. (a) (b) INSTALL FRONT FLOOR FOOTREST Install the footrest clips by engaging the claws with the front floor footrest. Before installation, check that the part to be engaged with the clips of front floor footrest is not damaged. NOTICE: If it is damaged, replace it with a new one. WhereEverybodyKnowsYourName 76−2 EXTERIOR/INTERIOR TRIM − FRONT BUMPER 761DM−01 REPLACEMENT HINT:

Installation is in the reverse order of removal. COMPONENTS: SEE PAGE 76−1. 1. (a) REMOVE FRONT BUMPER ASSY Remove the clip and the 2 bolts. (b) Turn the pin hold clip 90as shown in the illustration and remove it. (LH side) B85290 HINT: Remove the RH side by following the same procedure as for the LH side. B85305 (c) Remove the 9 screws. B85306 WhereEverybodyKnowsYourName 76−3 EXTERIOR/INTERIOR TRIM (d) − FRONT BUMPER Disengage the 3 claws by pulling the left side of the front bumper cover in the direction shown by the arrow. (LH side) HINT: Disengage the RH side by following the same procedure as for the LH side. (e) Disconnect the fog lamp connector (w/ fog lamp) and remove the front bumper assy. Claw B85293 2. (a) REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET Remove the 2 screws and the bumper extension mounting bracket. B86929 3. (a) REMOVE FRONT BUMPER HOLE COVER LH (W/O FOG LAMP) Remove the 2 screws and the front bumper hole cover LH. B86849 4. 5. 6. REMOVE FRONT BUMPER HOLE COVER RH (W/O FOG LAMP) REMOVE FOG LAMP ASSY LH (W/ FOG LAMP) (SEE PAGE 65−16) REMOVE FOG LAMP ASSY RH (W/ FOG LAMP) (SEE PAGE 65−16) 7. (a) REMOVE FRONT BUMPER ENERGY ABSORBER Remove the front bumper energy absorber. B85307 WhereEverybodyKnowsYourName 76−4 EXTERIOR/INTERIOR TRIM 8. (a) Clamp − FRONT BUMPER REMOVE FRONT BUMPER REINFORCEMENT SUB−ASSY Disengage the 5 clamps. B85308 (b) Remove the 6 bolts and the front bumper reinforcement sub−assy. 9. REMOVE FRONT BUMPER REINFORCEMENT SUB−ASSY UPPER Remove the 2 bolts and the 2 nuts. Remove the front bumper reinforcement sub−assy upper. B85309 (a) (b) B85310 10. (a) (b) REMOVE FRONT BUMBER REINFORCEMENT EXTENSION LH Remove the 2 bolts and the nut. Remove the front bumper reinforcement extension LH. B85311 11. REMOVE FRONT BUMBER REINFORCEMENT EXTENSION RH WhereEverybodyKnowsYourName 76−5 EXTERIOR/INTERIOR TRIM − FRONT BUMPER 12. 13. (a) (b) INSTALL FRONT BUMBER REINFORCEMENT EXTENSION LH (a) TMC MADE: (1) Install the front bumper reinforcement extension LH with the 2 bolts and nut. Torque: Bolt: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Nut: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) (b) TMMK MADE: B85311 (1) Install the front bumper reinforcement extension LH with the 2 bolts and nut. Torque: Bolt: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) Nut: 6.5 N⋅m (66 kgf⋅cm, 58 in.⋅lbf) INSTALL FRONT BUMBER REINFORCEMENT EXTENSION RH TMC MADE: (1) Install the front bumper reinforcement extension RH with the 2 bolts and nut. Torque: Bolt: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Nut: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) TMMK MADE: (1) Install the front bumper reinforcement extension RH with the 2 bolts and nut. Torque: Bolt: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) Nut: 6.5 N⋅m (66 kgf⋅cm, 58 in.⋅lbf) 14. INSTALL FRONT BUMPER REINFORCEMENT SUB−ASSY UPPER (a) TMC MADE: (1) Install the front bumper reinforcement sub−assy upper with the 2 bolts and 2 nuts. Torque: Bolt: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Nut: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) (b) TMMK MADE: B85310 (1) Install the front bumper reinforcement sub−assy upper with the 2 bolts and 2 nuts. Torque: Bolt: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) Nut: 6.5 N⋅m (66 kgf⋅cm, 58 in.⋅lbf) 15. (a) (b) B85309 INSTALL FRONT BUMPER REINFORCEMENT SUB−ASSY TMC MADE: (1) Install the front bumper reinforcement sub−assy with the 6 bolts. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) TMMK MADE: (1) Install the front bumper reinforcement sub−assy with the 6 bolts. Torque: 92 N⋅m (938 kgf⋅cm, 68 ft⋅lbf) WhereEverybodyKnowsYourName 76−6 EXTERIOR/INTERIOR TRIM 16. (a) − FRONT BUMPER INSTALL FRONT BUMPER ASSY TMMT MADE: (1) Install the front bumper assy with the 2 bolts. Torque: 6.5 N⋅m (66 kgf⋅cm, 58 in.⋅lbf) (2) Install the clip. B85290 17. FOG LAMP AIMING ADJUSTMENT (W/ FOG LAMP) (SEE PAGE 65−17) WhereEverybodyKnowsYourName 76−20 EXTERIOR/INTERIOR TRIM − ROOF HEADLINING ASSY ROOF HEADLINING ASSY 760C7−04 COMPONENTS w/ Curtain Shield Airbag Roof Side Garnish Inner RH w/ Curtain Shield Airbag Center Pillar Garnish RH Front Pillar Garnish RH Rear Door Opening Trim Weatherstrip RH Rear Door Scuff Plate RH Front Door Opening Trim Weatherstrip RH 42 (420, 31) Front Door Scuff Plate RH Center Pillar Garnish Lower RH Lap Belt Outer Anchor Cover w/ Curtain Shield Airbag Center Pillar Garnish LH Front Pillar Garnish LH w/ Curtain Shield Airbag Roof Side Garnish Inner LH Center Pillar Garnish Lower LH Rear Door Opening Trim Weatherstrip LH Front Door Scuff Plate LH Rear Door Scuff Plate LH 42 (420, 31) N⋅m (kgf⋅cm ft⋅lbf) : Specified torque Front Door Opening Trim Weatherstrip LH WhereEverybodyKnowsYourName B57089 76−21 EXTERIOR/INTERIOR TRIM − ROOF HEADLINING ASSY w/ Moon Roof Sun Roof Opening Trim Moulding Roof Headlining Assy Assist Grip Sub−assy Assist Grip Sub−assy Roof Headlining Assy w/ Sunshade: Sunshade Trim Holder w/ Sunshade: Sunshade Trim Holder Assist Grip Cover Assist Grip Cover Roof Console Box Assy Assist Grip Cover Assist Grip Sub−assy Assist Grip Sub−assy Room Lamp Assy No.1 Lens Visor Assy RH w/ Erector Chromic Inner Mirror: Inner Rear View Mirror Cover Visor Holder Visor Assy LH Visor Holder Visor Bracket Cover Visor Bracket Cover B57088 WhereEverybodyKnowsYourName 76−22 EXTERIOR/INTERIOR TRIM − ROOF HEADLINING ASSY 760C8−04 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the RH side, use the same procedures as on the LH side. REMOVE FRONT SEAT ASSEMBLY RH (Power Seat Type: See page 72−23, Manual Seat Type: See page 72−15) REMOVE FRONT SEAT ASSEMBLY LH (Power Seat Type: See page 72−23, Manual Seat Type: See page 72−15) REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72−32) REMOVE REAR SIDE SEAT BACK ASSY RH (See page 72−32) REMOVE REAR SIDE SEAT BACK ASSY LH (See page 72−32) REMOVE SEPARATE TYPE REAR SEAT BACK ASSY RH (See page 72−32) REMOVE SEPARATE TYPE REAR SEAT BACK ASSY LH (See page 72−32) REMOVE CONSOLE PANEL UPPER REAR (See page 71−16) REMOVE RR CONSOLE BOX (See page 71−16) REMOVE CONSOLE PANEL UPPER (See page 71−16) REMOVE CONSOLE BOX FRONT (See page 71−16) REMOVE CONSOLE BOX DUCT NO.1 (See page 55−34) REMOVE AIR DUCT REAR NO.1 (See page 55−34) REMOVE AIR DUCT REAR NO.2 (See page 55−34) REMOVE FLOOR SHIFT SHIFT LEVER ASSY (MANUAL TRANSAXLE) (See Page 41−5) REMOVE FLOOR SHIFT ASSY (AUTOMATIC TRANSAXLE) (See Page 40−54) 17. REMOVE FRONT DOOR SCUFF PLATE RH (a) Using a screwdriver, remove the front door scuff plate. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 18. REMOVE FRONT DOOR SCUFF PLATE LH B57751 WhereEverybodyKnowsYourName 76−23 EXTERIOR/INTERIOR TRIM − ROOF HEADLINING ASSY 19. REMOVE REAR DOOR SCUFF PLATE RH (a) Using a screwdriver, remove the rear door scuff plate. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 20. REMOVE REAR DOOR SCUFF PLATE LH B57752 21. 22. 23. 24. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 25. (a) (b) 26. REMOVE CENTER PILLAR GARNISH LOWER RH Pull the center pillar lower garnish upward to remove it. Employ the same manner described above to the other side. REMOVE CENTER PILLAR GARNISH LOWER LH B56896 27. (a) REMOVE CENTER PILLAR GARNISH UPPER RH Using a screwdriver, remove the lap belt outer anchor cover. HINT: Tape the screwdriver tip before use. (b) Remove the bolt and front seat outer belt floor anchor. B57064 (c) (d) Remove the 2 clips Using a screwdriver, remove the center pillar upper garnish. HINT: Tape the screwdriver tip before use. (e) Employ the same manner described above to the other side. 28. REMOVE CENTER PILLAR GARNISH UPPER LH B56900 WhereEverybodyKnowsYourName 76−24 EXTERIOR/INTERIOR TRIM 29. B56897 (a) REMOVE ROOF SIDE GARNISH INNER RH (W/ CURTAIN SHIELD AIR BAG) Using a screwdriver, remove the roof side garnish inner cover. REMOVE FRONT PILLAR GARNISH RH (W/O CURTAIN SHIELD AIR BAG) Using a screwdriver, remove the front pillar garnish. (a) HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 34. REMOVE FRONT PILLAR GARNISH LH (W/O CURTAIN SHIELD AIR BAG) 35. B56914 REMOVE ROOF SIDE GARNISH INNER RH (W/O CURTAIN SHIELD AIR BAG) Using a screwdriver, remove the roof side garnish inner. HINT: Tape the screwdriver tip before use. (b) Remove the bolt. (c) Using a screwdriver, remove the roof side garnish inner. HINT: Tape the screwdriver tip before use. 32. REMOVE ROOF SIDE GARNISH INNER LH (W/ CURTAIN SHIELD AIR BAG) 33. B56910 ROOF HEADLINING ASSY (a) HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 30. REMOVE ROOF SIDE GARNISH INNER LH (W/O CURTAIN SHIELD AIR BAG) 31. B56901 − REMOVE FRONT PILLAR GARNISH RH (W/ CURTAIN SHIELD AIR BAG) Using a screwdriver, remove the front pillar garnish cover. (a) HINT: Tape the screwdriver tip before use. (b) Remove the bolt. (c) Using a screwdriver, remove the front pillar garnish. HINT: Tape the screwdriver tip before use. WhereEverybodyKnowsYourName 76−25 EXTERIOR/INTERIOR TRIM 120 mm 700 mm Tape Tape − ROOF HEADLINING ASSY (d) Protect the curtain shield airbag. NOTICE: Cover the curtain shield airbag with the protection cover as soon as the front pillar garnish is removed. (1) Cover the airbag with cloth or nylon of 700 mm (27.56 in.) × 120 mm (4.72 in.) and fix the ends of the cover with tape, as shown in the illustration. (e) Employ the same manner described above to the other side. 36. REMOVE FRONT PILLAR GARNISH LH (W/ CURTAIN SHIELD AIR BAG) Tape Protective Cover B55645 Protection Tape 37. REMOVE ASSIST GRIP SUB−ASSY (a) Using a screwdriver, remove the assist grip cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and assist grip. B53950 38. (a) REMOVE RH VISOR ASSY Using a moulding remover, remove the visor bracket cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and assist grip. 39. REMOVE LH VISOR ASSY B57173 40. (a) REMOVE ROOF CONSOLE BOX ASSY Using a screwdriver, remove the roof console box then disconnect the connector. HINT: Tape the screwdriver tip before use. B56911 WhereEverybodyKnowsYourName 76−26 EXTERIOR/INTERIOR TRIM − ROOF HEADLINING ASSY 41. (a) REMOVE ROOM LAMP ASSY NO.1 Using a screwdriver, remove the lens. (b) Using a screwdriver, remove the room lamp assembly No.1 then disconnect the connector. Cutout Part B57174 HINT: Tape the screwdriver tip before use. B57175 42. (a) 90 REMOVE VISOR HOLDER Remove the holder of the sun visor by turning it to the left. B50596 43. REMOVE SUN ROOF OPENING TRIM MOULDING (W/ SLIDING ROOF) WhereEverybodyKnowsYourName 76−27 EXTERIOR/INTERIOR TRIM 44. (a) (b) (c) − ROOF HEADLINING ASSY REMOVE ROOF HEADLINING ASSY Remove the 2 sunshade trim holders. w/ Erector chromic inner mirror: Remove the inner rear view mirror cover. Tear off the tape on the adhered part of the wire harness. B56912 (d) Remove the headlining assembly from the passenger’s door. B56438 45. INSTALL ROOF HEADLINING ASSY (a) Align the markings, then install the wire harness with tape. HINT: Be careful for dirt or foreign objects not to stick to the adhered part when peeling the double−stick tape. (b) Attach the roof wire harness across the adhered part NOTICE: Roof wire harness should be attached securely. w/ Sliding roof Tape w/o Sliding roof Tape B56917 46. 47. INSTALL FRONT SEAT ASSEMBLY LH (Power Seat Type: See page 72−23, Manual Seat Type: See page 72−15) INSTALL FRONT SEAT ASSEMBLY RH (Power Seat Type: See page 72−23, Manual Seat Type: See page 72−15) WhereEverybodyKnowsYourName 76−7 EXTERIOR/INTERIOR TRIM − REAR BUMPER REAR BUMPER 760BL−05 COMPONENTS Luggage Compartment Trim Cover Inner RH Luggage Compartment Trim Cover Inner LH Luggage Compartment Floor Mat Luggage Compartment Side Cover Sub−assy RH Luggage Compartment Trim Hook No.1 Spare Wheel Cover Assy Luggage Compartment Trim Hook No.1 Rear Floor Finish Plate Rear Bumper Reinforcement Sub−assy 34 (347, 25) Rear Bumper Retainer Upper RH 34 (347, 25) Rear Bumper Energy Absorber Rear Bumper Retainer Upper LH Rear Bumper Side Retainer RH Rear Bumper Side Retainer LH Rear Bumper Cover N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque B56513 WhereEverybodyKnowsYourName 76−8 EXTERIOR/INTERIOR TRIM − REAR BUMPER 760BM−04 REPLACEMENT HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 2. REMOVE SPARE WHEEL COVER ASSY 3. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB−ASSY RH 4. REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO.1 (a) Remove the 2 bolts and luggage compartment trim hooks. 5. (a) 6. (a) 7. Clips REMOVE REAR FLOOR FINISH PLATE Disengage the clips and remove the rear floor finish plate. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER RH Using a clip remover, remove the 2 clips and luggage compartment trim cover inner. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH B56105 8. (a) (b) (c) REMOVE REAR BUMPER COVER Remove the 8 nuts, 4 bolts. (Inside) Remove the 2 screws, 4 clips and rear bumper cover. (outside) Disengage the rear bumper seal bracket and remove the rear bumper cover. B60006 9. (a) (b) 10. 11. (a) (b) 12. 13. 14. (a) 15. (a) REMOVE REAR BUMPER SIDE RETAINER RH Remove the clip and rear bumper side retainer. (Only TMC made) Remove the rivet and rear bumper side retainer. (Only TMMK made) REMOVE REAR BUMPER SIDE RETAINER LH REMOVE REAR BUMPER RETAINER UPPER RH Remove the 3 clips and rear bumper retainer upper. (Only TMC made) Remove the 4 rivets and rear bumper retainer upper. (Only TMMK made) REMOVE REAR BUMPER RETAINER UPPER LH REMOVE REAR BUMPER ENERGY ABSORBER REMOVE REAR BUMPER REINFORCEMENT SUB−ASSY Remove the 6 nuts and rear bumper reinforcement. INSTALL REAR BUMPER REINFORCEMENT SUB−ASSY Install the front bumper reinforcement with 6 nuts. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) WhereEverybodyKnowsYourName 76−9 EXTERIOR/INTERIOR TRIM − REAR SPOILER SUB−ASSY REAR SPOILER SUB−ASSY 760BK−05 REPLACEMENT HINT:


The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without torque specification is a standard bolt (see page 03−2). When replacing the moulding, heat the body and spoiler using a heat light. Heating temperature: Item Temperature Body 40 to 60C (104 to 140F) Spoiler 20 to 30C (68 to 86F) NOTICE: Do not heat the body and spoiler excessively. 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (a) Remove the 15 clips and door cover. 2. REMOVE REAR SPOILER SUB−ASSY (a) Remove the 2 nuts. (b) Put protective tape onto the body. (c) Using a heat light, heat the spoiler. (d) Clip Protective Tape B56106 Tie both piano wire ends to wooden blocks or similar objects. (1) Scrape the adhesive tape off by pulling the piano wire as shown in the illustration. (2) If reusing the rear spoiler, take care not to damage the rear spoiler. NOTICE: Do not damage the body. (e) Disconnect the connector. (f) Clip Remove the 2 clips and rear spoiler. B56107 3. 4. (a) (b) (c) REMOVE CENTER STOP LAMP ASSY (See page 65−22) INSTALL REAR SPOILER SUB−ASSY Using a heat light. Remove the protective tape from the body. Wipe off the stains with cleaner. WhereEverybodyKnowsYourName 76−10 EXTERIOR/INTERIOR TRIM (d) − REAR SPOILER SUB−ASSY Clean the rear spoiler (if reusing the spoiler). (1) Using a heat light, heat the spoiler. (2) Remove the adhesive tape from the rear spoiler. (3) Wipe off the stains with cleaner. (4) (e) (f) Install new adhesive tape to the rear spoiler as shown in the illustration. Using a heat light, heat the body and spoiler. Install the rear spoiler with 2 nuts. B55741 WhereEverybodyKnowsYourName 61−1 SEAT BELT − SEAT BELT WARNING SYSTEM (From July, 2003) SEAT BELT WARNING SYSTEM (From July, 2003) 610GF−01 LOCATION Combination Meter Clock Driver Side Seat Belt Warning Lamp Passenger Side Seat Belt Warning Lamp Occupant Classification ECU Instrument Panel J/B
IG1 Relay
GAUGE1 Fuse
AM1 Fuse Front Seat Inner Belt RH Airbag Sensor Assy Front Seat Inner Belt LH Passenger Seat Occupant Classification Sensor Rear Occupant Classification Sensor Front B74564 WhereEverybodyKnowsYourName 61−12 SEAT BELT − REAR SEAT BELT REAR SEAT BELT 61056−03 COMPONENTS w/ Curtain Shield Airbag TMMK Made: Center Stop Lamp Assy Package Tray Trim Panel Assy 18 (183,13) Roof Side Garnish Inner LH Room Partition Board Rear Side Seat Back Assy RH 18 (183,13) Roof Side Garnish Inner LH Rear Side Seat Back Assy LH Rear Seat Shoulder Belt Cover RH Center Stop Lamp Assy 42 (420, 31) Rear Seat Shoulder Belt Cover LH Rear Seat 3 Point Type Belt Assy Outer 42 (420, 31) 42 (420, 31) 42 (420, 31) Package Tray Trim Panel Assy 42 (420, 31) Child Restraint Seat Tether Anchor Cover Rear Seat Inner w/ Center Belt Assy RH Rear Seat Inner w/ Center Belt Assy LH Rear Seat Cushion Assy N⋅m (kgf⋅cm ft.⋅lbf) : Specified torque WhereEverybodyKnowsYourName B74557 61−13 SEAT BELT − REAR SEAT BELT (TMC MADE) REAR SEAT BELT (TMC MADE) 61057−04 REPLACEMENT HINT:

1. 2. 3. 4. The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the RH side, use the same procedures as on the LH side. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) REMOVE ROOF SIDE GARNISH INNER RH(See page 76−22) REMOVE ROOF SIDE GARNISH INNER LH(See page 76−22) REMOVE CENTER STOP LAMP ASSY (See page 65−22) 5. REMOVE REAR SEAT SHOULDER BELT COVER RH (a) Using a screwdriver, disengage the claws in the front side. HINT: Tape the screwdriver tip before use. (b) Pull out the shoulder belt cover to the front side to disengage the claws. (c) Pull out the shoulder belt from the slit to remove the shoulder belt cover. B60047 6. 7. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 72−32) REMOVE REAR SIDE SEAT BACK ASSY LH (See page 72−32) 8. (a) (b) Clip REMOVE PACKAGE TRAY TRIM PANEL ASSY Remove the 3 bolts and floor anchor of the seat belt. Disengage the clips and claws and pull out the belt to remove the package tray trim. B56642 9. (a) 10. (a) 11. (a) REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER Remove the bolt in the retractor, and disengage the claws of the stopper to remove the rear seat belt assembly outer. REMOVE REAR SEAT INNER W/CENTER BELT ASSY RH Remove the bolt, and disengage the claws of the stopper to remove the rear seat inner with center belt assembly RH. REMOVE REAR SEAT INNER W/CENTER BELT ASSY LH Remove the bolt in the retractor, and remove the rear seat inner with center belt assembly LH. WhereEverybodyKnowsYourName 61−14 SEAT BELT − REAR SEAT BELT (TMC MADE) 12. Protrusion Front INSTALL REAR SEAT INNER W/CENTER BELT ASSY RH (a) Install the floor anchor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. Protrusion B57709 13. (a) INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER Install the retractor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (b) Protrusion B36397 B57303 Install the anchor of the rear seat 3 point type belt assembly outer RH with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. (c) Check the degree of tilt when the belt begins to lock the ELR. (1) Check the degree in the same way as the rear seat inner with center belt assembly RH. (d) Check the ELR lock. (1) Check that the belt will lock when pulling out the belt quickly with the belt installed. (e) Check the fastening function for child restraint system. (1) Check the function in the same way as the rear seat inner with center belt assembly RH. WhereEverybodyKnowsYourName 61−15 SEAT BELT − REAR SEAT BELT (TMC MADE) 14. 45 B50564 INSTALL REAR SEAT INNER W/CENTER BELT ASSY LH (a) Check the degree of tilt when the belt begins to lock the ELR. (1) Check the belt will not lock within 15 degrees of tilt in all the direction but the belt will lock over 45 degrees of tilt when moving the installed retractor gently. (b) Install the retractor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (c) Check the ELR lock. (1) Check that the belt will lock when pulling out the belt quickly with the belt installed. (d) Check the fastening function for child restraint system. NOTICE: Check should be done with the assembly installed. (1) Check that the belt cannot be pulled out any more but can be rewound after the belt is fully pulled out. (2) Check that the belt can be pulled out and rewound after the belt is fully rewound. (e) Front Protrusion Protrusion B51963 B56863 Install the floor anchor with the bolt, directing an arrow mark on the plate to the vehicle’s front direction. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. (f) Check the ELR lock. (1) Check that the belt will lock when pulling out the belt quickly with the belt installed. WhereEverybodyKnowsYourName 61−16 SEAT BELT − REAR SEAT BELT (TMMK MADE) REAR SEAT BELT (TMMK MADE) 61058−04 REPLACEMENT HINT:

1. 2. 3. 4. The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the RH side, use the same procedures as on the LH side. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) REMOVE ROOF SIDE GARNISH INNER RH (See page 76−22) REMOVE ROOF SIDE GARNISH INNER LH (See page 76−22) REMOVE CENTER STOP LAMP ASSY (See page 65−22) 5. REMOVE REAR SEAT SHOULDER BELT COVER RH (a) Using a screwdriver, disengage the claws in the front side. HINT: Tape the screwdriver tip before use. (b) Pull out the shoulder belt cover to the front side to disengage the claws. (c) Pull out the shoulder belt from the slit to remove the shoulder belt cover. B60047 6. 7. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 72−32) REMOVE REAR SIDE SEAT BACK ASSY LH (See page 72−32) 8. (a) REMOVE ROOM PARTITION BOARD ASSY Remove the 9 clips and room partition board. 9. (a) (b) REMOVE PACKAGE TRAY TRIM PANEL ASSY Remove the 3 bolts and floor anchor of the seat belt. Disengage the clips and claws and pull out the belt to remove the package tray trim. B57227 B60048 WhereEverybodyKnowsYourName 61−17 SEAT BELT 10. (a) 11. (a) 12. (a) − REAR SEAT BELT (TMMK MADE) REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER Remove the bolt in the retractor, and disengage the claws of the stopper to remove the rear seat belt assembly outer. REMOVE REAR SEAT INNER W/CENTER BELT ASSY RH Remove the bolt, and disengage the claws of the stopper to remove the rear seat inner with center belt assembly RH. REMOVE REAR SEAT INNER W/CENTER BELT ASSY LH Remove the bolt in the retractor, and remove the rear seat inner with center belt assembly LH. 13. Protrusion Front INSTALL REAR SEAT INNER W/CENTER BELT ASSY RH (a) Install the floor anchor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. Protrusion B57709 14. (a) INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER Install the retractor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (b) Protrusion B36397 B57303 Install the anchor of the rear seat 3 point type belt assembly outer RH with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. (c) Check the degree of tilt when the belt begins to lock the ELR. (1) Check in the same way as the rear seat inner with center belt assembly RH. (d) Check the ELR lock. (1) Check the degree that the belt will lock when pulling out the belt quickly with the belt installed. (e) Check the fastening function for child restraint system. (1) Check the function in the same way as the rear seat inner with center belt assembly RH. WhereEverybodyKnowsYourName 61−18 SEAT BELT − REAR SEAT BELT (TMMK MADE) 15. 45 B50564 INSTALL REAR SEAT INNER W/CENTER BELT ASSY LH (a) Check the degree of tilt when the belt begins to lock the ELR. (1) Check the belt will not lock within 15 degrees of tilt in all the direction but the belt will lock over 45 degrees of tilt when moving the installed retractor gently. (b) Install the retractor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (c) Check the ELR lock. (1) Check that the belt will lock when pulling out the belt quickly with the belt installed. (d) Check the fastening function for child restraint system. NOTICE: Check should be done with the assembly installed. (1) Check that the belt cannot be pulled out any more but can be rewound after the belt is fully pulled out. (2) Check that the belt can be pulled out and rewound after the belt is fully rewound. (e) Front Protrusion Protrusion B51963 B56863 Install the floor anchor with the bolt, directing an arrow mark on the plate to the vehicle’s front direction. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) NOTICE: Take care for the anchor not to run onto the protrusion part of the floor panel. (f) Check the ELR lock. (1) Check that the belt will lock when pulling out the belt quickly with the belt installed. WhereEverybodyKnowsYourName 61−2 SEAT BELT − SEAT BELT WARNING SYSTEM (From July, 2003) 610GD−02 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Driver side seat belt warning light does not blink, or it does not go off after the seat belt is fastened when the ignition switch is on. 1. 2. 3. 4. 5. 6. IG1 relay AM1 fuse GAUGE1 fuse Front seat inner belt assy LH Combination meter Wire harness 61−1 61−1 61−1 61−3 05−2021 − Passenger side seat belt warning light does not blink with the front passenger’s seat occupied, or it does not go off after the seat belt is fastened when the ignition switch is on. 1. 2. 3. 4. 5. 6. 7. 8. 9. IG1 relay AM1 fuse GAUGE1 fuse Clock Front seat inner belt assy RH Occupant classification ECU Occupant classification sensor Airbag sensor assy Wire harness 61−1 61−1 61−1 05−2023 05−1478 05−1478 05−1478 05−1478 − NOTICE: The front seat inner belt RH can not be inspected. When the front seat inner belt seems to be malfunctioning, using the hand−held tester to check the DTC. WhereEverybodyKnowsYourName 61−3 SEAT BELT − SEAT BELT WARNING SYSTEM (From July, 2003) 610GE−01 INSPECTION 1. TMMK made (a) TMMK made: INSPECT FRONT SEAT INNER BELT ASSY LH Check the buckle switch. (1) Fasten the seat belt. (2) Check the resistance between the terminals. Standard: Tester Connection Specified Condition 3−6 1 MΩ or higher (3) Release the seat belt. (4) Check the resistance between the terminals. Standard: B75448 Tester Connection Specified Condition 3−6 Below 1 Ω If the result is not as specified, replace the inner belt assy. 2. TMC made No Pin No Pin (a) B75863 TMC made: INSPECT FRONT SEAT INNER BELT ASSY LH Check the buckle switch. (1) Fasten the seat belt. (2) Check the resistance between the terminals. Standard: Tester Connection Specified Condition 2−3 1 MΩ or higher (3) Release the seat belt. (4) Check the resistance between the terminals. Standard: Tester Connection Specified Condition 2−3 Below 1 Ω If the result is not as specified, replace the inner belt assy. WhereEverybodyKnowsYourName 61−4 SEAT BELT − FRONT SEAT BELT FRONT SEAT BELT 61053−03 COMPONENTS Rear Door Opening Trim Weatherstrip RH Center Pillar Garnish RH Rear Door Scuff Plate RH Front Door Opening Trim Weatherstrip RH 42 (420, 31) Center Pillar Garnish Lower RH Front Door Scuff Plate RH Belt Guide 42 (420, 31) Front Seat Outer Belt Assy RH 7.5 (77, 66 in. ft⋅lbf) 42 (420, 31) Lap Belt Outer Anchor Cover Front Seat Inner Belt Assy RH 42 (420, 31) Front Seat Assy RH TMMK Made: Front Seat Inner Belt Assy RH 42 (420, 31) N⋅m (kgf⋅cm ft.⋅lbf) : Specified torque WhereEverybodyKnowsYourName B74556 61−5 SEAT BELT − FRONT SEAT BELT 61054−04 REPLACEMENT HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
On the RH side, use the same procedures as on the LH side. 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE FRONT SEAT ASSY RH (See page 72−23 or 72−15) 3. REMOVE FRONT DOOR SCUFF PLATE RH (See page 76−22) 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76−22) 5. REMOVE REAR DOOR SCUFF PLATE RH (See page 76−22) 6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 76−22) 7. REMOVE LAP BELT OUTER ANCHOR COVER (See page 76−22) 8. REMOVE CENTER PILLAR GARNISH LOWER RH (See page 76−22) 9. REMOVE CENTER PILLAR GARNISH UPPER RH (See page 76−22) 10. REMOVE FRONT SEAT OUTER BELT ASSY RH (a) Remove the 2 screws and belt guide. (b) Remove the nut and the shoulder anchor. NOTICE: When removing the seat belt pretensioner, operation must be started after 90 seconds have passed from the time the ignition switch is turned to the LOCK position and the negative (−) terminal cable is disconnected from the battery. (c) Disconnect the connector. (1) Using a screwdriver, pull the locking button of the pretensioner connector to your side to release the lock. HINT: Tape the screwdriver tip before use. (d) Remove the 2 bolts and the front seat outer belt assembly. B50195 11. (a) (b) (c) 12. (a) (b) B57295 REMOVE FRONT SEAT INNER BELT ASSY RH Disconnect the connector and clamp. TMC made: Remove the bolt and the front seat inner belt assembly. TMMK made: Remove the nut and the front seat inner belt assembly. INSTALL FRONT SEAT INNER BELT ASSY RH TMC made: Install the front seat inner belt assembly with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) TMMK made: Install the front seat inner belt assembly with the nut. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) WhereEverybodyKnowsYourName 61−6 SEAT BELT − FRONT SEAT BELT 13. (a) 45 B50563 INSTALL FRONT SEAT OUTER BELT ASSY RH Check the degree of tilt when beginning to lock the ELR. (1) Make sure that the belt cannot be pulled out by over 45 degrees of tilt. NOTICE: Do not disassemble the retractor. (b) Install the retractor with the 2 bolts. Torque: 7.5 N⋅m (80 kgf⋅cm, 66 in.⋅lbf) (Upper part of retractor) 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (Lower part of retractor) (c) Install the shoulder anchor with the nut. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (d) Install the floor anchor with the bolt. Torque: 42 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) (e) Check the ELR lock. (1) Check that the seat belt is locked when the seat belt is pulled out quickly with the seat belt installed in the vehicle. WhereEverybodyKnowsYourName 61−7 SEAT BELT − FRONT SEAT BELT 6109J−02 DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner) always first active the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedures given in step 1−(d) in DISPOSAL. SST B50515 CAUTION:
Never dispose of front seat outer belt which has an inactivated pretensioner.
The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform operation out−of−door and where it will not create a nuisance to nearby residents.
When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front seat belt with an activated pretensioner.
Always wash your hands with water after completing operation.
Do not apply water, etc. to a front seat outer belt with an activated pretensioner.
When activating the seat belt pretensioner, always use the specified SST. (09062−00700, 09082−00770) (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. 1. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN SCRAPPING VEHICLE DEPLOYMENT METHOD) HINT: Check that the battery positive voltage is above 12 V. B50511 WhereEverybodyKnowsYourName 61−8 SEAT BELT − FRONT SEAT BELT (a) Check functioning of SST. CAUTION: When activating the seat belt pretensioner, always use a specified SST. SST B50515 (1) Battery Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (−) terminal. HINT: Do not connect the yellow connector which will be connected to the seat belt pretensioner. SST B50511 (2) SST Check the functioning of SST. Press SST activation switch, and check that the LED of SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not pressed, SST probably malfunctions, so definitely do not use SST. B50514 (b) Disconnect the pretensioner connector. (1) Remove the front door scuff plate RH (See page 76−22). (2) Remove the rear door scuff plate RH (See page 76−22). (3) Remove the front door opening trim weather strip RH (See page 76−22). (4) Remove the rear door opening trim weather strip RH (See page 76−22). (5) Remove the center pillar garnish lower RH (See page 76−22). (6) Remove the center pillar garnish upper RH (See page 76−22). (7) (8) B50195 Disconnect the pretensioner connector as shown in the illustration. Install the floor anchor of the seat belt. B57295 WhereEverybodyKnowsYourName 61−9 SEAT BELT − FRONT SEAT BELT (c) SST Install SST. (1) Connect 2 SST, then connect them to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 (2) Move SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect SST red clip to the battery positive (+) terminal and the black clip to the negative (−) terminal. 10 m (33 ft) or more B50513 (d) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED of SST activation switch lighting up. (e) Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:
The rear outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation.
Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with the activated front seat outer belt being installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD) NOTICE:
When disposing of a front seat outer belt (with seat belt pretensioner) only, never use the customer’s vehicle to activate the seat belt pretensioner.
Be sure to follow the procedures given on the next page when activating the seat belt pretensioner. WhereEverybodyKnowsYourName 61−10 SEAT BELT − FRONT SEAT BELT (a) Remove the front seat outer belt (See page 61−5). HINT: Cut the belt near the seat belt retractor. B63291 (b) Check functioning of SST (See step 1−(a)). Battery SST B50511 (c) SST Install SST. (1) Connect 2 SST, then connect them to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 (2) SST SST Place the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTICE: Place the front seat outer belt as shown in the illustration. (3) Move SST at least 10 m (33 ft) away from the wheel disc. NOTICE: Take care not to damage SST wire harness. B50509 WhereEverybodyKnowsYourName 61−11 SEAT BELT (d) 10 m (33 ft) or more B50541 − FRONT SEAT BELT Activate the seat belt pretensioner. (1) Connect SST red clip to the battery positive (+) terminal and black clip to the battery negative (−) terminal. (2) Check that no one is within 10 m (33 ft) area around the disc wheel. (3) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED of SST activation switch lighting up. (e) Dispose of the front seat outer belt (with seat belt pretensioner). (1) Remove the disc wheel and SST. (2) Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts. B51516 WhereEverybodyKnowsYourName 65−1 LIGHTING − LIGHTING SYSTEM LIGHTING SYSTEM 650BI−02 PRECAUTION 1. (a) (b) (c) (d) (e) PRECAUTION OF HEADLIGHT BULB REPLACEMENT If the adhered oil is left unremoved from the halogen lamp surface, the lamp service life is shortened as it becomes hot when it is turned on. Since the internal pressure of a halogen lamp is high, dropping, hitting or damaging the bulb may cause the glass to scatter. Therefore, handle it with great care. When replacing bulbs, do not remove until a new bulb is prepared. Because if it is left being removed for a long period of time, the lens may be covered with dirt or moisture. For replacement, be sure to use a bulb of the same watt. Firmly reinstall the socket after bulb replacement. Otherwise, cloudy lens or invasion by water will be caused. WhereEverybodyKnowsYourName 65−10 LIGHTING − HEADLAMP ASSY LH 651AN−01 ADJUSTMENT 1. (a) 2. (a) (b) VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT Prepare the vehicle:
Ensure there is no damage or deformation to the body around the headlamps.
Fill the fuel tank.
Make sure that the oil is filled to the specified level.
Make sure that the coolant is filled to the specified level.
Inflate the tires to the appropriate pressure.
Place the spare tire, tools, and jack in their original positions.
Unload the trunk.
Sit a person of average weight (68 kg, 150 lb) in the driver’s seat. PREPARATION FOR HEADLAMP AIMING (Using a tester) Prepare the vehicle for headlamp aim check. Adjust in accordance with headlamp tester instructions. 3. 7.62 m (25 ft) 3 m (9.84 ft) I43405 PREPARATION FOR HEADLAMP AIMING (Using a screen) (a) Prepare the vehicle according to the following conditions:
Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlamps can be observed and above which it cannot.
Place the vehicle at a 90 angle to the wall.
Create a 7.62 m (25 ft) distance between the vehicle (headlamp bulb center) and the wall.
Place the vehicle on a level surface.
Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (headlamp bulb center) and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft) for check and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. (c) Draw a vertical line down the center of screen (V line). WhereEverybodyKnowsYourName 65−11 LIGHTING − HEADLAMP ASSY LH (d) Set the screen as shown in the illustration. HINT:
Stand the screen perpendicular to the ground.
Align the V line on the screen with the center of the vehicle. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V RH Line V RH Line 90 90 V Line V Line 3 m (9.84 ft) 7.62 m (25 ft) V LH Line V LH Line H Line H Line 90 90 7.62 m (25 ft) 3 m (9.84 ft) I43406 (e) V LH Line V Line V RH Line Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration. HINT: H Line

Ground I33423 The base lines differ for ”low−beam inspection” and ”high−beam inspection”. Mark the headlamp bulb center marks on the screen. If the center mark cannot be observed on the headlamp, use the center of the headlamp bulb or the manufacturer’s name marked on the headlamp as the center mark. (1) H Line (Headlamp height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlamp bulb center marks of the low−beam headlamps. (2) V LH Line, V RH Line (Center mark position of left− hand (LH) and right−hand (RH) headlamps): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low−beam headlamp bulbs). WhereEverybodyKnowsYourName 65−12 LIGHTING − HEADLAMP ASSY LH 4. (a) HEADLAMP AIMING INSPECTION Cover or disconnect the connector of the headlamp on the opposite side to prevent light from the headlamp not being inspected from affecting headlamp aiming inspection. NOTICE: Do not keep the headlamp covered for more than 3 minutes. The headlamp lens is made of synthetic resin, and may easily melt or be damaged due to heat. HINT: When checking the aim of the high−beam, cover the low−beam or disconnect the connector. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. (c) Turn on the headlamp and make sure that the cutoff line falls within the specified area, as shown in the illustration. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V LH Line V RH Line Low Beam: 101 mm (3.97 in.) H Line 0 mm (0 in.) 40 mm (1.57 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) 40 mm (1.57 in.) 40 mm (1.57 in.) Cutoff Line Cutoff Line High Beam: V LH Line V RH Line Low Beam: 40 mm 0 mm (1.57 in.) (0 in.) H Line V LH Line V RH Line High Beam: 101 mm (3.97 in.) 40 mm (1.57 in.) H Line H Line 40 mm (1.57 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) V LH Line V RH Line 40 mm (1.57 in.) 40 mm (1.57 in.) I41214 WhereEverybodyKnowsYourName 65−13 LIGHTING − HEADLAMP ASSY LH HINT:






Since the low−beam light and the high−beam light are a unit, if the aim on one is correct, the other should also be correct. However, check both beams just to make sure. Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as left and right of the V line with low−beam (SAE J599). Alignment distance is 3 m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as left and right of the V line with low−beam (SAE J599). Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as left and right of the V line with high−beam (SAE J599). Alignment distance is 3 m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as left and right of the V line with high−beam (SAE J599). Alignment distance is 7.62 m (25 ft): The cutoff line is 53 mm (2.08 in.) below the H line with low−beam. Alignment distance is 3 m (9.84 ft): The cutoff line is 21 mm (0.82 in.) below the H line with low−beam. 5. (a) Aiming Screw A I43493 HEADLAMP AIMING ADJUSTMENT Adjust the aim vertically: Adjust the headlamp aim into the specified range by turning aiming screw A with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. HINT:
Perform low−beam aim adjustment.
The headlamp aim moves up when turning the aiming screw clockwise, and moves down when turning the aiming screw counterclockwise. WhereEverybodyKnowsYourName 65−14 LIGHTING − HEADLAMP ASSY LH 651AO−01 REPAIR HINT:



1. 2. COMPONENTS: SEE PAGE 65−7. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. If the area where the headlamp unit LH is installed is broken, the repairs listed below can be performed inexpensively through the use of a repair use bracket. This may only be done if the headlamp assy LH itself is not damaged. REMOVE FRONT BUMPER ASSY (SEE PAGE 76−2) REMOVE HEADLAMP ASSY LH (SEE PAGE 65−8) 3. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH HINT:

If the installation area of the headlamp assy LH is damaged, use the supply bracket for low−cost repair. Ensure that the headlamp assy LH is not damaged. (a) Cut off the part shaded in the illustration and sand smooth with sandpaper. NOTICE: After cutting off the part, place the headlamp protector retainer UPPER LH against the bosses and gradually file away until installation is possible. I43494 (b) Install the headlamp protector retainer UPPER LH with the 2 screws. I43495 4. 5. 6. 7. 8. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (SEE PAGE 65−10) PREPARATION FOR HEADLAMP AIMING (Using a screen) (SEE PAGE 65−10) HEADLAMP AIMING INSPECTION (SEE PAGE 65−10) HEADLAMP AIMING ADJUSTMENT (SEE PAGE 65−10) VEHICLE PREPARATION FOR FOG LAMP AIM ADJUSTMENT (SEE PAGE 65−17) WhereEverybodyKnowsYourName 65−15 LIGHTING 9. 10. 11. − HEADLAMP ASSY LH PREPARATION FOR FOG LAMP AIMING (SEE PAGE 65−17) FOG LAMP AIMING INSPECTION (SEE PAGE 65−17) FOG LAMP AIMING ADJUSTMENT (SEE PAGE 65−17) WhereEverybodyKnowsYourName 65−16 LIGHTING − FOG LAMP ASSY LH FOG LAMP ASSY LH 651AP−01 OVERHAUL HINT:


1. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE FRONT BUMPER ASSY (SEE PAGE 76−2) Hook 2. (a) (b) REMOVE FOG LAMP ASSY LH Remove the 2 screws. Move the fog lamp assy LH in the direction indicated by the arrow, disengage the hook, and remove the fog lamp assy LH. 3. (a) REMOVE FOG LAMP BULB Turn the fog lamp bulb in the direction as shown in the illustration and remove the fog lamp bulb. I44544 I43401 4. 5. 6. 7. VEHICLE PREPARATION FOR FOG LAMP AIM ADJUSTMENT (SEE PAGE 65−17) PREPARATION FOR FOG LAMP AIMING (SEE PAGE 65−17) FOG LAMP AIMING INSPECTION (SEE PAGE 65−17) FOG LAMP AIMING ADJUSTMENT (SEE PAGE 65−17) WhereEverybodyKnowsYourName 65−17 LIGHTING − FOG LAMP ASSY LH 651AQ−01 ADJUSTMENT 1. (a) VEHICLE PREPARATION FOR FOG LAMP AIM ADJUSTMENT Prepare the vehicle:
Ensure there is no damage or deformation to the body around the fog lamps.
Fill the fuel tank.
Make sure that the oil is filled to the specified level.
Make sure that the coolant is filled to the specified level.
Inflate the tires to the appropriate pressure.
Place the spare tire, tools, and jack in their original positions.
Unload the trunk.
Sit a person of average weight (68 kg, 150 lb) in the driver’s seat. 2. (a) 7.62 m (25 ft) 3 m (9.84 ft) I43408 PREPARATION FOR FOG LAMP AIMING Prepare the vehicle according to the following conditions:
Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lamps can be observed and above which it cannot.
Place the vehicle at a 90 angle to the wall.
Create a 7.62 m (25 ft) distance between the vehicle (fog lamp bulb center) and the wall.
Place the vehicle on a level surface.
Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (fog lamp bulb center) and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft) for check and adjustment. (The target zone will change with the distance, so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. (c) Draw a vertical line down the center of screen (V line). WhereEverybodyKnowsYourName 65−18 LIGHTING − FOG LAMP ASSY LH (d) Set the screen as shown in the illustration. HINT:
Stand the screen perpendicular to the ground.
Align the V line on the screen with the center of the vehicle. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V RH Line V RH Line 90 90 V Line 7.62 m (25 ft) V LH Line H Line 3 m (9.84 ft) V Line V LH Line 90 H Line 90 3 m (9.84 ft) 7.62 m (25 ft) I43480 (e) V LH Line V Line V RH Line H Line Ground I33423 Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration. HINT: Mark the fog lamp bulb center marks on the screen. If the center mark cannot be observed on the fog lamp, use the center of the fog lamp bulb or the manufacturer’s name marked on the fog lamp as the center mark. (1) H Line (Fog lamp height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog lamp bulb center marks of the low−beam fog lamps. (2) V LH Line, V RH Line (Center mark position of left− hand (LH) and right−hand (RH) fog lamps): Draw two vertical lines so that they intersect the H line at each center mark. WhereEverybodyKnowsYourName 65−19 LIGHTING − FOG LAMP ASSY LH 3. (a) FOG LAMP AIMING INSPECTION Cover or disconnect the connector of the fog lamp on the opposite side to prevent light from the fog lamp not being inspected from affecting fog lamp aiming inspection. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. (c) Turn on the fog lamp and make sure that the cutoff line falls within the specified area, as shown in the illustration. Aligning distance is 3 m (9.84 ft): Aligning distance is 7.62 m (25 ft): V LH Line V RH Line 133 mm (5.24 in.) H Line V LH Line V RH Line 52 mm (2.05 in.) H Line I41221 4. (a) FOG LAMP AIMING ADJUSTMENT Adjust the fog lamp aim into the specified range by turning aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. Aiming Screw I43481 WhereEverybodyKnowsYourName 65−2 LIGHTING − LIGHTING SYSTEM 650BJ−02 ON−VEHICLE INSPECTION 1. (a) INSPECT TURN SIGNAL FLASHER CIRCUIT Measure voltage between terminal as shown in the chart below. E15683 Tester connection Condition Specified condition 7 − Ground Constant Continuity 1 − Ground Turn igniton switch ON Battery positive voltage 1 − Ground Turn igniton switch OFF No voltage 4 − Ground Constant Battery positive voltage (b) Connect the connector to turn signal flasher and inspect the wire harness side connector from the back side as shown in the chart below. Tester connection Condition Specified condition 2 − Ground Hazard switch OFF → ON 0V → 10 − 14 V (60 to 120 time per minutes) 2 − Ground Turn signal switch (right turn) OFF → ON 0V → 10 − 14 V (60 to 120 time per minutes) 3 − Ground Hazard switch OFF → ON 0V → 10 − 14 V (60 to 120 time per minutes) 3 − Ground Turn signal switch (left turn) OFF → ON 0V → 10 − 14 V (60 to 120 time per minutes) 5 − Ground Turn signal switch (left turn) OFF → ON 10 − 14 V → 0 V 6 − Ground Turn signal switch (right turn) OFF → ON 10 − 14 V → 0 V 8 − Ground Hazard switch OFF → ON 10 − 14 V → 0 V WhereEverybodyKnowsYourName 65−20 LIGHTING − REAR COMBINATION LAMP ASSY LH REAR COMBINATION LAMP ASSY LH 651AR−01 OVERHAUL HINT:


1. 2. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO.1 (SEE PAGE 76−8) REMOVE REAR FLOOR FINISH PLATE (SEE PAGE 76−8) 3. (a) (b) REMOVE REAR COMBINATION LAMP ASSY LH Disconnect the connector. Remove the 3 nuts and the rear combination lamp assy LH. (c) Remove the rear combination lamp gasket RH. 4. (a) REMOVE REAR COMBINATION LAMP BULB Turn in the direction indicated by the arrow and remove the 3 rear combination lamp socket & wire sub−assy RHs and the 3 rear combination lamp bulbs as a unit. Remove the 3 rear combination lamp bulbs from the 3 rear combination lamp socket & wire sub−assy RHs. I43402 I43496 (b) I43497 5. (a) (b) REMOVE REAR COMBINATION LAMP BULB Turn in the direction indicated by the arrow and remove the rear combination lamp socket & wire sub−assy RH and the rear combination lamp bulb as a unit. Remove the rear combination lamp bulb from the rear combination lamp socket & wire sub−assy RH. I43498 WhereEverybodyKnowsYourName 65−21 LIGHTING − LICENSE PLATE LAMP ASSY LICENSE PLATE LAMP ASSY 650BR−02 REPLACEMENT 1. 2. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See Page 76−18) REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB−ASSY OUTSIDE (See Page 76−18) 3. (a) B REMOVE LICENSE PLATE LAMP ASSY Pull the license plate light assy to the side of vehicle as shown in the illustration and release the claw, then disconnect the connector. A E58310 WhereEverybodyKnowsYourName 65−22 LIGHTING − CENTER STOP LAMP ASSY CENTER STOP LAMP ASSY 650BS−02 REPLACEMENT 1. (a) (b) REMOVE CENTER STOP LAMP ASSY (W/O REAR SPOILER LED) Pull out the center stop light assy shown in the illustration. Disconnect connector. E59473 2. 3. REMOVE LUGGAGE COMPARTMENT DOOR COVER (W/ REAR SPOILER LED) (See Page 76−9) REMOVE REAR SPOILER SUB−ASSY (W/ REAR SPOILER LED) (See Page 76−9) 4. (a) REMOVE CENTER STOP LAMP ASSY (W/ REAR SPOILER LED) Remove the 2 screws and center stop light assy. E58311 5. INSTALL REAR SPOILER SUB−ASSY (W/ REAR SPOILER LED) (See Page 76−9) WhereEverybodyKnowsYourName 65−23 LIGHTING − HEADLAMP DIMMER SWITCH ASSY HEADLAMP DIMMER SWITCH ASSY 650BT−02 REPLACEMENT 1. REMOVE STEERING COLUMN COVER (See Page 50−9) 2. (a) (b) REMOVE HEADLAMP DIMMER SWITCH ASSY Disconnect the connector. Using a screwdriver, release the claw and pull out the headlight dimmer switch assy. NOTICE: Pressing the claw hard breaks the claw. HINT: Tape the screwdriver tip before use. Claw E57796 WhereEverybodyKnowsYourName 65−3 LIGHTING − LIGHTING SYSTEM 650BK−03 INSPECTION 1. (a) E57951 (b) (c) (d) GND 2. (a) HEADLAMP DIMMER SWITCH ASSY Inspect light control switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition OFF − No continuity TAIL 14 − 16 Continuity HEAD 13 − 16 − 14 Continuity Inspect headlamp dimmer switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition FLASH 7 −8 − 16 Continuity LOW BEAM 16 − 17 Continuity HI BEAM 7 − 16 Continuity Inspect turn signal switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition Right turn 2−3 Continuity Neutral − No continuity Left turn 1−2 Continuity Inspect front fog light switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition OFF − No continuity ON 10 − 11 Continuity HEATER CONTROL HOUSING SUB−ASSY Auto A/C: Inspect hazard warning signal switch. Switch operation Tester connection Specified condition OFF 1 − 34 No continuity ON 1 − 34 Continuity SW1 E57879 WhereEverybodyKnowsYourName 65−4 LIGHTING (b) SW − LIGHTING SYSTEM Manual A/C: Inspect hazard warning signal switch. Switch operation Tester connection Specified condition OFF 6 − 32 No continuity ON 6 − 32 Continuity GND E57924 3. (a) BACK UP LAMP SWITCH ASSY Inspect back−up lamp switch continuity. (1) Check that there is continuity between terminals upon switch operation. Standard: OFF (When ball is not pressed): No continuity ON (When ball is pressed): Continuity 4. (a) LUGGAGE COMPARTMENT DOOR LOCK ASSY Inspect luggage compartment door courtesy lamp switch continuity. (1) Check that there is continuity between terminal 2 and body ground when switch is operated. Standard: ON (When shaft is pressed): No continuity OFF (When shaft is not pressed): Continuity 5. (a) FOG LAMP RELAY Inspect relay continuity. E56904 Condition Tester connection Specified condition Constant 1−2 Continuity Apply B+ between terminals 1 and 2. 3−5 Continuity B16200 6. (a) ROOF CONSOLE BOX ASSY Inspect map lamp continuity. (1) Check that there is continuity between terminal 1 and 5 when switch is operated. Standard: ON: Continuity OFF: No continuity E57880 WhereEverybodyKnowsYourName 65−5 LIGHTING − LIGHTING SYSTEM 7. (a) ROOM LAMP ASSY NO.1 Inspect room lamp assy No. 1 continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Standard: Switch operation E50228 Tester connection Specified condition OFF − No continuity DOOR 1−2 Continuity *1 ON 2−3 Continuity *2 ON 1−3 Continuity *1: TMMK Made *2: TMC Made 8. (a) 9. (a) (b) 1 GLOVE BOX LAMP ASSY Inspect glove box lamp assy continuity. (1) Check that there is continuity between terminals when switch is operated. Standard: ON (When shaft is pressed): No continuity OFF (When shaft is not pressed): Continuity LUGGAGE COMPARTMENT LAMP ASSY NO.1 Inspect luggage compartment lamp assy No. 1. Check that there is continuity between terminals when switch is operated. Standard: ON: Continuity OFF No continuity 10. (a) 2 3 5 5 1 2 TAIL LAMP RELAY Inspect relay continuity. Condition Tester connection Specified condition Constant 1−2 Continuity Apply B+ between terminal 1 and 2 3−5 Continuity 3 N14863 11. (a) DAY TIME RUNNING LIGHT RELAY NO.2 Inspect relay continuity. Condition Tester connection Specified condition Constant 1−2 Continuity Apply B+ between terminal 1 and 2 3−5 Continuity B16200 WhereEverybodyKnowsYourName 65−6 LIGHTING 12. (a) − LIGHTING SYSTEM RUNNING LIGHT RELAY Inspect relay continuity. Condition Tester connection Specified condition Constant 1 − 3, 2 − 4 Continuity Apply B+ between terminal 1 and 3 4−5 Continuity E57950 WhereEverybodyKnowsYourName 65−7 LIGHTING − HEADLAMP ASSY LH HEADLAMP ASSY LH 651AL−01 COMPONENTS Headlamp Protector Retainer UPPER LH
Headlamp Assy LH Headlamp Bulb No.1 Headlamp Bulb No.2 Socket Plug Assy Headlamp Housing RH Front Turn Signal Lamp Bulb Clearance Lamp Bulb Headlamp Unit Assy LH
: Supply Parts for Low − Cost Repair WhereEverybodyKnowsYourName I43490 65−8 LIGHTING − HEADLAMP ASSY LH 651AM−01 OVERHAUL HINT:



1. COMPONENTS: SEE PAGE 65−7. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE FRONT BUMPER ASSY (SEE PAGE 76−2) Pin 2. (a) (b) REMOVE HEADLAMP ASSY LH Remove the 2 bolts and disengage the pin. Pull the headlamp assy LH in the direction indicated by the arrow and remove the headlamp assy LH. 3. (a) REMOVE HEADLAMP, NO.2 BULB Turn in the direction indicated by the arrow and remove the headlamp, No.2 bulb. 4. (a) REMOVE HEADLAMP, NO.1 BULB Turn in the direction indicated by the arrow and remove the headlamp, No.1 bulb. 5. (a) REMOVE FRONT TURN SIGNAL LAMP BULB Turn in the direction indicated by the arrow and remove the socket plug assy and the front turn signal lamp bulb as a unit. I43503 I43392 I43491 I43395 WhereEverybodyKnowsYourName 65−9 LIGHTING (b) (c) − HEADLAMP ASSY LH Turn in the direction indicated by the arrow and remove the front turn signal lamp bulb. Remove the socket plug assy. I43396 6. (a) (b) REMOVE CLEARANCE LAMP BULB Turn in the direction indicated by the arrow and remove the headlamp housing RH and the clearance lamp bulb as a unit. Remove the clearance lamp bulb from the headlamp housing RH. I43492 7. 8. 9. 10. 11. 12. 13. 14. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (SEE PAGE 65−10) PREPARATION FOR HEADLAMP AIMING (Using a screen) (SEE PAGE 65−10) HEADLAMP AIMING INSPECTION (SEE PAGE 65−10) HEADLAMP AIMING ADJUSTMENT (SEE PAGE 65−10) VEHICLE PREPARATION FOR FOG LAMP AIM ADJUSTMENT (SEE PAGE 65−17) PREPARATION FOR FOG LAMP AIMING (SEE PAGE 65−17) FOG LAMP AIMING INSPECTION (SEE PAGE 65−17) FOG LAMP AIMING ADJUSTMENT (SEE PAGE 65−17) WhereEverybodyKnowsYourName 18−1 IGNITION − IGNITION SYSTEM (2AZ−FE)(From July, 2003) IGNITION SYSTEM (2AZ−FE)(From July, 2003) 1809Q−05 ON−VEHICLE INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. ”Cold” means approximately −10
C (14
F) to 50
C (122
F). ”Hot” means approximately 50
C (122
F) to 100
C (212
F). 1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST (a) Check for DTCs. NOTICE: If a DTC is present, perform troubleshooting in accordance with the procedure for that DTC. (b) Check if sparks occur. (1) Remove the engine cover No. 1 (see page 14−29). (2) Remove the ignition coils. (3) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (4) Install the spark plugs to each ignition coil and connect the ignition coil connectors. (5) Disconnect the 4 injector connectors. (6) Ground the spark plugs. (7) Check if sparks occur at each spark plug while the engine is being cranked. NOTICE: Do not crank the engine for more than 2 seconds. If the sparks do not occur, perform the following test: SPARK TEST NG CHECK IF WIRE HARNESS SIDE CONNECTOR OF IGNITION COIL (WITH IGNITER) IS SECURE OK PERFORM SPARK TEST WITH A DIFFERENT IGNITION COIL (WITH IGNITER) NG OK Connect securely. If sparks occur, replace faulty ignition coil (with igniter). 1. Replace current ignition coil (with igniter) with a different, functioning ignition coil (with igniter). 2. Perform spark test again. NG CHECK POWER SUPPLY TO IGNITION COIL (WITH IGNITER) 1. Turn ignition switch ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. OK CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR (See page 18−3) Hot Cold 835 to 1,400 Ω 1,060 to 1,645 Ω Standard: NG NG Check wiring between ignition switch to ignition coil (with igniter). Replace camshaft position sensor. OK Continue on next page WhereEverybodyKnowsYourName 18−2 IGNITION − IGNITION SYSTEM (2AZ−FE)(From July, 2003) Continued from previous page OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See page 18−3) Cold Hot Standard: 985 to 1,600 Ω 1,265 to 1,890 Ω OK CHECK IGT SIGNAL FROM ECM (See page 05−51) OK NG NG Replace crankshaft position sensor. Check ECM (see page 05−35). REPAIR WIRING BETWEEN IGNITION COIL AND ECM (8) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (9) Install the ignition coils. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (10) Install the engine cover No. 1. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) WhereEverybodyKnowsYourName 18−11 IGNITION − VVT SENSOR (1MZ−FE/3MZ−FE) VVT SENSOR (1MZ−FE/3MZ−FE) 1809W−02 REPLACEMENT HINT: A bolt without torque specification is a standard bolt (see page 03−2). 1. REMOVE AIR CLEANER INLET ASSY 2. REMOVE AIR CLEANER ASSY (See page 14−164) 3. (a) (b) Bank 1 REMOVE VVT SENSOR Disconnect the sensor connector. Remove the bolt and sensor. Bank 2 A79541 A78529 4. (a) (b) (c) 5. 6. 7. A86853 INSTALL VVT SENSOR Apply a light coat of engine oil to the O−ring on the sensor. Install the sensor with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Connect the sensor connector. INSTALL AIR CLEANER ASSY (See page 14−164) INSTALL AIR CLEANER INLET ASSY CHECK CONNECTION OF VACUUM HOSE WhereEverybodyKnowsYourName 18−12 IGNITION − CRANKSHAFT POSITION SENSOR (1MZ−FE/3MZ−FE) CRANKSHAFT POSITION SENSOR (1MZ−FE/3MZ−FE) 1809X−02 REPLACEMENT HINT: A bolt without torque specification is a standard bolt (see page 03−2). 1. (a) REMOVE ENGINE UNDER COVER RH Remove the 5 screws, 3 clips and the under cover. 2. (a) REMOVE FRONT FENDER APRON SEAL RH Remove the clip, 2 bolts and apron seal. 3. (a) (b) REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. A85635 A80512 A79763 4. 5. 6. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH WhereEverybodyKnowsYourName 18−3 IGNITION − IGNITION SYSTEM (2AZ−FE)(From July, 2003) 1809R−02 INSPECTION NOTICE: In this section , the terms “cold”and “hot” refer to the temperature of the coils. “Cold” means approximately −10C (14F) to 50C (122F). ”Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT SPARK PLUG NOTICE:
Do not use a wire brush for cleaning.
Do not attempt to adjust the electrode gap of a used spark plug. (a) Ohmmeter Ground I39522 Check the electrode. (1) Using an ohmmeter, measure the insulation resistance. Correct insulation resistance: 10 MΩ or more If the resistance is less than the specified value, proceed to step (d). HINT: If the ohmmeter is not available, perform the following simple inspection instead. (b) B02629 Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug.
If the electrode is dry, the spark plug is functioning. Proceed to step 2.
If the electrode is damp, proceed to steps (c), (d), and (e). (4) Install the spark plug. (c) Check the spark plug for any damage on its thread and insulator. If there is damage, replace the spark plug. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 WhereEverybodyKnowsYourName 18−4 IGNITION (d) 1.0 to 1.1 mm B02630 B62019 2. (a) − IGNITION SYSTEM (2AZ−FE)(From July, 2003) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: P−ZEV 1.33 mm (0.052 in.) Except P−ZEV 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Air pressure: 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: Use the spark plug cleaner only when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. INSPECT CAMSHAFT POSITION SENSOR Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 835 to 1,400 Ω Hot 1,060 to 1,645 Ω If the resistance is not as specified, replace the sensor. 3. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 985 to1,600 Ω Hot 1,265 to 1,890 Ω If the resistance is not as specified, replace the sensor. WhereEverybodyKnowsYourName IGNITION − CAMSHAFT POSITION SENSOR (2AZ−FE)(From July, 2003) 18−5 CAMSHAFT POSITION SENSOR (2AZ−FE)(From July, 2003) 1809S−03 REPLACEMENT HINT: A bolt without torque specification is a standard bolt (see page 03−2). 1. REMOVE AIR CLEANER ASSY (See page 14−29) 2. (a) (b) REMOVE CAMSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. A85637 3. (a) (b) 4. 5. INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to the O−ring on the sensor. Install the sensor with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80in.⋅lbf) INSTALL AIR CLEANER ASSY (See page 14−29) CHECK CONNECTION OF VACUUM HOSE WhereEverybodyKnowsYourName 18−6 IGNITION − CRANKSHAFT POSITION SENSOR (2AZ−FE)(From July, 2003) CRANKSHAFT POSITION SENSOR (2AZ−FE)(From July, 2003) 1809T−03 REPLACEMENT HINT: A bolt without torque specification is a standard bolt (see page 03−2). 1. (a) REMOVE ENGINE UNDER COVER RH Remove the 5 screws, 3 clips and the under cover. 2. (a) REMOVE FRONT FENDER APRON SEAL RH Remove the clip, 2 bolts and apron seal. 3. (a) (b) REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt, clamp and sensor. A85635 A80512 A85638 4. 5. 6. INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH WhereEverybodyKnowsYourName 18−7 IGNITION − IGNITION SYSTEM (1MZ−FE/3MZ−FE) IGNITION SYSTEM (1MZ−FE/3MZ−FE) 1809U−03 ON−VEHICLE INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. “Cold” means approximately −10
C (14
F) to 50
C (122
F). “Hot” means approximately 50
C (122
F) to 100
C (212
F). 1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST (a) Check for DTCs. NOTICE: If a DTC is present, perform troubleshooting in accordance with the procedure for that DTC. (b) Check if sparks occur. (1) Remove the V−bank cover (see page 14−164). (2) Remove the intake air surge tank (see page 14−164). (3) Remove the ignition coils. (4) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (5) Install the spark plugs to each ignition coil and connect the ignition coil connectors. (6) Disconnect the 6 injector connectors. (7) Ground the spark plugs. (8) Check if sparks occur at each spark plug while the engine is being cranked. NOTICE: Do not crank the engine for more than 2 seconds. If sparks do not occur, perform the following test: SPARK TEST NG CHECK IF WIRE HARNESS SIDE CONNECTOR OF IGNITION COIL (WITH IGNITER) IS SECURE OK PERFORM SPARK TEST WITH A DIFFERENT IGNITION COIL (WITH IGNITER) NG OK 1. Replace current ignition coil (with igniter) with a different functioning ignition coil (with igniter). Connect securely. If sparks occur, replace faulty ignition coil with igniter. 2. Perform spark test again. NG CHECK POWER SUPPLY TO IGNITION COIL WITH IGNITER 1. Turn ignition switch ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. OK CHECK RESISTANCE OF VVT SENSOR (See page 18−9) Cold Hot 835 to 1,400 Ω 1,060 to 1,645 Ω Standard: NG Check wiring between ignition switch to ignition coil (with igniter). Replace VVT sensor. NG OK Continue on next page WhereEverybodyKnowsYourName 18−8 IGNITION − Continued from previous page OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See page 18−9) Cold Hot Standard: 1,630 to 2,740 Ω 2,065 to 3,225 Ω OK CHECK IGT SIGNAL FROM ECM (See page 05−543) OK IGNITION SYSTEM (1MZ−FE/3MZ−FE) NG NG Replace crankshaft position sensor. Check ECM (see page 05−525). REPAIR WIRING BETWEEN IGNITION COIL AND ECM (9) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 25 N⋅m (255 kgf⋅cm, 18.5 ft⋅lbf) (10) Install the ignition coil. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (11) Install the intake air surge tank (see page 14−164). (12) Install the V−bank cover (see page 14−164). WhereEverybodyKnowsYourName 18−9 IGNITION − IGNITION SYSTEM (1MZ−FE/3MZ−FE) 1809V−01 INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. “Cold” means approximately −10C (14F) to 50C (122F). “Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT SPARK PLUG NOTICE:
Do not use a wire brush for cleaning.
Do not attempt to adjust the electrode gap of a used spark plug. (a) Ohmmeter Ground I39522 Check the electrode. (1) Using an ohmmeter, measure the insulation resistance. Correct insulation resistance: 10 MΩ or more If the resistance is less than the specified value, proceed to step (d). HINT: If the ohmmeter is not available, perform the following simple inspection instead. (b) B02629 Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug.
If the electrode is dry, the spark plug is functioning. Proceed to step 2.
If the electrode is damp, proceed to steps (c), (d) and (e). (4) Install the spark plug. (c) Check the spark plug for any damage on its thread and insulator. If there is damage, replace the spark plug. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 (d) 1.0 to 1.1 mm B02630 Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. WhereEverybodyKnowsYourName 18−10 IGNITION B62019 2. (a) − IGNITION SYSTEM (1MZ−FE/3MZ−FE) (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Air pressure: 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. INSPECT VVT SENSOR (CAMSHAFT POSITION SENSOR) Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 835 to 1,400 Ω Hot 1,060 to 1,645 Ω If the resistance is not as specified, replace the sensor. 3. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 1,630 to 2,740 Ω Hot 2,065 to 3,225 Ω If the resistance is not as specified, replace the sensor. WhereEverybodyKnowsYourName 50−1 STEERING COLUMN − STEERING STEERING 5000O−05 PRECAUTION 1. (a) 2. (a) HANDLING PRECAUTIONS ON STEERING SYSTEM Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering system and result in a driving hazard. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page 60−1). WhereEverybodyKnowsYourName 50−2 STEERING COLUMN − STEERING 5002P−17 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. Symptom Suspect Area 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) See page 9. Power steering gear 28−1 51−3 14−5 14−140 26−5 − 26−19 − 51−8 51−17 51−28 Poor return 1. 2. 3. 4. Tires (Improperly inflated) Front wheel alignment (Incorrect) Steering column (Binding) Power steering gear 28−1 26−5 − 51−28 Excessive play 1. 2. 3. 4. 5. Steering system joints (Worn) Suspension arm ball joints (Worn) Intermediate shaft, Sliding yoke (Worn) Front wheel bearing (Worn) Power steering gear − 26−19 − 30−23 51−28 Hard steering Abnormal noise 4. 5. 6. 7. 8. Front wheel alignment (Incorrect) Steering system joints (Worn) Suspension arm ball joints (Worn) Steering column (Binding) Power steering vane pump 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 4. Power steering gear WhereEverybodyKnowsYourName 51−3 − 51−8 51−17 51−28 50−21 STEERING COLUMN − STEERING COLUMN ASSY (TMMK MADE) STEERING COLUMN ASSY (TMMK MADE) 5002T−06 OVERHAUL 1. 2. 3. 4. 5. 6. 7. PRECAUTION(See page 60−1) SEPARATE BATTERY NEGATIVE TERMINAL REMOVE STEERING WHEEL COVER LOWER NO.2(See page 60−25) REMOVE STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) REMOVE CONNECTOR COVER (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY)(See page 60−25) PLACE FRONT WHEELS FACING STRAIGHT AHEAD 8. REMOVE HORN BUTTON ASSY NOTICE: If the airbag connector is disconnected with the ignition switch at ON, DTCs will be recorded. (a) Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. (b) Pull out the horn button assy from the steering wheel. C92272 (c) Using a screwdriver, release the lock part of each airbag connector and disconnect the 2 airbag connectors. (d) Disconnect the horn connector. (4 Spoke steering wheel) NOTICE: When removing the horn button assy, take care not to pull the airbag wire harness. Pull Out Lock Part 4 Spoke Steering Wheel 3 Spoke Steering Wheel C92270 WhereEverybodyKnowsYourName 50−22 STEERING COLUMN − STEERING COLUMN ASSY (TMMK MADE) CAUTION:
When storing the horn button assy, keep the upper surface of the pad facing upward.
Never disassemble the horn button assy. C92310 Matchmarks 9. SST REMOVE STEERING WHEEL ASSY SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) C90603 10. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY(See page 71−16) 11. (a) REMOVE STEERING COLUMN COVER LWR Remove the 2 screws and steering column cover upper. C92273 12. REMOVE STEERING COLUMN COVER UPR 13. (a) DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY Using a screwdriver, disconnect the floor shift parking lock cable from the upper bracket. C90585 WhereEverybodyKnowsYourName 50−23 STEERING COLUMN 14. 15. (a) 16. (a) 17. 18. 19. 20. 21. − STEERING COLUMN ASSY (TMMK MADE) REMOVE SPIRAL CABLE SUB−ASSY(See page 05−1456) REMOVE HEADLAMP DIMMER SWITCH ASSY Disconnect the connector and remove the headlamp dimmer switch assy. REMOVE WINDSHIELD WIPER SWITCH ASSY Disconnect the connector and remove the windshield wiper switch assy. REMOVE FRONT DOOR SCUFF PLATE LH(See page 71−16) REMOVE COWL SIDE TRIM SUB−ASSY LH(See page 71−16) REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH(See page 71−16) REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH(See page 71−16) REMOVE HEATER TO FOOT DUCT NO.3(See page 71−16) 22. DISCONNECT STEERING INTERMEDIATE SHAFT ASSY B (a) Loosen the bolt A and remove the clamp from the steering column hole cover No.1. (b) Separate the steering column hole cover No.2 from the steering column hole cover No.1. A (c) Loosen the bolt B. C92274 (d) Matchmarks (e) Place matchmarks on the steering intermediate shaft sub−assy and steering gear assy. Remove the bolt and disconnect the steering intermediate shaft sub−assy. F40352 23. (a) (b) REMOVE STEERING COLUMN ASSY Disconnect the connectors and wire harness clamps from the steering column assy. Remove the 3 bolts and steering column assy. C92305 WhereEverybodyKnowsYourName 50−24 STEERING COLUMN 24. (a) Matchmarks (b) − STEERING COLUMN ASSY (TMMK MADE) REMOVE STEERING INTERMEDIATE SHAFT ASSY Place matchmarks on the steering intermediate shaft sub−assy and steering sliding yoke sub−assy. Remove the bolt and steering intermediate shaft sub− assy. C92361 25. C92306 26. REMOVE TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Disengage the claw hung on the upper bracket with a screwdriver. (b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open. NOTICE: Take care not to apply excessive force to prevent the case from being damaged. REMOVE KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 27. (a) Screw Extractor (b) (c) REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Using a centering punch, mark the center of the 2 tapered−head bolts. Using a 3 − 4 mm (0.12 − 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts and steering column upper w/ switch bracket assy. C92363 28. REMOVE STEERING COLUMN CLAMP UPPER 29. (a) (b) REMOVE IGNITION SWITCH LOCK CYLINDER ASSY Place the ignition switch lock cylinder assy at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder assy. C90811 WhereEverybodyKnowsYourName 50−25 STEERING COLUMN 30. (a) (b) − STEERING COLUMN ASSY (TMMK MADE) REMOVE UN−LOCK WARNING SWITCH ASSY Disconnect the un−lock warning switch assy connector from the ignition or starter switch assy. Remove the un−lock warning switch assy. C90812 31. (a) 32. (a) REMOVE IGNITION OR STARTER SWITCH ASSY Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition or starter switch assy to the steering column bracket assy with the 2 screws. 33. (a) (b) INSTALL UN−LOCK WARNING SWITCH ASSY Install the un−lock warning switch assy. Connect the un−lock warning switch assy connector to the ignition or starter switch assy. C90812 34. (a) (b) 35. (a) (b) INSTALL IGNITION SWITCH LOCK CYLINDER ASSY Make sure that the ignition switch lock cylinder assy is at the ACC position. Install the ignition switch lock cylinder assy. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism is activated when removing the key. Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position. 36. (a) (b) INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Temporarily install the steering column upper w/switch bracket assy and steering column upper clamp with 2 new tapered−head bolts. Tighten the 2 tapered−head bolts until the bolt heads break off. C93841 37. INSTALL KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) WhereEverybodyKnowsYourName 50−26 STEERING COLUMN − STEERING COLUMN ASSY (TMMK MADE) 38. C92306 474.5
1 mm (18.681
0.039 in.) INSTALL TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. (b) Push the trasponder key amplifier up and connect it to the upper bracket. NOTICE: Take care not to push the amplifier up with excessive force to prevent it from being damaged. 39. (a) INSPECT STEERING COLUMN ASSY Measure the length of steering main shaft. Standard length: 474.5
1 mm (18.681
0.039 in.) 40. (a) INSTALL STEERING INTERMEDIATE SHAFT ASSY Align the matchmark with the one on the steering intermediate shaft sub−assy and steering main shaft assy. Temporarily install the steering intermediate shaft sub− assy with the bolt. C92656 Matchmarks (b) C92361 41. (a) (b) INSTALL STEERING COLUMN ASSY Install the steering column assy with the 3 bolts. Torque: 20.6 N⋅m (210 kgf⋅cm, 15 ft⋅lbf) Connect the connectors and wire harness clamps. C92305 WhereEverybodyKnowsYourName 50−27 STEERING COLUMN 42. (a) Matchmarks (b) − STEERING COLUMN ASSY (TMMK MADE) CONNECT STEERING INTERMEDIATE SHAFT ASSY Align the matchmarks on the intermediate shaft sub−assy and steering gear assy. Install the steering intermediate shaft sub−assy with the bolt. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) F40352 (c) A (d) (e) B Tighten the bolt A. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Install the steering column hole cover No. 2 to the steering hole cover No.1. Connect the clamp to the steering column hole cover No.1 and tighten the bolt B. C92274 43. (a) 44. (a) 45. 46. INSTALL HEADLAMP DIMMER SWITCH ASSY Install the windshield wiper switch assy and connect the connector. INSTALL WINDSHIELD WIPER SWITCH ASSY Install the headlamp dimmer switch assy and connect the connector. PLACE FRONT WHEELS FACING STRAIGHT AHEAD INSTALL SPIRAL CABLE SUB−ASSY(See page 60−34) 47. (a) (b) CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY Turn the ignition switch to ACC or ON. Connect the cable to the upper bracket. C90585 48. 49. CHECK KEY INTERLOCK OPERATION(See page 40−51) INSTALL STEERING COLUMN COVER UPR WhereEverybodyKnowsYourName 50−28 STEERING COLUMN 50. (a) − STEERING COLUMN ASSY (TMMK MADE) INSTALL STEERING COLUMN COVER LWR Install the steering column cover with the 2 screws. C92273 51. 52. 53. 54. 55. 56. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSY INSTALL HEATER TO FOOT DUCT NO.3 INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH INSTALL COWL SIDE TRIM SUB−ASSY LH INSTALL FRONT DOOR SCUFF PLATE LH 57. CENTER SPIRAL CABLE (a) Check that the ignition switch is to OFF. (b) Check that the battery negative terminal is disconnected. NOTICE: Do not start the operation for 90 seconds after removing the terminal. (c) Turn the cable counterclockwise by hand until it becomes harder to turn. H41415 (d) Marks Then rotate the cable clockwise about 2.5 turns to align the marks. HINT: The cable will rotate about 2.5 turns to both right and left of the center. H41416 58. (a) (b) (c) 59. INSTALL STEERING WHEEL ASSY Align the matchmark with the one on the steering wheel assy and steering main shaft assy. Install the steering wheel assy with the set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Connect the connector. INSPECT HORN BUTTON ASSY(See page 60−25) WhereEverybodyKnowsYourName 50−29 STEERING COLUMN − STEERING COLUMN ASSY (TMMK MADE) 60. INSTALL HORN BUTTON ASSY NOTICE:
Never use the airbag parts removed from another vehicle. When replacing parts, replace with new ones.
Make sure that the horn button assy is installed with the specified torque.
If the horn button assy has been dropped, or there are cracks, dents or other defects in the case or connector, replace the horn button assy with a new one.
When installing the horn button assy, take care so that the wirings do not interfere with other parts and that they are not pinched between other parts. Lock Part 4 Spoke Steering Wheel (a) (b) Connect the 2 airbag connectors. Connect the horn connector. (4 Spoke steering wheel) (c) Install the horn button assy after confirming that the circumference groove of the torx screws is caught on the screw case. Using a torx socket wrench, torque the 2 screws. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) Push In 3 Spoke Steering Wheel C92271 (d) C92272 61. 62. 63. INSTALL STEERING WHEEL COVER LOWER NO.2(See page 60−25) INSTALL STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) INSTALL CONNECTOR COVER (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) WhereEverybodyKnowsYourName 50−30 STEERING COLUMN 64. 65. 66. − STEERING COLUMN ASSY (TMMK MADE) INSTALL STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY)(See page 60−25) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT(See page 05−1456) WhereEverybodyKnowsYourName 50−3 STEERING COLUMN − STEERING 5000P−07 ON−VEHICLE INSPECTION 1. (a) (b) Maximum Freeplay CHECK STEERING WHEEL FREEPLAY Stop the vehicle and face the tires straight ahead. Rock the steering wheel gently up and down by your hand, check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 in.) 30 mm (1.18 in.) F08857 WhereEverybodyKnowsYourName 50−4 STEERING COLUMN − STEERING 5002Q−04 REPAIR 1. (a) Steering Wheel Masking Tape Steering Column Upper Cover STEERING OFF CENTER REPAIR PROCEDURE Inspect steering wheel off center. (1) Apply masking tape on the top center of the steering wheel and steering column upper cover. (2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/h), and hold the steering wheel to maintain the course. F16015 (3) Steering Column Upper Cover Draw a line on the masking tape as shown in the illustration. Marked Line Steering Wheel Masking Tape F16016 (4) Turn the steering wheel to its straight position. HINT: Refer to the upper surface of the steering wheel, steering spoke and SRS airbag line for the straight position. (5) Draw a new line on the masking tape or the steering wheel as shown in the illustration. (6) Measure the distance between the 2 lines on the masking tape of the steering wheel. Steering Column Upper Cover Marked Line Steering Wheel F16017 WhereEverybodyKnowsYourName 50−5 STEERING COLUMN − STEERING (7) Convert the measured distance to steering angle. Measured distance 1 mm (0.04 in.) = Steering angle approximately 1 deg. HINT: Make a note of the steering angle. (b) Adjust steering angle. NOTICE: The adjustment method for steering angle is different depending on the models. Check whether it is type A or B. (1) (2) Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. Using a paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws. HINT:

Marked Line Measure the RH side and LH side. Make a note of the measured values. R00429 (3) F16018 Remove the RH and LH boot clips from the rack boots. (4) Loosen the RH and LH lock nuts. (5) Turn the RH and LH rack end by the same amount (but in different directions) according to the steering angle. 1 turn 360 deg. of rack end (1.5 mm (0.059 in.) horizontal movement) − 12 deg. of steering angle. (6) Tighten the RH and LH lock nuts by the specified torque. Torque: 74 N·m (750 kgf·cm, 54 ft⋅lbf) NOTICE: Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 in.). (7) Install the RH and LH boot clips. WhereEverybodyKnowsYourName 50−6 STEERING COLUMN − STEERING COLUMN STEERING COLUMN 5002R−02 COMPONENTS 4 Spoke Steering Wheel: 3 Spoke Steering Wheel: Horn Button Assy Steering Wheel Cover Lower No. 2 50 (510, 37) 50 (510, 37) Horn button Assy Steering Wheel Assy Steering Wheel Assy Steering Wheel Cover Lower No.2 8.8 (90, 78 in.⋅lbf) Steering Wheel Cover Lower No.3 Spiral Cable Sub−assy Windshield Wiper Switch Assy w/o steering Pad Switch: Steering wheel Cover Lower No.3 w/ Steering Pad Switch: Connector Cover Floor Shift Parking Lock Cable Steering Column Cover Headlamp Dimmer Switch Assy 20.6 (210, 15) 20.6 (210, 15) Instrument Cluster Finish panel Steering Sliding Yoke Sub−assy Steering Column Assy 35.3 (360, 26) Steering Intermediate Shaft Sub−assy Instrument Panel Sub−assy Upper Clip Door Scuff Plate Clamp 35.3 (360, 26) Cowl Side Trim Sub−assy Heater to Foot Duct No.3 Instrument PNL Insert Sub−assy LWR LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName C92312 50−7 STEERING COLUMN − STEERING COLUMN TMC Made: w/ Engine Immobilizer System: Transponder Key Amplifier w/ Illuminated Entry System: Key Cylinder Lamp Assy Ignition Switch Lock Cylinder Assy Un−lock Warning Switch Assy Steering Column Clamp Upper Steering Column Upper w/ Switch Bracket Assy Ignition or Starter Switch Assy Steering Column Tube
Snap Ring
Steering Main Shaft Radial Ball Bearing Steering Main Shaft Assy
Non−reusable part C92313 WhereEverybodyKnowsYourName 50−8 STEERING COLUMN − STEERING COLUMN TMMK Made: w/ Engine Immobilizer System: Transponder Key Amplifier W/ Illuminated Entry System: Key Cylinder Lamp Assy Ignition Switch Lock Cylinder Assy Un−lock Warning Switch Assy Steering Column Clamp Upper Steering Column Upper w/ Switch Bracket Assy Ignition or Starter Switch Assy Steering Column Assy C92652 C92313 WhereEverybodyKnowsYourName 50−9 STEERING COLUMN − STEERING COLUMN ASSY (TMC MADE) STEERING COLUMN ASSY (TMC MADE) 5002S−05 OVERHAUL 1. 2. 3. 4. 5. 6. 7. PRECAUTION(See page 60−1) DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE STEERING WHEEL COVER LOWER NO.2(See page 60−25) REMOVE STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) REMOVE CONNECTOR COVER (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY)(See page 60−25) INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD 8. REMOVE HORN BUTTON ASSY NOTICE: If the airbag connector is disconnected with the ignition switch being at ON, DTCs will be recorded. (a) Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. (b) Pull out the horn button assy from the steering wheel. C92272 (c) Using a screwdriver, release the lock part of each airbag connector and disconnect the 2 airbag connectors. (d) Disconnect the horn connector. (4 Spoke steering wheel) NOTICE: When removing the horn button assy, take care not to pull the airbag wire harness. Pull Out Lock Part 4 Spoke Steering Wheel 3 Spoke Steering Wheel C92270 WhereEverybodyKnowsYourName 50−10 STEERING COLUMN − STEERING COLUMN ASSY (TMC MADE) CAUTION:
When storing the horn button assy, keep the upper surface of the horn button assy facing upward.
Never disassemble the horn button assy. C92310 Matchmarks 9. (a) (b) (c) SST (d) REMOVE STEERING WHEEL ASSY Disconnect the connector. Remove the steering wheel assy set nut. Place matchmarks on the steering wheel assy and main shaft assy. Using SST, remove the steering wheel assy. SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) C90603 10. REMOVE INSTRUMENT CLUSTER FINISH PANEL(See page 71−16) 11. (a) REMOVE STEERING COLUMN COVER Remove the 2 screws and steering column cover. 12. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY Using a screwdriver, disconnect the floor shift parking lock cable from the upper bracket. C92273 (a) C90585 13. 14. (a) 15. (a) REMOVE SPIRAL CABLE SUB−ASSY(See page 60−34) REMOVE HEADLAMP DIMMER SWITCH ASSY Disconnect the connector and remove the headlamp dimmer switch assy. REMOVE WINDSHIELD WIPER SWITCH ASSY Disconnect the connector and remove the windshield wiper switch assy. WhereEverybodyKnowsYourName 50−11 STEERING COLUMN 16. 17. 18. 19. 20. 21. − STEERING COLUMN ASSY (TMC MADE) REMOVE FRONT DOOR SCUFF PLATE LH(See page 71−16) REMOVE COWL SIDE TRIM SUB−ASSY LH(See page 71−16) REMOVE INSTRUMENT PANEL COIN BOX SUB−ASSY(See page 71−16) REMOVE INSTRUMENT PANEL SUB−ASSY UPPER(See page 71−16) REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH(See page 71−16) REMOVE HEATER TO FOOT DUCT NO.3(See page 71−16) 22. B (a) (b) A (c) DISCONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY Loosen the bolt A and remove the clamp from the steering column hole cover No.1. Separate the steering column hole cover No.2 from the steering column hole cover No.1. Loosen the bolt B. C92274 (d) Matchmarks (e) Place matchmarks on the steering intermediate shaft sub−assy and steering gear assy. Remove the bolt and disconnect the steering intermediate shaft sub−assy. F40352 23. (a) (b) REMOVE STEERING COLUMN ASSY Disconnect the connectors and wire harness clamps from the steering column assy. Remove the 3 bolts and steering column assy. C92305 WhereEverybodyKnowsYourName 50−12 STEERING COLUMN 24. Matchmarks (a) (b) − STEERING COLUMN ASSY (TMC MADE) REMOVE STEERING INTERMEDIATE SHAFT SUB−ASSY Place matchmarks on the steering intermediate shaft sub−assy and steering sliding yoke sub−assy. Remove the bolt and steering intermediate shaft sub− assy. C92361 25. REMOVE STEERING COLUMN HOLE COVER SUB−ASSY NO.2 26. (a) (b) REMOVE STEERING SLIDING YOKE SUB−ASSY Place matchmarks on the steering sliding yoke sub−assy and steering main shaft assy. Remove the bolt and steering sliding yoke sub−assy from the steering main shaft assy. Matchmarks C92362 474.5
1 mm (18.681
0.039 in.) 27. (a) INSPECT STEERING COLUMN ASSY Measure the length of steering main shaft. Standard length: 474.5
1 mm (18.681
0.039 in.) C92656 28. C92306 29. REMOVE TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Disengage the claw hung on the upper bracket with a screwdriver. (b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open. NOTICE: Take care not to apply excessive force to prevent the case from being damaged. REMOVE KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) WhereEverybodyKnowsYourName 50−13 STEERING COLUMN 30. (a) Screw Extractor (b) (c) − STEERING COLUMN ASSY (TMC MADE) REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Using a centering punch, mark the center of the 2 lapered−head bolts. Using a 3 − 4 mm (0.12 − 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts and steering column upper w/ switch bracket assy. C92363 31. REMOVE STEERING COLUMN CLAMP UPPER 32. (a) REMOVE STEERING MAIN SHAFT ASSY Using a snap ring expander, remove the steering main shaft snap ring (outer side). C92358 (b) Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft radial ball bearing. NOTICE: Be careful not to drop the steering main shaft assy. C92307 (c) Using a snap ring expander, remove the steering main shaft snap ring (inner side). F40490 WhereEverybodyKnowsYourName 50−14 STEERING COLUMN 33. (a) (b) − STEERING COLUMN ASSY (TMC MADE) REMOVE IGNITION SWITCH LOCK CYLINDER ASSY Place the ignition switch lock cylinder assy at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder assy. C90811 34. (a) (b) REMOVE UN−LOCK WARNING SWITCH ASSY Disconnect the un−lock warning switch assy connector from the ignition or starter switch assy. Remove the un−lock warning switch assy. C90812 35. (a) 36. (a) REMOVE IGNITION OR STARTER SWITCH ASSY Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition or starter switch assy to the steering column bracket assy with the 2 screws. 37. (a) (b) INSTALL UN−LOCK WARNING SWITCH ASSY Install the un−lock warning switch assy. Connect the un−lock warning switch assy connector to the ignition or starter switch assy. C90812 38. (a) (b) 39. (a) (b) INSTALL IGNITION SWITCH LOCK CYLINDER ASSY Make sure that the ignition switch lock cylinder assy is at the ACC position. Install the ignition switch lock cylinder assy. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism is activated when removing the key. Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position. WhereEverybodyKnowsYourName 50−15 STEERING COLUMN 40. (a) (b) − STEERING COLUMN ASSY (TMC MADE) INSTALL STEERING MAIN SHAFT ASSY Using a snap ring expander, install a new steering main shaft snap ring (inner side) to the steering main shaft assy. Install the steering main shaft assy to the steering column tube. C92359 (c) Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy. 41. (a) INSTALL STEERING MAIN SHAFT BEARING Using SST and a hammer, install a new steering main radial ball bearing. SST 09608−06041 42. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Temporarily install the steering column upper w/switch bracket assy and steering column upper clamp with 2 new tapered−head bolts. Tighten the 2 tapered−head bolts until the bolt heads break off. C92358 SST C92360 (a) (b) C93841 WhereEverybodyKnowsYourName 50−16 STEERING COLUMN 43. − STEERING COLUMN ASSY (TMC MADE) INSTALL KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 44. C92306 INSTALL TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. (b) Push the trasponder key amplifier up and connect it to the upper bracket. NOTICE: Take care not to push the amplifier up with excessive force to prevent it from being damaged. 45. (a) (b) INSTALL STEERING SLIDING YOKE SUB−ASSY Align the matchmark with the one on the steering sliding yoke sub−assy and steering main shaft assy. Install the steering sliding yoke sub−assy with the bolt. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Matchmarks C92362 46. (a) INSTALL STEERING COLUMN HOLE COVER SUB−ASSY NO.2 Install the steering column hole cover sub−assy No.2 to the steering intermediate shaft sub−assy. C83097 47. Matchmarks (a) (b) INSTALL STEERING INTERMEDIATE SHAFT SUB−ASSY Align the matchmark with the one on the steering intermediate shaft sub−assy and steering main shaft assy. Temporarily install the steering intermediate shaft sub− assy with the bolt. C92361 WhereEverybodyKnowsYourName 50−17 STEERING COLUMN 48. (a) (b) − STEERING COLUMN ASSY (TMC MADE) INSTALL STEERING COLUMN ASSY Install the steering column assy with the 3 bolts. Torque: 20.6 N⋅m (210 kgf⋅cm, 15 ft⋅lbf) Connect the connectors and wire harness clamps. C92305 49. Matchmarks (a) (b) CONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY Align the matchmarks on the intermediate shaft sub−assy and steering gear assy. Install the steering intermediate shaft sub−assy with the bolt. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) F40352 (c) A (d) (e) B Tighten the bolt A. Torque: 35.3 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Install the steering column hole cover No. 2 to the steering hole cover No.1. Connect the clamp to the steering column hole cover No.1 and tighten the bolt B. C92274 50. (a) 51. (a) 52. 53. INSTALL WINDSHIELD WIPER SWITCH ASSY Install the windshield wiper switch assy and connect the connector. INSTALL HEADLAMP DIMMER SWITCH ASSY Install the headlamp dimmer switch assy and connect the connector. PLACE FRONT WHEELS FACING STRAIGHT AHEAD INSTALL SPIRAL CABLE SUB−ASSY(See page 60−34) WhereEverybodyKnowsYourName 50−18 STEERING COLUMN 54. (a) (b) − STEERING COLUMN ASSY (TMC MADE) CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY Turn the ignition switch to ACC or ON. Connect the cable to the upper bracket. C90585 55. CHECK KEY INTERLOCK OPERATION(See page 40−51) 56. (a) INSTALL STEERING COLUMN COVER Install the steering column cover with the 2 screws. C92273 57. 58. 59. 60. 61. 62. 63. INSTALL INSTRUMENT CLUSTER FINISH PANEL INSTALL HEATER TO FOOT DUCT NO.3 INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH INSTALL INSTRUMENT PANEL SUB−ASSY UPPER INSTALL INSTRUMENT PANEL COIN BOX SUB−ASSY INSTALL COWL SIDE TRIM SUB−ASSY LH INSTALL FRONT DOOR SCUFF PLATE LH 64. CENTER SPIRAL CABLE (a) Check that the ignition switch is at OFF. (b) Check that the battery negative terminal is disconnected. NOTICE: Do not start the operation for 90 seconds after removing the terminal. (c) Turn the cable counterclockwise by hand until it becomes harder to turn. H41415 WhereEverybodyKnowsYourName 50−19 STEERING COLUMN (d) Marks − STEERING COLUMN ASSY (TMC MADE) Then rotate the cable clockwise about 2.5 turns to align the marks. HINT: The cable will rotate about 2.5 turns to both right and left of the center. H41416 65. (a) (b) (c) 66. INSTALL STEERING WHEEL ASSY Align the matchmark with the one on the steering wheel assy and steering main shaft assy. Install the steering wheel assy with the set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Connect the connector. INSPECT HORN BUTTON ASSY(See page 60−25) 67. INSTALL HORN BUTTON ASSY NOTICE:
Never use the airbag parts removed from another vehicle. When replacing parts, replace with new ones.
Make sure that the horn button assy is installed with the specified torque.
If the horn button assy has been dropped, or there are cracks, dents or other defects in the case or connector, replace the horn button assy with a new one.
When installing the horn button assy, take care so that the wirings do not interfere with other parts and that they are not pinched between other parts. WhereEverybodyKnowsYourName 50−20 STEERING COLUMN Lock Part 4 Spoke Steering Wheel − STEERING COLUMN ASSY (TMC MADE) (a) (b) Connect the 2 airbag connectors. Connect the horn connector. (4 Spoke steering wheel) (c) Install the horn button assy after confirming that the circumference groove of the torx screws is caught on the screw case. Using a torx socket wrench, torque the 2 screws. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) Push In 3 Spoke Steering Wheel C92271 (d) C92272 68. 69. 70. 71. 72. 73. INSTALL STEERING WHEEL COVER LOWER NO.2(See page 60−25) INSTALL STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) INSTALL CONNECTOR COVER (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)(See page 60−25) INSTALL STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY)(See page 60−25) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT(See page 05−1456) WhereEverybodyKnowsYourName 16−1 COOLING − COOLING SYSTEM (2AZ−FE)(From July, 2003) COOLING SYSTEM (2AZ−FE)(From July, 2003) 1602Y−06 ON−VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKS CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using the radiator cap tester, increase the pressure inside A59902 the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, non−amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology up to the ”FULL” line. 3. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free from oil. HINT: If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. WhereEverybodyKnowsYourName 16−10 COOLING − WATER PUMP ASSY (2AZ−FE)(From July, 2003) 160PT−02 INSPECTION 1. (a) (b) INSPECT WATER PUMP ASSY Visually check for drain hole coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump. A36661 WhereEverybodyKnowsYourName 16−11 COOLING − THERMOSTAT (2AZ−FE)(From July, 2003) THERMOSTAT (2AZ−FE)(From July, 2003) 1602X−08 REPLACEMENT 1. 2. 3. 4. DRAIN ENGINE COOLANT (See page 16−6) REMOVE FAN AND GENERATOR V BELT (See page 16−6) REMOVE GENERATOR ASSY (See page 19−17) DISCONNECT RADIATOR HOSE INLET 5. (a) REMOVE WATER INLET Remove the 2 nuts and disconnect the water inlet from the cylinder block. A59903 6. REMOVE THERMOSTAT 10
10
Jiggle Valve 7. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. (b) Install the thermostat with the jiggle valve facing up. HINT: The jiggle valve may be set within 10
on either side of the prescribed position. B11281 8. (a) 9. 10. 11. 12. 13. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL RADIATOR HOSE INLET INSTALL GENERATOR ASSY (See page 19−17) INSTALL FAN AND GENERATOR V BELT (See page 14−5) ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName 16−12 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) RADIATOR ASSY (2AZ−FE)(From July, 2003) 160PU−02 ON−VEHICLE CLEANING 1. INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE:
If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: A73603

Injection Distance Injection Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kg/cm2, 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kg/cm2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components. WhereEverybodyKnowsYourName 16−13 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) 160PV−02 COMPONENTS Breather hose (Radiator Reserve Hose) Radiator Assy Fan Motor Connector Radiator Support Lower 5.0 (51, 44 in.⋅lbf) Air Cleaner Inlet Radiator Hose Outlet Oil Cooler Outlet Hose No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Radiator Hose Inlet Oil Cooler Outlet Hose No. 3 WhereEverybodyKnowsYourName A91254 16−14 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) 5.0 (51, 44 in.⋅lbf) Radiator Hose Outlet Fan Assy w/ Motor Oil Cooler Outlet Hose No. 2 Oil Cooler Outlet Hose No. 3 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Radiator Cap A87109 Radiator Tank Upper
O−Ring A/T 8.3 (85, 73 in.⋅lbf)
O−Ring Cooler Pipe 14.7 (150, 11) 8.3 (85, 73 in.⋅lbf) Oil Cooler Assy
O−Ring
O−Ring ECT Sensor
O−Ring Radiator Tank Lower Drain Plug N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A87110 16−15 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) 160PW−02 REPLACEMENT 1. 2. 3. 4. 5. 6. DRAIN ENGINE COOLANT (See page 16−6) DISCONNECT BREATHER HOSE DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET DISCONNECT OIL COOLER OUTLET HOSE NO.2 (A/T) DISCONNECT OIL COOLER OUTLET HOSE NO.3 (A/T) 7. (a) REMOVE AIR CLEANER INLET ASSY Remove the 2 bolts and air cleaner inlet. 8. (a) REMOVE RADIATOR SUPPORT UPPER Disconnect the 2 horn connectors. (b) Remove the hood lock release lever cover. (c) (d) Remove the bolt shown in the illustration. Remove the 4 bolts and radiator support upper. A60824 Clip A60497 A60480 9. (a) (b) (c) 10. REMOVE RADIATOR ASSY Disconnect the fan motor connector. Disconnect the ECT sensor connector. Remove the radiator from the body. REMOVE RADIATOR SUPPORT LOWER WhereEverybodyKnowsYourName 16−16 COOLING 11. (a) 12. (a) 13. (a) (b) (c) 14. (a) (b) − RADIATOR ASSY (2AZ−FE)(From July, 2003) REMOVE FAN ASSY W/MOTOR Remove the 3 bolts and fan w/ motor from the radiator. INSTALL FAN ASSY W/MOTOR Install the fan w/ motor to the radiator with the 3 bolts. Torque: 5.0 N·m (51 kgf·cm, 44 in.⋅lbf) INSTALL RADIATOR ASSY Install the radiator to the body. Connect the ECT sensor connector. Connect the fan motor connector. INSTALL RADIATOR SUPPORT UPPER Install the radiator support upper with the 4 bolts. Torque: 14 N·m (142 kgf·cm,10 ft·lbf) Connect the 2 horn connectors. 15. (a) INSTALL AIR CLEANER INLET ASSY Install the air cleaner inlet with the 2 bolts. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) A60824 16. 17. 18. ADJUST HOOD SUB−ASSY (See page 75−1) ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName 16−17 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) 160PX−04 OVERHAUL 1. (a) (b) REMOVE DRAIN PLUG Remove the drain plug. Remove the O−ring. 2. Part ”A” Dimension ”B” SST Claw Stopper Bolt Overhaul Handle A87082 Tank SST Lock Plate Stopper Bolt ASSEMBLE SST SST 09230−01010 (09231−01010, 09231−01030) (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Dimension: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. 3. REMOVE UNCAULK LOCK PLATE Using SST to release the caulking, grip the handle until stopped by the stopper bolt. SST 09230−01010 (09231−01010, 09231−01030) A87083 4. (a) Tap (b) REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft−faced hammer, and remove the tank. Remove the O−ring. A87084 5. (a) (b) (c) (d) A/T: REMOVE OIL COOLER ASSY Remove the cooler pipe Loosen the 2 nuts and 2 plate washers. Remove the oil cooler Remove the 2 O−rings from the oil cooler. A87085 WhereEverybodyKnowsYourName 16−18 COOLING 6. Pipe (a) 18° Downward (b) (c) A87086 Lock Plate Lock Plate Core A87087 (d) (a) O−Ring RADIATOR ASSY (2AZ−FE)(From July, 2003) A/T: INSTALL OIL COOLER ASSY Clean the O−ring contact surface of the lower tank and oil cooler. Install 2 new O−rings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.3 N·m (85 kgf·cm, 73 in.·lbf) Install the cooler pipe in the direction indicated in the illustration. Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf) 7. INSPECT LOCK PLATE FOR DAMAGE HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object.
Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 8.  Normal X Twisted − INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O−ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. X Twisted A87088 CORRECT WRONG Tap Tank (b) (c) Install the tank without damaging the O−ring. Tap the lock plate with a soft−faced hammer so that there is no gap between the lock plate and the tank. Lock Plate A87089 WhereEverybodyKnowsYourName 16−19 COOLING 9. Part ”A” (a) Dimension ”B” SST Punch Assembly (b) Stopper Bolt Overhaul Handle 3 7 2 1 6 4 RADIATOR ASSY (2AZ−FE)(From July, 2003) ASSEMBLE SST SST 09230−01010, 09231−14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Dimension: 8.4 mm (0.331 in) A87090 10. (a) 5 − 8 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230−01010 SST Stopper Bolt Tank Lock Plate A88425 HINT:
Do not tap the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. A87092 A87093 WhereEverybodyKnowsYourName 16−20 COOLING − RADIATOR ASSY (2AZ−FE)(From July, 2003) (b) H Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. A87094 11. (a) (b) INSTALL DRAIN PLUG Install a new O−ring to the drain plug. Install the drain plug. 12. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230−01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water. A87095 Tank Lock Plate O−Ring (d) Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, swish the radiator around in the water first until all air bubbles disappear. A87096 WhereEverybodyKnowsYourName 16−2 COOLING − COOLING SYSTEM (2AZ−FE)(From July, 2003) 1602Z−07 INSPECTION 1. INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. P13560 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 to 84
C (176 to 183
F) If the valve opening temperature is not as specified, replace the thermostat. P00436 (c) Check the valve lift. Valve lift: 10 mm (0.394 in.) or more at 95
C (203
F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77
C (171
F)). If not closed, replace the thermostat. 10 mm A91387 2. INSPECT RADIATOR CAP SUB−ASSY NOTICE:
If the reservoir cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the tester at an angle of over 30
above the horizontal. WhereEverybodyKnowsYourName 16−3 COOLING − COOLING SYSTEM (2AZ−FE)(From July, 2003) (a) Radiator Cap Tester 30
or more Radiator Cap A51912 Using a radiator cap tester, slowly pump the tester and check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the reservoir cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: The pump speed above should be followed for the first pump only. It will close the vacuum valve. Once the vacuum valve is closed, the pump speed can be reduced. Standard opening pressure: 78 to 122 kPa (0.80 to 1.25 kgf/cm2, 11.3 to 17.8 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure above, replace the radiator cap. WhereEverybodyKnowsYourName 16−21 COOLING − COOLING SYSTEM (1MZ−FE/3MZ−FE) COOLING SYSTEM (1MZ−FE/3MZ−FE) 16034−07 ON−VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKS CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using the radiator cap tester, increase the pressure inside A59519 the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, non−amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology up to the ”FULL” line. 3. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free from oil. HINT: If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. WhereEverybodyKnowsYourName 16−22 COOLING − COOLING SYSTEM (1MZ−FE/3MZ−FE) 16035−08 INSPECTION 1. INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. P13560 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 to 84
C (176 to 183
F) If the valve opening temperature is not as specified, replace the thermostat. P00436 (c) Check the valve lift. Valve lift: 10 mm (0.394 in.) or more at 95
C (203
F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77
C (171
F)). If not closed, replace the thermostat. 10 mm A91387 2. INSPECT WATER OUTLET CAP SUB−ASSY NOTICE:
If the reservoir cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the tester at an angle of over 30
above the horizontal. WhereEverybodyKnowsYourName 16−23 COOLING − COOLING SYSTEM (1MZ−FE/3MZ−FE) (a) Radiator Cap Tester 30
or more Radiator Cap A51912 Using a radiator cap tester, slowly pump the tester and check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the reservoir cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: The pump speed above should be followed for the first pump only. it will close the vacuum valve. Once the vacuum is colosed, the pump speed can be reduced. Standard opening pressure: 69.0 to 112.8 kPa (0.70 to 1.15 kgf/cm2, 10.0 to 16.4 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure above, replace the radiator cap. WhereEverybodyKnowsYourName 16−24 COOLING − COOLING FAN SYSTEM (1MZ−FE/3MZ−FE) COOLING FAN SYSTEM (1MZ−FE/3MZ−FE) 16036−07 ON−VEHICLE INSPECTION HINT: The cooling fan may rotate when the ignition switch is turned from ACC to ON. This is normal. 1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switches, and check for disconnected connectors or wire breaks between the cooling fan relay and ECT switches. (c) Disconnect the ECT switch No. 1 connector. (d) Connect the terminals on the ECT switch No. 1 connector. (e) Check that the No. 1 cooling fan rotates at a high speed. If not, check the No. 1 cooling fan relay and No. 1 cooling fan. (f) Reconnect the ECT switch No. 1 connector. (g) Disconnect the ECT switch No. 2 connector. (h) Ground the terminal on the ECT switch No. 2 wire harness side connector. (i) Check that the No. 1 and No. 2 cooling fans rotate at a low speed. If not, check the No. 2 cooling fan relay, No. 3 cooling fan relay and No. 2 cooling fan. (j) Reconnect the ECT switch No. 2 connector. 2. CHECK COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect battery and ammeter to the cooling fan connector. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.0 to 12.0 A at 20
C (68
F) If not, replace the cooling fan. (d) Reconnect the cooling fan connector. WhereEverybodyKnowsYourName 16−25 COOLING − COOLING FAN SYSTEM (1MZ−FE/3MZ−FE) 160Q8−01 INSPECTION 1 5 2 3 1. (a) Tester Connection Specified Condition 3−5 10 kΩ or higher 3−5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 INSPECT RELAY (FAN NO. 1, FAN NO. 3) Check the resistance of the relay. Standard: If the result is not as specified, replace the relay. B60778 1 4 2 4 3 5 2. (a) Tester Connection Specified Condition 3−4 Below 1 Ω 3−5 10 kΩ or higher 3−5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 A87121 If the result is not as specified, replace the relay. 3. (a) P01924 INSPECT RELAY (FAN NO. 2) Check the resistance of the relay. Standard: INSPECT ECT SWITCH (NO. 1) Check the resistance. Standard: Temperature Specified Condition Above 98
C (208
F) Below 1 Ω Below 88
C (190
F) 10 kΩ or higher If the result is not as specified, replace the switch. NOTICE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check dry the sensor. WhereEverybodyKnowsYourName 16−26 COOLING 4. (a) − COOLING FAN SYSTEM (1MZ−FE/3MZ−FE) INSPECT ECT SWITCH (NO. 2) Check the resistance. Standard: Temperature P06722 Specified Condition Above 93
C (199
F) Below 1 Ω Below 83
C (181
F) 10 kΩ or higher If the result is not as specified, replace the switch. NOTICE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check dry the sensor. WhereEverybodyKnowsYourName 16−27 COOLING − COOLANT (1MZ−FE/3MZ−FE) COOLANT (1MZ−FE/3MZ−FE) 16038−09 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Drain engine coolant by loosening the radiator drain cock plug and the engine’s cylinder block drain cock plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. (c) Tighten the cylinder block drain cock plugs. Torque: 13 N⋅m (130 kgf⋅cm, 10 ft⋅lbf) Radiator Cap Cylinder Block Drain Cock Plug Radiator Drain Plug (equipped Vent Plug) Radiator Drain Cock Plug Cylinder Block Drain Cock Plug A80493 2. (a) (b) ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts) HINT:



Use of improper coolants may damage the engine cooling system. Use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, non− amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene− glycol concentration is approximately 50% and freezing temperature is −35C (−31F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. WhereEverybodyKnowsYourName 16−28 COOLING − COOLANT (1MZ−FE/3MZ−FE) NOTICE: Do not use plain water alone. (c) Pour coolant into the radiator reservoir tank until the coolant reaches the full line. (d) Installl the radiator cap. (e) Warm up the engine. HINT: As the engine warms up, press the inlet and outlet radiator hoses several times by hand. (f) Stop the engine and wait until the coolant cools down to room temperature. (g) Remove the radiator cap and check the coolant level inside the radiator. (h) If the coolant level is below the full level, repeat steps (c) to (g) until the coolant level stays the same from step (c) to (g). (i) Install the radiator cap and the check the radiator reservoir tank coolant level. If it is below the full line, add coolant. 3. CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi) and check leakage. WhereEverybodyKnowsYourName 16−29 COOLING − WATER PUMP ASSY (1MZ−FE/3MZ−FE) WATER PUMP ASSY (1MZ−FE/3MZ−FE) 1602G−14 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. DRAIN ENGINE COOLANT (See page 16−27) REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V BELT NO. 1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14−186) 15. (a) REMOVE TIMING BELT IDLER SUB−ASSY NO.2 Remove the bolt and timing belt idler. A05055 16. 17. REMOVE CAMSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT NO.3 COVER (See page 14−186) 18. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts and water pump. A36739 19. (a) 20. 21. INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL TIMING BELT NO.3 COVER (See page 14−186) INSTALL CAMSHAFT TIMING PULLEY (See page 14−186) WhereEverybodyKnowsYourName 16−30 COOLING 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. − WATER PUMP ASSY (1MZ−FE/3MZ−FE) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V BELT NO. 1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) INSTALL FRONT WHEEL RH WhereEverybodyKnowsYourName 16−31 COOLING − WATER PUMP ASSY (1MZ−FE/3MZ−FE) 160Q1−02 INSPECTION 1. (a) (b) INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump. P12487 WhereEverybodyKnowsYourName 16−32 COOLING − THERMOSTAT (1MZ−FE/3MZ−FE) THERMOSTAT (1MZ−FE/3MZ−FE) 1602F−08 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. (a) 8. (a) 9. DRAIN ENGINE COOLANT (See page 16−27) REMOVE AIR CLEANER INLET ASSY REMOVE AIR CLEANER ASSEMBLY WITH HOSE REMOVE AIR CLEANER BRACKET REMOVE AIR CLEANER INLET NO.1 DISCONNECT RADIATOR HOSE OUTLET REMOVE WATER INLET PIPE Remove the bolt and inlet pipe. REMOVE WATER INLET Remove the 3 bolts and water inlet. REMOVE THERMOSTAT 10. (a) (b) 15
15
INSTALL THERMOSTAT Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15
of either side of the prescribed position. Jiggle Valve A51994 11. 12. (a) (b) (c) (d) 13. 14. 15. 16. INSTALL WATER INLET Torque: 8 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL WATER INLET PIPE Install a new O−ring to the inlet pipe. Apply soapy water to the O−ring. Connect the inlet pipe to the water inlet. Install the bolt holding the inlet pipe to the cylinder head. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) INSTALL AIR CLEANER ASSEMBLY WITH HOSE CONNECT VACUUM HOSES ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) WhereEverybodyKnowsYourName 16−33 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) RADIATOR ASSY (1MZ−FE/3MZ−FE) 160Q2−02 ON−VEHICLE CLEANING 1. (a) INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE:
If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: A73603

Injection Distance Injection Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kg/cm2, 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kg/cm2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components. WhereEverybodyKnowsYourName 16−34 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) 160Q3−02 COMPONENTS 5.0 (51, 44 in.⋅lbf) Radiator Assy Oil Cooler Outlet Hose No. 2 Fan Motor Connector Fan Assy w/ Motor ECT Switch No. 1 Radiator Hose Outlet Fan Motor Connector Radiator Hose Inlet Oil Cooler Outlet Hose No. 3 Radiator Assy Air Cleaner Inlet 5.0 (51, 44 in.⋅lbf) Fan Motor Connector Radiator Support Lower Air Cleaner Inlet No. 1 Radiator Hose Outlet Oil Cooler Outlet Hose No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Oil Cooler Outlet Hose No. 3 WhereEverybodyKnowsYourName A91255 16−35 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) Radiator Tank Upper
O−Ring
O−Ring Cooler Pipe 14.7 (150, 11) Oil Cooler Assy Lock Plate Core 8.3 (85, 73 in.⋅lbf)
O−Ring
O−Ring Radiator Tank Lower
O−Ring N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A87107 16−36 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) 160Q4−02 REPLACEMENT 1. 2. 3. 4. 5. 6. DRAIN ENGINE COOLANT (See page 16−27) DISCONNECT BREATHER HOSE DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET DISCONNECT OIL COOLER OUTLET HOSE NO.2 DISCONNECT OIL COOLER OUTLET HOSE NO.3 7. (a) REMOVE AIR CLEANER INLET ASSY Remove the 3 bolts, 2 air cleaner inlets. 8. (a) REMOVE RADIATOR SUPPORT UPPER Disconnect the 2 horn connectors. (b) Remove the hood lock release lever cover. (c) (d) Remove the bolt shown in the illustration. Remove the 4 bolts and radiator support upper. A60481 Clip A60497 A60480 9. (a) (b) (c) REMOVE RADIATOR ASSY Disconnect the fan motor connector. Disconnect the ECT switch No. 1 connector. Remove the radiator from the body. WhereEverybodyKnowsYourName 16−37 COOLING 10. 11. (a) 12. (a) 13. (a) (b) (c) 14. (a) (b) − RADIATOR ASSY (1MZ−FE/3MZ−FE) REMOVE RADIATOR SUPPORT LOWER REMOVE FAN ASSY W/MOTOR Remove the 3 bolts and fan w/ motor from the radiator. INSTALL FAN ASSY W/MOTOR Install the fan w/ motor to the radiator with the 3 bolts. Torque: 5.0 N·m (51 kgf·cm, 44 in.⋅lbf) INSTALL RADIATOR ASSY Install the radiator to the body. Connect the ECT switch No. 1 connector. Connect the fan motor connector. INSTALL RADIATOR SUPPORT UPPER Install the radiator support upper with the 4 bolts. Torque: 14 N·m (142 kgf·cm,10 ft·lbf) Connect the 2 horn connectors. 15. (a) INSTALL AIR CLEANER INLET ASSY Install the 2 air cleaner inlets with the 3 bolts. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) A60481 16. 17. 18. ADJUST HOOD SUB−ASSY (See page 75−1) ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) WhereEverybodyKnowsYourName 16−38 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) 160Q5−04 OVERHAUL 1. (a) (b) REMOVE DRAIN PLUG Remove the drain plug. Remove the O−ring. 2. Part ”A” Dimension ”B” SST Claw Stopper Bolt Overhaul Handle A87082 Tank Lock Plate SST Stopper Bolt ASSEMBLE SST SST 09230−01010 (09231−01010, 09231−01030) (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Dimension: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. 3. REMOVE UNCAULK LOCK PLATE Using SST to release the caulking, grip the handle until stopped by the stopper bolt. SST 09230−01010 (09231−01010, 09231−01030) A87097 4. (b) REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft−faced hammer and remove the tank. Remove the O−ring. 5. (a) (b) (c) (d) REMOVE OIL COOLER ASSY Remove the screw and pipe. Remove the nut and plate washer. Remove the oil cooler. Remove the 2 O−rings from the oil cooler. (a) Tap A87098 A87099 WhereEverybodyKnowsYourName 16−39 COOLING (6) (7) (5) (4) (3) (1) A87100 Lock Plate Lock Plate RADIATOR ASSY (1MZ−FE/3MZ−FE) 6. (a) (1) (2) − Core A87087 INSTALL OIL COOLER ASSY Clean the O−ring contact surface of the lower tank and oil cooler. (b) Install 2 new O−rings (1) to the oil cooler (2). (c) Install the oil cooler to the lower tank (3). (d) Install the plate washer (4) and nut (5). Torque: 8.3 N·m (85 kgf·cm, 73 in.·lbf) (e) Install the pipe (6). Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf) (f) Install the screw (7). 7. INSPECT LOCK PLATE FOR DAMAGE Inspect the lock plate for damage. HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, correct any deformation with pliers or similar object first.
Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 8. (a)  Normal X Twisted O−Ring INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O−ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. X Twisted A87088 CORRECT (b) (c) Install the tank without damaging the O−ring. Tap the lock plate with a soft−faced hammer so that there is no gap between the lock plate and the tank. Tank Tap WRONG Lock Plate A87101 WhereEverybodyKnowsYourName 16−40 COOLING 9. Part ”A” (a) Dimension ”B” SST Punch Assembly (b) Stopper Bolt Overhaul Handle 3 7 2 1 4 6 RADIATOR ASSY (1MZ−FE/3MZ−FE) ASSEMBLE SST SST 09230−01010, 09231−14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the illustration. Dimension ”B”: 8.4 mm (0.331 in.) A87090 10. (a) 5 − 8 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230−01010 SST Stopper Bolt Tank Lock Plate A88425 HINT: Rib
Do not tap the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. Bracket A87103 A87104 WhereEverybodyKnowsYourName 16−41 COOLING − RADIATOR ASSY (1MZ−FE/3MZ−FE) (b) Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. H A87105 11. (a) (b) INSTALL DRAIN PLUG Install a new O−ring to the drain plug. Install the drain plug. 12. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230−01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water. A87095 Tank Lock Plate O−Ring (d) Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, swish the radiator around in the water first until all air bubbles disappear. A87096 WhereEverybodyKnowsYourName 16−4 COOLING − COOLING FAN SYSTEM (2AZ−FE)(From July, 2003) COOLING FAN SYSTEM (2AZ−FE)(From July, 2003) 16030−06 ON−VEHICLE INSPECTION HINT: sThe cooling fan may rotate when the ignition switch is turned from ACC to ON. This is nornal. 1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT sensor, and check for disconnected connector or wire breaks between the cooling fan relay and ECT sensor. (c) Disconnect the ECT sensor connector. (d) Check that the cooling fan rotates. If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the cooling fan relay and ECT Sensor.. (e) Reconnect ECT sensor connector. 2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 98
C (208
F)) (a) Start the engine, and raise ECT to above 98
C (208
F). (b) Check that the cooling fan rotates. If not, replace the ECT sensor. 3. INSPECT COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect battery and ammeter to the cooling fan connector. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 4.9 to 8.5 A at 20
C (68
F) If not, replace the cooling fan. (d) Reconnect the cooling fan connector. WhereEverybodyKnowsYourName 16−5 COOLING − COOLING FAN SYSTEM (2AZ−FE)(From July, 2003) 160Q7−02 INSPECTION 1 5 2 1. (a) 3 Tester Connection Specified Condition 3−5 10 kΩ or higher 3−5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 INSPECT RELAY (FAN NO. 1, FAN NO. 3) Check the resistance of the relay. Standard: If the result is not as specified, replace the relay. B60778 1 4 2 4 3 2. (a) 5 Tester Connection Specified Condition 3−4 Below 1 Ω 3−5 10 kΩ or higher 3−5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 A87121 INSPECT RELAY (FAN NO. 2) Check the resistance of the relay. Standard: If the result is not as specified, replace the relay. 3. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Check the resistance between terminals 1 and 2. Standard: Condition 2.29 to 2.6 kΩ Approx. 80
C (176
F) 0.300 to 0.327 kΩ If the result is not as specified, replace the sensor. NOTICE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check, dry the sensor. 30 20 10 5 Resistance kΩ Specified Condition Approx. 20
C (68
F) 3 2 1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68) (104) (140) (176) (212) Temperature
C (
F) A91388 WhereEverybodyKnowsYourName 16−6 COOLING − COOLANT (2AZ−FE)(From July, 2003) COOLANT (2AZ−FE)(From July, 2003) 16032−07 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Drain engine coolant by loosening the radiator drain plug and the engine’s water drain plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. (c) Tighten the cylinder block drain cock plugs. Torque: 13 N⋅m (130 kgf⋅cm, 10 ft⋅lbf) Radiator Cap Water Drain Plug Radiator Drain Plug A52575 2. (a) (b) ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: 6.2 liters (6.6 US qts, 5.4 lmp. qts) HINT:

Use of improper coolants may damage the engine cooling system. Use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, non− amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology.
New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene− glycol concentration is approximately 50% and freezing temperature is −35C (−31F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTICE: Do not use plain water alone. (c) Pour coolant into the radiator reservoir tank until the coolant reaches the full line. WhereEverybodyKnowsYourName 16−7 COOLING − COOLANT (2AZ−FE)(From July, 2003) (d) Install the radiator cap. (e) Start the engine and run the engine for 10 seconds. (f) Remove the radiator cap after 10 seconds. Pour coolant if the coolant level is lower. (g) Repeat (d) to (f) until the coolant level remains the same from steps (d) to (f). HINT: Perform the procedures above before the engine warms up. A warmed up engine causes the thermostat valve to open, and the air inside of the engine circulates between the radiator and the engine. (h) Install the radiator cap. (i) Warm up the engine until the thermostat valve begins to open. HINT: As the engine warms up, press the radiator inlet and outlet hose several times by hand. (j) Stop the engine and wait until the coolant cools down to room temperature. If the coolant is below the full line, add coolant. (k) Install the radiator cap and check the radiator reservoir tank coolant level. If it is below the full line, add coolant. 3. CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi) and check leakage. WhereEverybodyKnowsYourName 16−8 COOLING − WATER PUMP ASSY (2AZ−FE)(From July, 2003) WATER PUMP ASSY (2AZ−FE)(From July, 2003) 1602V−09 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. DRAIN ENGINE COOLANT (See page 16−6) REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14−29) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−29) REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14−29) REMOVE FAN AND GENERATOR V BELT (See page 14−5) REMOVE GENERATOR ASSY (See page 19−17) 9. (a) SST (b) REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and pump pulley. SST 09960−10010 (09962−01000, 09963−00700) Disconnect the crankshaft position sensor wire harness clamp. B11275 10. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump. 11. (a) INSTALL WATER PUMP ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the water pump and cylinder block. B11276 HINT:


Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all loose material. Using a non−residue solvent, clean both sealing surfaces. WhereEverybodyKnowsYourName 16−9 COOLING (b) − WATER PUMP ASSY (2AZ−FE)(From July, 2003) Apply seal packing to the water pump as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent HINT:
2.2 to 2.5 mm A89934

(c) (d) Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall cap. Install the water pump and bracket with the 4 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the crankshaft position sensor wire harness clamp. B11276 12. (a) SST INSTALL WATER PUMP PULLEY Using SST, install the pump pulley with the 4 bolts. SST 09960−10010 (09962−01000, 09963−00700) Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B11275 13. 14. 15. 16. 17. 18. 19. 20. 21. INSTALL GENERATOR ASSY (See page 19−17) INSTALL FAN AND GENERATOR V BELT (See page 14−5) INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14−29) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14−29) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−29) INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT WHEEL RH ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) WhereEverybodyKnowsYourName EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−1 EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 120BJ−03 ON−VEHICLE INSPECTION 1. 23(AF1A+)(+) E1(−) (a) E6 ECM E7 31(AF1A−)(+) ECM INSPECT AIR−FUEL RATIO COMPENSATION SYSTEM Measure the voltage between terminals of the engine ECM connectors. Standard: A76903 Tester Connection Condition Specified Condition E7−23 (AF1A+) − E6−1(E1) Ignition switch ON 3.3 V E7−31 (AF1A−) − E6−1(E1) Ignition switch ON 3.0 V NOTICE: Connect test leads to the connector’s backside. The connectors should not be disconnected from the ECM. HINT: Voltage between the terminals of the ECM is kept constant regardless of the voltage of the A/F sensor. (b) Connect the hand−held tester to the DLC3. (c) Select ”DATA MONITOR”. Then select ”A/FS B1 S1”, ”A/FS B2 S1” and ”O2S B1 S2” to display the monitors. (d) Warm up the A/F sensor with the engine speed at 2,500 rpm for approximately 2 minutes. (e) Keep engine speed Lean (V) Air 14.6 fuel Ratio 3.3V HINT:

Rich Time 2. (a) (b) (c) A91104 Keep the engine speed at 2,500 rpm and confirm that the displays of ”A/FS B1 S1” and ”A/FS B2 S1” are as shown in the illustration. (f) The illustration may differ slightly from the display on the hand held tester. Only the hand−held tester displays the waveform of the A/F sensor. Confirm that the display of ”O2S B1 S2” changes between 0 V to 1 V with the engine speed at 2,500 rpm. INSPECT FUEL CUT OFF RPM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for injector operating sounds. Check that when the throttle lever is released, injector operation sounds stop momentarily (at 2,500 rpm) and then resume (at 1,400 rpm). Standard: Item Specified Condition Fuel cut off rpm 2,500 rpm Fuel return rpm 1,400 rpm WhereEverybodyKnowsYourName 12−2 EMISSION CONTROL 3. B11449 EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. (a) HINT: Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. If necessary, replace any damaged parts. 4. Vacuum Gauge (a) (b) B06544 − Using Hand−Held Tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 Hand−Held Tester (c) (d) (e) (f) Connect the hand−held tester to the DLC3. Start the engine. Turn the hand−held tester main switch ON. Use the ACTIVE TEST mode on the hand−held tester to operate the VSV for EVAP. (g) Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in. Aq) for over 5 seconds. A59675 Vacuum Gauge B06545 A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (h) Stop the engine. (i) Disconnect the hand−held tester from the DLC3. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. WhereEverybodyKnowsYourName EMISSION CONTROL (k) Pressure Gauge − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−3 Connect a pressure gauge to the EVAP service port on the purge line. A72589 Hand−Held Tester A59675 (l) (m) (n) (o) Connect the hand−held tester to the DLC3. Turn the ignition switch ON. Turn the hand−held tester main switch ON. Use the ACTIVE TEST mode on the hand−held tester to operate the VSV for CCV. NOTICE: In step (m), the ignition switch should be ON, but the engine should not be running. HINT: If the check is not completed within 10 minuites, the VSV for CCV will be reset and close automatically. (p) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap Check the pressure. (1) Add 13.5 to 15.5 in.Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in.Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (q) Turn the ignition switch OFF. (r) Disconnect the hand−held tester from the DLC3. A67133 WhereEverybodyKnowsYourName 12−4 EMISSION CONTROL 5. Vacuum Gauge (a) (b) B06544 − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) Not Using Hand−Held Tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 (c) (d) (e) Disconnect the VSV for EVAP connector. Connect the battery’s positive (+) and negative (−) leads to the VSV for EVAP terminals. Start the engine. Battery A75314 (f) Vacuum Gauge B06545 A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (g) Stop the engine. (h) Disconnect the battery’s positive (+) and negative (−) leads from the VSV for EVAP terminals. (i) Reconnect the VSV for EVAP connector. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Pressure Gauge Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds. Connect a pressure gauge to the EVAP service port on the purge line. A72589 WhereEverybodyKnowsYourName EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−5 (l) (m) Disconnect the VSV for CCV connector. Connect the battery’s positive (+) and negative (−) leads to the VSV for CCV terminals. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery A75315 (n) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap A67133 Check the pressure. (1) Add 13.5 to 15.5 in.Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in.Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (o) Disconnect the battery’s positive (+) and negative (−) leads from the VSV for CCV terminals. (p) Reconnect the VSV for CCV connector. (q) Disconnect the pressure gauge from the EVAP service port on the purge line. 6. Vent Line Hose A66040 CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank (see page 11−21). (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If malfunctions, damage or other problems are found, replace the fuel tank and filler pipe. (g) Reconnect the vent line hose to the fuel tank. WhereEverybodyKnowsYourName 12−6 EMISSION CONTROL 7. (a) (b) (c) (d) − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the vent line hose from the fuel tank (see page 11−21). Connect the pressure gauge to the fuel tank. Fill the fuel tank with fuel until full. Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that pressure drops. If pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. Fuel Tank Cap Vent Line Hose A66041 8. (a) CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. Air Air Inlet Line Hose A66042 VC (+) E8 ECM 9. (a) INSPECT VAPOR PRESSURE SENSOR Check the power source voltage of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Using a voltmeter, measure the voltage between terminals E8−18 (VC) and E8−28 (E2) of the ECM connectors. Standard: 4.5 to 5.5 V (3) Turn the ignition switch OFF. (b) Check the power output of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Remove the fuel tank cap. (3) Using a voltmeter, measure the voltage between terminals E4−21 (PTNK) and E8−28 (E2) of the ECM connectors. Standard: 3.0 to 3.6 V (4) Reinstall the fuel tank cap. E2 (−) A76903 E8 ECM E2 (−) E4 ECM PTNK (+) A87779 WhereEverybodyKnowsYourName 12−16 EMISSION CONTROL − CHARCOAL CANISTER ASSY (2AZ−FE)(From July, 2003) CHARCOAL CANISTER ASSY (2AZ−FE)(From July, 2003) 120BG−03 REPLACEMENT 1. REMOVE FUEL TANK ASSY (See page 11−21) A 2. (a) REMOVE CHARCOAL CANISTER ASSY Disconnect the fuel tank vent hose. (1) Push the connector deep into the charcoal canister assy to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. (b) (c) (d) Disconnect the VSV connector for CCV. Disconnect the fuel emission hose. Disconnect the air inlet line hose. (e) 3. Remove the 2 bolts and charcoal canister. INSTALL CHARCOAL CANISTER ASSY Torque: 39.2 N⋅m (400 kgf⋅cm, 29 in.⋅lbf) A Push A Pinch Pinch A A89716 (c) (b) (d) A89717 A89718 4. INSTALL FUEL TANK ASSY (See page 11−21) WhereEverybodyKnowsYourName EMISSION CONTROL − VENTILATION VALVE SUB−ASSY (2AZ−FE)(From July, 2003) 12−17 VENTILATION VALVE SUB−ASSY (2AZ−FE)(From July, 2003) 120BQ−05 REPLACEMENT 1. (a) (b) REMOVE VENTILATION VALVE SUB−ASSY Disconnect the PCV hose from the PCV valve. Remove the PCV valve. 2. (a) Adhesive A88710 (b) INSTALL VENTILATION VALVE SUB−ASSY Reinstall the PCV valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (2) Reinstall the PCV valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) Connect the PCV hose to the PCV valve. WhereEverybodyKnowsYourName 12−18 EMISSION CONTROL − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) 120BO−03 ON−VEHICLE INSPECTION 23(A2A+)(+) 31(A2A−)(+) 22(A1A+)(+) E7 1(E1)(−) ECM E6 ECM 30(A1A−)(+) A76903 1. INSPECT AIR−FUEL RATIO COMPENSATION SYSTEM Measure the voltage between the terminals of the ECM connectors. Standard: (a) Tester Connection Condition Specified Condition E7−22 (A1A+) − E6−1(E1) Ignition switch ON 3.3 V E7−30 (A1A−) − E6−1(E1) Ignition switch ON 3.0 V E7−23 (A2A+) − E6−1(E1) Ignition switch ON 3.3 V E7−31 (A2A−) − E6−1(E1) Ignition switch ON 3.0 V NOTICE: Connect test leads to the connector’s backside. The connectors should not be disconnected from the ECM. HINT: Voltage between the terminals of the engine ECM is kept constant regardless of the voltage of the A/F sensor. (b) Connect the hand−held tester to the DLC3. (c) Select ”DATA MONITOR”. Then select ”A/FS B1 S1”, ”A/FS B2 S1” and ”O2S B1 S2” to display the monitors. (d) Warm up the A/F sensor with the engine speed at 2,500 rpm for approximately 2 minutes. (e) Keep engine speed Lean (V) Air 14.6 fuel Ratio 3.3V HINT:

Rich Time 2. (a) (b) (c) A91104 Keep the engine speed at 2,500 rpm and confirm that the displays of ”A/FS B1 S1” and ”A/FS B2 S1” are as shown in the illustration. (f) The illustration may differ slightly from the display on the hand held tester. Only the hand−held tester displays the waveform of A/F sensor. Confirm that the display of ”O2S B1 S2” changes between 0 V to 1 V with the engine speed at 2,500 rpm. INSPECT FUEL CUT OFF RPM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for injector operating sounds. Check that when the throttle lever is released, injector operation sounds stop momentarily (at 2,500 rpm) and then resume (at 1,400 rpm). Standard: Item Specified Condition Fuel cut off rpm 2,500 rpm Fuel return rpm 1,400 rpm WhereEverybodyKnowsYourName 12−19 EMISSION CONTROL 3. P12931 EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. (a) HINT: Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. If necessary, replace any damage parts. 4. Vacuum Gauge (a) (b) B06544 − Using Hand−Held Tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 Hand−Held Tester (c) (d) (e) (f) Connect the hand−held tester to the DLC3. Start the engine. Turn the hand−held tester main switch ON. Use the ACTIVE TEST mode on the hand−held tester to operate the VSV for EVAP. (g) Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in. Aq) for over 5 seconds. A59675 Vacuum Gauge B06545 A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (h) Stop the engine. (i) Disconnect the hand−held tester from the DLC3. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. WhereEverybodyKnowsYourName 12−20 EMISSION CONTROL (k) Pressure Gauge − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) Connect a pressure gauge to the EVAP service port on the purge line. A72589 Hand−Held Tester A59675 (l) (m) (n) (o) Connect the hand−held tester to the DLC3. Turn the ignition switch ON. Turn the hand−held tester main switch ON. Use the ACTIVE TEST mode on the hand−held tester to operate the VSV for CCV. NOTICE: In step (m), the ignition switch should be ON, but the engine should not be running. HINT: If the check is not completed within 10 minutes, the VSV for CCV will be reset and close automatically. (p) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap Check the pressure. (1) Add 13.5 to 15.5 in. Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in. Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (q) Turn the ignition switch OFF. (r) Disconnect the hand−held tester from the DLC3. A67133 WhereEverybodyKnowsYourName 12−21 EMISSION CONTROL 5. Vacuum Gauge (a) (b) B06544 − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) Not Using Hand−Held Tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 (c) (d) (e) Disconnect the VSV for EVAP connector. Connect the battery’s positive (+) and negative (−) leads to the VSV for EVAP terminals. Start the engine. Battery A75314 (f) Vacuum Gauge B06545 A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (g) Stop the engine. (h) Disconnect the battery’s positive (+) and negative (−) leads from the VSV for EVAP terminals. (i) Reconnect the VSV for EVAP connector. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Pressure Gauge Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in. Aq) for over 5 seconds. Connect a pressure gauge to the EVAP service port on the purge line. A72589 WhereEverybodyKnowsYourName 12−22 EMISSION CONTROL − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) (l) (m) Disconnect the VSV for CCV. Connect the battery’s positive (+) and negative (−) leads to the VSV for CCV terminals. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery A75315 (n) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap A67133 Check the pressure. (1) Add 13.5 to 15.5 in. Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in. Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (o) Disconnect the battery’s positive (+) and negative (−) leads from the VSV for CCV terminals. (p) Reconnect the VSV for CCV connector. (q) Disconnect the pressure gauge from the EVAP service port on the purge line. 6. Vent Line Hose A66040 CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank (see page 11−52). (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If malfunctions, damage or other problems are found, replace the fuel tank and filler pipe. (g) Reconnect the vent line hose to the fuel tank. WhereEverybodyKnowsYourName 12−23 EMISSION CONTROL 7. (a) (b) (c) (d) − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the vent line hose from the fuel tank (see page 11−52). Connect the pressure gauge to the fuel tank. Fill the fuel tank with fuel until full. Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that pressure drops. If pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. Fuel Tank Cap Vent Line Hose A66041 8. (a) CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. Air Air Inlet Line Hose A66042 VC (+) E8 ECM 9. (a) INSPECT VAPOR PRESSURE SENSOR Check the power source voltage of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Using a voltmeter, measure the voltage between connector terminals E8−18 (VC) and E8−28 (E2) of the ECM connectors. Standard: 4.5 to 5.5 V (3) Turn the ignition switch OFF. (b) Check the power output of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Remove the fuel tank cap. (3) Using a voltmeter, measure the voltage between terminals E4−21 (PTNK) and E8−28 (E2) of the ECM connectors. Standard: 3.0 to 3.6 V (4) Reinstall the fuel tank cap. E2 (−) A76903 E8 ECM E2 (−) E4 ECM PTNK (+) A87779 WhereEverybodyKnowsYourName 12−24 EMISSION CONTROL − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) 120BP−04 INSPECTION 1. (a) (b) INSPECT VENTILATION VALVE SUB−ASSY Install a clean hose to the ventilation valve. Check ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Cylinder Head Side Clean Hose A59511 (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If the result is not as specified, replace the ventilation valve. (c) Remove the clean hose from the ventilation valve. Intake Manifold Side Clean Hose A59512 2. (a) INSPECT FUEL TANK CAP ASSY Visually check if the cap and gasket are deformed or damaged. Gasket A76682 3. (a) INSPECT CHARCOAL CANISTER ASSY Visually check the charcoal canister for cracks or damage. If cracks or damage is found, replace the charcoal canister assy. A67137 WhereEverybodyKnowsYourName 12−25 EMISSION CONTROL Air Vent Port Air Vent Port EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) (b) Check the charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port − A67138 (2) While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port A67139 (3) Vacuum Vent Port While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the vent port, and check that air is sucked in from the purge port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port A67140 (c) Vacuum Vent Port Purge Port Air Inlet Port A67141 A Vent Port Vacuum B Purge Port Check air tightness. (1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute. HINT: In order to maintain air tightness, the check should be performed while holding the CCV terminal port closed. If the result is not as specified, replace the charcoal canister. (d) Check the diaphragm. (1) Remove the air hose between ports A and B. (2) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B. Air Inlet Port A67142 WhereEverybodyKnowsYourName 12−26 EMISSION CONTROL − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) (3) A Vacuum Vent Port While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop. Vacuum drop time: 10 seconds or more If the result is not as specified, replace the charcoal canister. (4) Reinstall the air hose between ports A and B. Air Inlet Port Purge Port A67143 (e) Ohmmeter Check the VSV for open circuit. (1) Measure the resistance between the terminals. Standard: Condition Specified Condition 20
C (68
F) 25 to 30 Ω 100
C (212
F) 32 to 40 Ω If the result is not as specified, replace the charcoal canister. A74866 (f) Check VSV operation. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the charcoal canister. C B Air A A74867 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Valve C Closed A74868 No Air B (4) Check that air does not flow from port A to port B. (5) Check that air flows from port A to port C. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Air A A74869 WhereEverybodyKnowsYourName 12−27 EMISSION CONTROL 4. Ohmmeter (a) 26 to 30 Ω − EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) INSPECT VACUUM SWITCHING VALVE ASSY FOR EVAP Check the VSV for open circuit. (1) Measure the resistance. Tester Connection Specified Condition 1−2 26 to 30 Ω at 20
C (68
F) 1 − Body ground 2 − Body ground 10 kΩ or higher If the resistance is not as specified, replace the VSV assy. Ohmmeter 10 kΩ or Higher B16402 B16403 A87785 (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. No Air Air B16404 A75323 (2) (3) Apply battery positive voltage across the terminals. Check that air flows from the port as shown in the illustration. If the result is not as specified, replace the VSV assy. Air Battery B16405 A75324 5. (a) +B AF− HT AF+ INSPECT AIR FUEL RATIO SENSOR Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition Specified Condition 20
C (68
F) 0.8 to 1.4 Ω 800
C (1,472
F) 1.8 to 3.2 Ω If the result is not as specified, replace the sensor. A75325 WhereEverybodyKnowsYourName 12−28 EMISSION CONTROL 6. +B (a) HT 2 1 4 3 EMISSION CONTROL SYSTEM (1MZ−FE/3MZ−FE) INSPECT HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition OX E1 A91026 +B (a) HT 2 1 4 3 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω INSPECT HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition OX A91027 Specified Condition If the result is not as specified, replace the sensor. 7. E1 − Specified Condition 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω If the result is not as specified, replace the sensor. WhereEverybodyKnowsYourName 12−29 EMISSION CONTROL − CHARCOAL CANISTER ASSY (1MZ−FE/3MZ−FE) CHARCOAL CANISTER ASSY (1MZ−FE/3MZ−FE) 120BL−03 REPLACEMENT 1. REMOVE FUEL TANK ASSY(See page 11−52) A 2. (a) REMOVE CHARCOAL CANISTER ASSY Disconnect the fuel tank vent hose. (1) Push the connector deep into the charcoal canister assy to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. (b) (c) (d) Disconnect the VSV connector for CCV. Disconnect the fuel emission hose. Disconnect the air inlet line hose. (e) 3. Remove the 2 bolts and charcoal canister. INSTALL CHARCOAL CANISTER ASSY Torque: 39.2 N⋅m (400 kgf⋅cm, 29 in.⋅lbf) A Push A Pinch Pinch A A89716 (c) (b) (d) A89717 A89718 4. INSTALL FUEL TANK ASSY (See page 11−52) WhereEverybodyKnowsYourName 12−30 EMISSION CONTROL − VENTILATION VALVE SUB−ASSY (1MZ−FE/3MZ−FE) VENTILATION VALVE SUB−ASSY (1MZ−FE/3MZ−FE) 120BR−05 REPLACEMENT 1. (a) (b) REMOVE VENTILATION VALVE SUB−ASSY Disconnect the PCV hose from the PCV valve. Remove the PCV valve. 2. (a) Adhesive A88710 (b) INSTALL VENTILATION VALVE SUB−ASSY Reinstall the PCV valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (2) Reinstall the PCV valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) Connect the PCV hose to the PCV valve. WhereEverybodyKnowsYourName EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−7 120CJ−02 INSPECTION 1. (a) (b) INSPECT VENTILATION VALVE SUB−ASSY Install a clean hose to the ventilation valve. Check ventilation valve operation. (1) Blow air into the cylinder head side, and check air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Cylinder Head Side Clean Hose A59511 (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the ventilation valve. (c) Remove the clean hose from the ventilation valve. Intake Manifold Side Clean Hose A59512 2. (a) INSPECT FUEL TANK CAP ASSY Visually check if the cap and gasket are deformed or damaged. Gasket A76682 3. INSPECT CHARCOAL CANISTER ASSY (Except PZEV) (a) Visually check the charcoal canister for cracks or damage. If cracks or damage is found, replace the charcoal canister assy. A67137 WhereEverybodyKnowsYourName 12−8 EMISSION CONTROL Air Vent Port Air Vent Port EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) (b) Check charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port − A67138 (2) While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port A67139 (3) Vacuum Vent Port While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the vent port, and check that air is sucked in from the purge port. If the result is not as specified, replace the charcoal canister. Air Inlet Port Purge Port A67140 (c) Vacuum Vent Port Purge Port Air Inlet Port A67141 A Vent Port Vacuum B Purge Port Check the air tightness. (1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute. HINT: In order to maintain air tightness, the check should be performed while holding the CCV terminal port closed. If the result is not as specified, replace the charcoal canister. (d) Check the diaphragm. (1) Remove the air hose between ports A and B. (2) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B. Air Inlet Port A67142 WhereEverybodyKnowsYourName EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−9 (3) A Vacuum Vent Port While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop. Vacuum drop time: 10 seconds or more If the result is not as specified, replace the charcoal canister. (4) Reinstall the air hose between ports A and B. Air Inlet Port Purge Port A67143 (e) Ohmmeter Check the VSV for open circuit. (1) Measure the resistance between the terminals. Standard: Condition Specified Condition 20
C (68
F) 25 to 30 Ω 100
C (212
F) 32 to 40 Ω If the result is not as specified, replace the charcoal canister. A74866 (f) Check VSV operation. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the charcoal canister. C B Air A A74867 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Valve C Closed A74868 No Air B (4) Check that air does not flow from port A to port B. (5) Check that air flows from port A to port C. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Air A A74869 WhereEverybodyKnowsYourName 12−10 EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 4. (a) INSPECT CHARCOAL CANISTER ASSY (PZEV) Visually check the charcoal canister for cracks or damage. (b) Inspect the charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the air line port. A66045 Vent Port Air Line Port Air Purge Port A66046 WhereEverybodyKnowsYourName EMISSION CONTROL − (2) Vent Port EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−11 While holding the air line port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the purge port. Air Line Port Air Purge Port A66047 (3) While holding the air line port closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the vent port, and check that air is sucked in from the purge port. If operation is not as specified, replace the charcoal canister. Vent Port Vacuum Air Line Port Purge Port A66048 WhereEverybodyKnowsYourName 12−12 EMISSION CONTROL (c) − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) Inspect air tightness. (1) While holding the vent and air line ports closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute. HINT: In order to maintain air tightness, this check should be performed with the CCV terminal port held closed by your fingers. If operation is not as specified, replace the charcoal canister. Vacuum Vent Port Air Line Port Purge Port A66049 (d) B Inspect the diaphragm. (1) Remove the air hose between ports A and B. (2) While holding the vent, purge and air line ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B. A Vacuum Air Line Port Vent Port Purge Port A66050 WhereEverybodyKnowsYourName EMISSION CONTROL − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−13 (3) While holding the vent, purge and air line ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop. Vacuum drop time: 10 sec. or more If operation is not as specified, replace the charcoal canister. (4) Reinstall the air hose between ports A and B. A Vacuum Air Line Port Vent Port Purge Port A66051 (e) Ohmmeter Check the VSV for open circuit. (1) Measure the resistance between the terminals. Standard: Condition Specified Condition 20
C (68
F) 25 to 30 Ω 100
C (212
F) 32 to 40 Ω If the result is not as specified, replace the charcoal canister. A74866 (f) Check VSV operation. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the charcoal canister. C B Air A A74867 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Valve Closed A74868 WhereEverybodyKnowsYourName 12−14 EMISSION CONTROL No Air C B − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) (4) Check that air does not flow from port A to port B. (5) Check that air flows from port A to port C. If the result is not as specified, replace the charcoal canister. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery Air A A74869 5. Ohmmeter (a) 26 to 30 Ω INSPECT VACUUM SWITCHING VALVE ASSY FOR EVAP Check the VSV for open circuit. (1) Measure the resistance. Tester Connection Specified Condition 1−2 26 to 30 Ω at 20
C (68
F) 1 − Body ground 2 − Body ground 10 kΩ or higher If the resistance is not as specified, replace the VSV assy. Ohmmeter 10 kΩ or Higher B16402 B16403 A87785 (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. No Air Air B16404 A75323 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from the ports. If the result is not as specified, replace the VSV assy. Air Battery B16405 A75324 WhereEverybodyKnowsYourName EMISSION CONTROL 6. (a) +B HT AF− AF+ − EMISSION CONTROL SYSTEM (2AZ−FE)(From July, 2003) 12−15 INSPECT AIR FUEL RATIO SENSOR Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition Specified Condition 20
C (68
F) 0.8 to 1.4 Ω 800
C (1,472
F) 1.8 to 3.2 Ω If the result is not as specified, replace the sensor. A75325 7. +B E1 (a) HT 2 1 4 3 INSPECT HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition OX A91027 Specified Condition 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω If the result is not as specified, replace the sensor. WhereEverybodyKnowsYourName 68−1 WIRING − POWER SOURCE POWER SOURCE 6805I−01 LOCATION Engine Room Relay Block Engine Room Junction Block Assy w/ VSC: ABS Relay Block Sub−Assy Instrument Panel Junction Block Assy Turn Signal Flasher Assy I31154 WhereEverybodyKnowsYourName 68−2 WIRING − POWER SOURCE Engine Room Junction Block Assy: RELAY: A, EFI B, HORN C, C/ OPN D, FAN No.1 E, HEAD FUSE: 1, A/ F 2, DOOR 1 3, − 4, AM 2 5, − 6, EFI 7, ALT−S 8, HEAD LH UPR 9, ETCS 10, HORN 11, IGN 12, HEAD RH UPR 13, HAZ 25 A 25 A 30 A 20 A 5A 10 A 10 A 10 A 15 A 10 A 15 A 14, D.C.C 15, IG 2 16, ST 17, ADJ PDL 18, CDS 19, ABS No.2 20, MAIN 21, ABS No.3 22, HTR 23, RDI 30 A 10 A 5A 30 A 30 A 40 A 40 A 30 A 50 A 30 A I31155 WhereEverybodyKnowsYourName 68−3 WIRING − POWER SOURCE Engine Room Relay Block: RELAY: A, ST B, HTR C, FAN No.2 D, DRL No.3 E, DRL No.2 F, A/ F HTR (1MZ) G, MG CLT FUSE: H, FAN No.3 I, ADJ PDL J, DRL No.4 1, ABS No.1 2, ALT 3, A/C 4, DRL 5, HEAD RH LWR 6, HEAD LH LWR 7, SPARE 8, SPARE 9, SPARE 50 A 120 A (2AZ) 120 A (1MZ) 10 A 5A 15 A 15 A 5A 10 A 15 A I44138 WhereEverybodyKnowsYourName 68−4 WIRING − POWER SOURCE Instrument Panel Junction Block Assy: RELAY: A, FOG B, RR DEF C, TAIL D, IG 1 E, ACC F, PWR FUSE: 1, ECU−B 10 A 2, DOME 7.5 A 3, CIG 15 A 4, ECU−ACC 5A 5, RAD No.2 10 A 6, POWER POINT 15 A 7, RAD No.1 20 A 8, GAUGE 1 10 A 9, ECU−IG 10 A 10, WIPER 25 A 11, HTR 10 A 12, MIR HTR 13, AM 1 14, FOG 15, − 16, GAUGE 2 17, PANEL 18, TAIL 19, − 20, − 21, OBD 22, SEAT HTR 10 A 5A 15 A 10 A 10 A 10 A 7.5 A 20 A 23, WASHER 24, FAN RLY 25, STOP 26, 27, 28, 29, 30, PWR SEAT 31, PWR No.1 32, DEF 15 A 10 A 15 A 30 A 30 A 40 A I31157 WhereEverybodyKnowsYourName 68−5 WIRING − POWER SOURCE w/ VSC: ABS Relay Block Sub−Assy: A B RELAY: A, VSC CUT B, VSC MTR I43451 WhereEverybodyKnowsYourName 03−1 SERVICE SPECIFICATIONS − STANDARD BOLT STANDARD BOLT 0307K−02 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt 4 Weld Bolt Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 WhereEverybodyKnowsYourName 03−10 SERVICE SPECIFICATIONS − EMISSION CONTROL 030EQ−03 TORQUE SPECIFICATION 2AZ−FE: Part Tightened Charcoal canister assy x Body Ventilation valve sub−assy x Cylinder head cover N⋅m kgf⋅cm ft⋅lbf 39.2 400 29 19 193 9 1MZ−FE/3MZ−FE: Part Tightened Charcoal canister assy x Body Ventilation valve sub−assy x Cylinder head cover N⋅m kgf⋅cm ft⋅lbf 39.2 400 29 19 193 9 WhereEverybodyKnowsYourName 03−11 SERVICE SPECIFICATIONS − INTAKE INTAKE 030ER−04 SERVICE DATA 2AZ−FE Intake manifold runner valve assy Standard voltage Resistance IAC valve open IAC valve close Terminals 4 and 5 at 20
C (68
F) 3.0 to 4.2 V 0.3 to 1.0 V 3.0 to 10 Ω 1MZ−FE/3MZ−FE Vacuum switching valve assy for No. 1 (1MZ−FE only) and No. 2 Resistance at 20
C (68
F) 33 to 39 Ω Vacuum switching valve assy for No. 3 Resistance 37 to 44 Ω at 20
C (68
F) WhereEverybodyKnowsYourName 03−12 SERVICE SPECIFICATIONS − INTAKE 030ES−03 TORQUE SPECIFICATION 2AZ−FE N⋅m kgf⋅cm ft⋅lbf Intake manifold x Cylinder head Part Tightened 30 306 22 Air cleaner cap sub−assy x Air cleaner case sub−assy 5.0 51 44 in.⋅lbf Engine cover sub−assy No. 1 x Cylinder head cover sub−assy 7.0 71 62 in.⋅lbf Part Tightened N⋅m kgf⋅cm ft⋅lbf Intake air control valve assy x Intake air surge tank (see page 13−12) Bolt A and nut A Bolt B 21 20 214 204 15 15 Intake air control valve assy No. 2 x Intake air surge tank 10 102 7 1MZ−FE/3MZ−FE WhereEverybodyKnowsYourName 03−13 SERVICE SPECIFICATIONS − ENGINE MECHANICAL ENGINE MECHANICAL 030ET−04 SERVICE DATA 2AZ−FE Ignition timing w/ Terminals TC and CG of DLC3 connected w/ Terminals TC and CG of DLC3 disconnected Idle speed M/T A/T Compression Compression pressure PZEV Except PZEV PZEV Except PZEV PZEV Except PZEV Minimum pressure Difference between each cylinder Valve clearance (cold) 8 to 12
BTDC @ idle 5 to 15
BTDC @ idle 650 to 750 rpm 610 to 710 rpm 1.300 MPa (13.3 kgf/cm2, 189 psi) 1.360 MPa (13.9 kgf/cm2, 198 psi) 1.000 MPa (10.2 kgf/cm2, 145 psi) 0.98 MPa (10 kgf/cm2, 142 psi) 29 kPa (0.3 kgf/cm2, 4.3 psi) 100 kPa (1.0 kgf/cm2, 14 psi) Intake 0.19 to 0.29 mm (0.008 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) Balanceshaft Specified thrust clearance Specified oil clearance Housing journal bore diameter Mark 1 Mark 2 Mark 3 Journal diameter Bearing center wall thickness Mark 1 Mark 2 Mark 3 0.050 to 0.090 mm (0.0020 to 0.0035 in.) 0.004 to 0.031 mm (0.0002 to 0.0012 in.) 26.000 to 26.006 mm (1.0236 to 1.0239 in.) 26.006 to 26.012 mm (1.0239 to 1.0241 in.) 26.012 to 26.018 mm (1.0241 to 1.0243 in.) 22.985 to 23.000 mm (0.9049 to 0.9055 in.) 1.486 to 1.489 mm (0.0585 to 0.0586 in.) 1.489 to 1.492 mm (0.0586 to 0.0587 in.) 1.492 to 1.495 mm (0.0587 to 0.0589 in.) Oil pump drive sprocket Minimum sprocket diameter (w/ chain) 48.2 mm (1.898 in.) Oil pump drive shaft sprocket Minimum sprocket diameter (w/ chain) 48.2 mm (1.898 in.) Crankshaft timing sprocket Minimum sprcoket diameter (w/ chain) 51.6 mm (2.031 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper No. 1 Maximum wear 1.0 mm (0.039 in.) Cylinder head set bolt Specfied bolt length 161.3 to 164.2 mm (6.350 to 6.465 in.) Chain sub−assy Maximum chain elongation 115.4 mm (4.543 in.) Camshaft timing gear or sprocket Minimum gear or sprocket diameter (w/ chain) 97.3 mm (3.831 in.) Intake manifold Maximum warpage 0.20 mm (0.0079 in.) Exhaust manifold Maximum warpage 0.70 mm (0.0276 in.) WhereEverybodyKnowsYourName 03−14 SERVICE SPECIFICATIONS Camshaft (Intake) Maximum circle runout Specified cam lobe height No. 1 journal diameter Other journal diameter Specified journal thrust clearance Specified journal oil clearance Cylinder head journal bore diameter Standard bearing center wall thickness − ENGINE MECHANICAL No. 1 journal bearing mark 1 No. 1 journal bearing mark 2 No. 1 journal bearing mark 3 Other journals Mark 1 Mark 2 Mark 3 Mark 1 Mark 2 Mark 3 Camshaft journal diameter Camshaft No. 2 (Exhaust) Maximum circle runout Specified cam lobe height No. 1 journal diameter Other journal diameter Specified thrust clearance Specified journal oil clearance Cylinder head journal bore diameter Standard bearing center wall thickness No. 1 journal Other journals Mark 1 Mark 2 Mark 3 Mark 1 Mark 2 Mark 3 Camshaft journal diameter Cylinder head Maximum warpage Cylinder block side Intake manifold side Exhaust manifold side 0.03 mm (0.0012 in.) 46.599 to 46.809 mm (1.8346 to 1.8429 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 0.040 to 0.110 mm (0.0016 to 0.0043 in.) 0.007 to 0.070 mm (0.0003 to 0.0028 in.) 0.008 to 0.070 mm (0.0003 to 0.0028 in.) 0.008 to 0.070 mm (0.0003 to 0.0028 in.) 0.025 to 0.100 mm (0.0010 to 0.0039 in.) 40.000 to 40.009 mm (1.5748 to 1.5752 in.) 40.009 to 40.017 mm (1.5752 to 1.5755 in.) 40.017 to 40.025 mm (1.5755 to 1.5758 in.) 2.000 to 2.004 mm (0.0787 to 0.0789 in.) 2.004 to 2.008 mm (0.0789 to 0.0791 in.) 2.008 to 2.012 mm (0.0791 to 0.0792 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 0.03 mm (0.0012 in.) 46.599 to 46.809 mm (1.8346 to 1.8429 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 0.080 to 0.150 mm (0.0032 to 0.0059 in.) 0.040 to 0.100 mm (0.0016 to 0.0039 in.) 0.025 to 0.100 mm (0.0010 to 0.0039 in.) 40.000 to 40.009 mm (1.5748 to 1.5752 in.) 40.009 to 40.017 mm (1.5752 to 1.5755 in.) 40.017 to 40.025 mm (1.5755 to 1.5758 in.) 2.000 to 2.004 mm (0.0787 to 0.0789 in.) 2.004 to 2.008 mm (0.0789 to 0.0791 in.) 2.008 to 2.012 mm (0.0791 to 0.0792 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 0.05 mm (0.0020 in.) 0.08 mm (0.0031 in.) 0.08 mm (0.0031 in.) Inner compression spring Free length Maximum deviation 45.7 mm (1.799 in.) 1.6 mm (0.063 in.) Intake valve Specified overall length Valve stem diameter Minimum margin thickness 101.21 to 101.71 mm (3.9846 to 4.0043 in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) 0.50 to 1.45 mm (0.0197 to 0.0571 in.) Exhaust valve Specified overall length Valve stem diameter Minimum margin thickness 100.70 to 101.15 mm (3.9646 to 3.9823 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) 0.50 to 1.60 mm (0.0197 to 0.0630 in.) Intake valve guide bush Bush inside diameter Specified bush oil clearance 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.025 to 0.080 mm (0.0010 to 0.0031 in.) Exhaust valve guide bush Bush inside diameter Specified bush oil clearance 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.030 to 0.100 mm (0.0012 to 0.0039 in.) Valve lifter Lifter diameter Lifter bore diameter Specified oil clearance 30.966 to 30.976 mm (1.2191 to 1.2195 in.) 31.009 to 31.025 mm (1.2208 to 1.2215 in.) 0.033 to 0.070 mm (0.0013 to 0.0028 in.) Cylinder block Maximum warpage Specified cylinder bore diameter 0.05 mm (0.0020 in.) 88.500 to 88.633 mm (3.4843 to 3.4894 in.) WhereEverybodyKnowsYourName 03−15 SERVICE SPECIFICATIONS Connecting rod Specified thrust clearance Specified oil clearance Connecting rod bearing center wall thickness (Reference) Bush inside diameter Bush inside diameter (Reference) − ENGINE MECHANICAL Mark 1 Mark 2 Mark 3 Mark A Mark B Mark C Maximum rod out−of−alignment per 100 mm (3.94 in.) Maximum rod twist per 100 mm (3.94 in.) Piston Piston diameter Specified piston oil clearance Piston pin hole bush inside diameter Piston pin hole bush inside diameter (Reference) Piston ring Ring groove clearance Specified end gap Mark 1 Mark 2 Mark 3 No. 1 No. 2 Oil (side rail) Piston pin Piston pin diameter Piston pin diameter (Reference) Mark A Mark B Mark C Mark D Specified oil clearance Connecting rod bolt Specified diameter 88.439 to 88.449 mm (3.4818 to 3.4822 in.) 0.051 to 0.100 mm (0.0020 to 0.0039 in.) 22.001 to 22.010 mm (0.8662 to 0.8665 in.) 22.001 to 22.004 mm (0.8662 to 0.8663 in.) 22.004 to 22.007 mm (0.8663 to 0.8664 in.) 22.007 to 22.010 mm (0.8664 to 0.8665 in.) 0.030 to 0.070 mm (0.0012 to 0.0028 in.) 0.22 to 0.892 mm (0.0087 to 0.0350 in.) 0.50 to 1.35 mm (0.0197 to 0.0531 in.) 0.10 to 0.73 mm (0.0039 to 0.0287 in.) 21.997 to 22.009 mm (0.8660 to 0.8665 in.) 21.997 to 22.000 mm (0.8660 to 0.8661 in.) 22.000 to 22.003 mm (0.8661 to 0.8663 in.) 22.003 to 22.006 mm (0.8663 to 0.8664 in.) 22.006 to 22.009 mm (0.8664 to 0.8665 in.) 0.001 − 0.010 mm (0.00004 − 0.00039 in.) 7.0 to 7.3 mm (0.276 to 0.287 in.) Crankshaft Specified thrust clearance Thrust washer thickness Cylinder block main journal bore diameter (Reference) Main journal diameter Main journal diameter (Reference) Standard main bearing center wall thickness (Reference) Maximum circle runout Specified main journal oil clearance Maximum main journal taper and out−of−round Maximum crank pin taper and out−of−round Crank pin diameter Crankshaft bearing cap set bolt Specified diameter 0.160 to 0.362 mm (0.0063 to 0.0143 in.) 0.024 to 0.080 mm (0.0009 to 0.0031 in.) 1.485 to 1.488 mm (0.0585 to 0.0586 in.) 1.488 to 1.491 mm (0.0586 to 0.0587 in.) 1.491 to 1.494 mm (0.0587 to 0.0588 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) 22.005 to 22.008 mm (0.8663 to 0.8665 in.) 22.008 to 22.011 mm (0.8665 to 0.8666 in.) 22.011 to 22.014 mm (0.8666 to 0.8667 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 1 Mark 2 Mark 3 Mark 4 0.040 to 0.300 mm (0.0016 to 0.0118 in.) 1.930 to 1.980 mm (0.0760 to 0.0780 in.) 59.000 to 59.002 mm (2.3228 to 2.3229 in.) 59.002 to 59.004 mm (2.3229 to 2.3230 in.) 59.004 to 59.006 mm (2.3230 to 2.3231 in.) 59.006 to 59.009 mm (2.3231 to 2.3232 in.) 59.009 to 59.011 mm (2.3232 to 2.3233 in.) 59.011 to 59.013 mm (2.3233 to 2.3233 in.) 59.013 to 59.016 mm (2.3233 to 2.3235 in.) 54.988 to 55.000 mm (2.1648 to 2.1654 in.) 54.998 to 55.000 mm (2.1653 to 2.1654 in.) 54.996 to 54.998 mm (2.1652 to 2.1653 in.) 54.994 to 54.996 mm (2.1651 to 2.1652 in.) 54.992 to 54.994 mm (2.1650 to 2.1651 in.) 54.990 to 54.992 mm (2.1650 to 2.1650 in.) 54.988 to 54.990 (2.1649 to 2.1650 in.) 1.993 to 1.996 mm (0.0785 to 0.0786 in.) 1.996 to 1.999 mm (0.0786 to 0.0787 in.) 1.999 to 2.002 mm (0.0787 to 0.0788 in.) 2.002 to 2.005 mm (0.0788 to 0.0789 in.) 0.03 mm (0.0012 in.) 0.008 to 0.024 mm (0.00031 to 0.00094 in.) 0.003 mm (0.0001 in.) 0.003 mm (0.0001 in.) 47.990 to 48.000 mm (1.8894 to 1.8898 in.) 7.2 to 7.6 mm (0.283 to 0.299 in.) WhereEverybodyKnowsYourName 03−16 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1MZ−FE/3MZ−FE V−Rebbed belt New drive belt tension Cooler compressor to crankshaft Vane pump Cooler compressor to crankshaft Vane pump Used drive belt tension Ignition timing w/ Terminals TC and CG of DLC3 connected w/ Terminals TC and CG of DLC3 disconnected Idle speed Compression 139 to 192 lbf 154 to 176 lbf 66 to 110 lbf 77 to 110 lbf 8 to 12
BTDC @ idle 7 to 24
BTDC @ idle 1MZ−FE 550 − 650 rpm 3MZ−FE 630 − 730 rpm Compression pressure Minimum pressure Difference between each cylinder Valve clearance (cold) 1.47 MPa (15 kgf/cm2, 213 psi) 1.0 MPa (10.2 kgf/cm2, 145 psi) 100 kPa (1.0 kgf/cm2, 15 psi) Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) Intake air surge tank Maximum warpage 0.10 mm (0.0039 in.) Intake manifold Maximum warpage Air intake surge tank side Cylinder head side Exhaust manifold Maximum warpage 0.15 mm (0.0059 in.) 0.08 mm (0.0031 in.) 0.50 mm (0.0196 in.) Camshaft Maximum circle runout Specified cam lobe height 1MZ−FE Intake Exhaust 3MZ−FE Intake Exhaust Camshaft Journal diameter Specified gear backlash Specified journal thrust clearance Specified journal oil clearance Cylinder head set bolt Specified outside diameter at tension portion Cylinder head Maximum warpage 0.06 mm (0.0024 in.) 42.780 to 43.032 mm (1.6842 to 1.6942 in.) 42.610 to 42.864 mm (1.6776 to 1.6876 in.) 42.980 to 43.232 mm (1.6921 to 1.7020 in.) 42.960 to 43.110 mm (1.6874 to 1.6972 in.) 26.959 to 26.975 mm (1.0614 to 1.0620 in.) 0.020 to 0.300 mm (0.0008 to 0.0118 in.) 0.040 to 0.120 mm (0.0016 to 0.0047 in.) 0.025 to 0.100 mm (0.0010 to 0.0039 in.) 8.75 to 9.05 mm (0.3445 to 0.3563 in.) Cylinder block side Intake manifold side Exhaust manifold side 0.05 mm (0.0020 in.) 0.10 mm (0.0039 in.) 0.10 mm (0.0039 in.) Intake valve Specified overall length Valve stem diameter Minimum margin thickness 94.95 to 95.45 mm (3.7382 to 3.7579 in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) 0.5 to 1.0 mm (0.020 to 0.039 in.) Exhaust valve Specified overall length Valve stem diameter Minimum margin thickness 94.90 to 95.40 mm (3.7362 to 3.7559 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) 0.5 to 1.0 mm (0.020 to 0.039 in.) Inner compression spring Free length Maximum deviation Installed tension at 33.8 mm (1.331 in.) 45.50 mm (1.7913 in.) 2.0 mm (0.079 in.) 186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) Valve guide bush Bush inside diameter Specified bush oil clearance Cylinder head valve guide bush bore diameter Bush diameter Intake Exhaust STD O/S 0.05 STD O/S 0.05 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.025 to 0.080 mm (0.0010 to 0.0031 in.) 0.030 to 0.100 mm (0.0012 to 0.0039 in.) 10.295 to 10.313 mm (0.4053 to 0.4060 in.) 10.345 to 10.363 mm (0.4073 to 0.4080 in.) 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.) WhereEverybodyKnowsYourName 03−17 SERVICE SPECIFICATIONS Valve lifter Lifter diameter Lifter bore diameter Specified oil clearance ENGINE MECHANICAL 30.966 to 30.976 mm (1.2191 to 1.2195 in.) 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard 0.033 to 0.070 mm (0.0013 to 0.0028 in.) Connecting rod Specified thrust clearance Connecting rod thickness Specified connecting rod oil clearance Connecting rod bearing center wall thickness Crankshaft Crankshaft thrust clearance Thrust washer thickness Specified main journal oil clearance − Mark 1 Mark 2 Mark 3 Mark 4 No. 1 and No. 4 journals No. 2 and No. 3 journals Cylinder block main journal bore diameter (Reference) Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Main journal diameter Main journal diameter (Reference) Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Standard main bearing center wall thickness (Reference) Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Maximum circle runout Main journal taper and out−of−round Crank pin diameter Maximum crank pin taper and out−of−round Cylinder block Maximum warpage Specified cylinder bore diameter 0.15 to 0.35 mm (0.0059 to 0.0138 in.) 20.80 to 20.85 mm (0.8189 to 0.8209 in.) 0.038 to 0.080 mm (0.0015 to 0.0031 in.) 1.484 to 1.487 mm (0.0584 to 0.0585 in.) 1.487 to 1.490 mm (0.0585 to 0.0587 in.) 1.490 to 1.493 mm (0.0587 to 0.0588 in.) 1.493 to 1.496 mm (0.0588 to 0.0589 in.) 0.04 to 0.30 mm (0.0016 to 0.0118 in.) 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 0.014 to 0.050 mm (0.0006 to 0.0020 in.) 0.026 to 0.060 mm (0.0010 to 0.0024 in.) 66.000 mm (2.5984 in.) 66.001 mm (2.5985 in.) 66.002 mm (2.5985 in.) 66.003 mm (2.5985 in.) 66.004 mm (2.5986 in.) 66.005 mm (2.5986 in.) 66.006 mm (2.5987 in.) 66.007 mm (2.5987 in.) 66.008 mm (2.5987 in.) 66.009 mm (2.5988 in.) 66.010 mm (2.5988 in.) 66.011 mm (2.5989 in.) 66.012 mm (2.5989 in.) 66.013 mm (2.5989 in.) 66.014 mm (2.5990 in.) 66.015 mm (2.5990 in.) 66.016 mm (2.5990 in.) 61.000 mm (4.1016 in.) 60.999 mm (4.4015 in.) 60.998 mm (4.4015 in.) 60.997 mm (4.4015 in.) 60.996 mm (4.4014 in.) 60.995 mm (4.4014 in.) 60.994 mm (4.4013 in.) 60.993 mm (4.4012 in.) 60.992 mm (4.4012 in.) 60.991 mm (4.4012 in.) 60.990 mm (4.4012 in.) 60.989 mm (4.4011 in.) 60.988 mm (4.4011 in.) 2.486 to 2.489 mm (0.0979 to 0.0980 in.) 2.489 to 2.492 mm (0.0980 to 0.0981 in.) 2.492 to 2.495 mm (0.0981 to 0.0982 in.) 2.495 to 2.498 mm (0.0982 to 0.0983 in.) 2.498 to 2.501 mm (0.0983 to 0.0985 in.) 2.501 to 2.504 mm (0.0985 to 0.0986 in.) 2.504 to 2.507 mm (0.0986 to 0.0987 in.) 0.06 mm (0.0024 in.) 60.988 to 61.000 mm (2.4011 to 2.4016 in.) 0.02 mm (0.0008 in.) 52.992 to 53.000 mm (2.0863 to 2.0866 in.) 0.02 mm (0.0008 in.) 0.05 mm (0.0020 in.) 1MZ−FE 87.500 to 87.632 mm (3.4449 to 3.4501 in.) 3MZ−FE 92.000 to 92.132 mm (3.6220 to 3.6272 in.) WhereEverybodyKnowsYourName 03−18 SERVICE SPECIFICATIONS Piston Piston diameter − ENGINE MECHANICAL 1MZ−FE for AISIN made 1MZ−FE for MAHLE made 3MZ−FE 1MZ−FE for AISIN made 1MZ−FE for MAHLE made 3MZ−FE Specified oil clearance 87.106 to 87.416 mm (3.4412 to 3.4416 in.) 87.453 to 87.467 mm (3.4430 to 3.4436 in.) 91.983 to 91.967 mm (3.6202 to 3.6207 in.) 0.084 to 0.130 mm (0.0033 to 0.0051 in.) 0.033 to 0.130 mm (0.0013 to 0.0051 in.) 0.033 to 0.130 mm (0.0013 to 0.0051 in.) Connecting rod Maximum misalignment per 100 mm (3.94 in.) Maximum rod twist per 100 mm (3.94 in.) Bush inside diameter 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Piston pin Piston pin diameter Pecified oil clearance 21.997 to 22.006 mm (0.8660 to 0.8664 in.) 0.005 to 0.050 mm (0.0002 to 0.0020 in.) Piston ring Piston ring groove clearance Specified end gap 1MZ−FE No. 1 No. 2 Oil 3MZ−FE No. 1 No. 2 Oil 1MZ−FE No. 1 No. 2 Oil (Side rail) 3MZ−FE No. 1 No. 2 Oil 0.02 to 0.07 mm (0.0008 to 0.0028 in.) 0.02 to 0.06 mm (0.0008 to 0.0024 in.) 0.04 to 0.12 mm (0.0016 to 0.0047 in.) 0.03 to 0.08 mm (0.0012 to 0.0031 in.) 0.02 to 0.06 mm (0.0008 to 0.0024 in.) 0.03 to 0.11 mm (0.0012 to 0.0043 in.) 0.25 to 0.95 mm (0.0098 to 0.0374 in.) 0.35 to 1.05 mm (0.0138 to 0.0413 in.) 0.15 to 1.00 mm (0.0059 to 0.0394 in.) 0.30 to 0.95 mm (0.0118 to 0.0374 in.) 0.50 to 1.05 mm (0.0197 to 0.0413 in.) 0.15 to 1.00 mm (0.0059 to 0.0394 in.) Connecting rod bolt Specified diameter 7.0 to 7.3 mm (0.276 to 0.287 in.) Crankshaft bearing cap set bolt Specified diameter 7.2 to 7.6 mm (0.283 to 0.299 in.) WhereEverybodyKnowsYourName 03−19 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 030EU−04 TORQUE SPECIFICATION 2AZ−FE N⋅m kgf⋅cm ft⋅lbf Engine mounting bracket No. 2 RH x Timing chain cover Part Tightened 52 531 38 Engine moving control rod w/ bracket x Engine mounting bracket No. 2 RH 64 653 47 Engine moving control rod w/ bracket x Fender apron RH 64 653 47 Engine mounting stay No. 2 RH x Cylinder head 64 653 47 Engine mounting stay No. 2 RH x Engine mounting bracket No. 2 RH 64 653 47 Drain plug (A/T) 49 500 36 Drain plug (M/T) 49 500 36 Engine hanger No. 1 x Cylinder head 38 387 28 Engine hanger No. 2 x Cylinder head 38 387 28 ECT sensor x Cylinder head 20 204 15 Knock sensor x Cylinder block 39 398 29 Engine oil pressure switch assy x Cylinder head 15 153 11 Water by−pass pipe No. 1 x Cylinder block 9.0 92 80 in.⋅lbf Transverse engine engine mounting bracket x Cylinder block 54 551 40 47 Drive shaft bearing bracket x Cylinder block 64 653 V−ribbed belt tensioner assy x Timing chain cover 59.5 607 44 Ignition coil assy x Cylinder head 9.0 92 80 in.⋅lbf Water inlet x Cylinder block 9.0 92 80 in.⋅lbf Exhaust manifold converter x Cylinder head 37 378 27 Exhaust manifold stay x Exhaust manifold converter 44 449 32 Manifold converter insulator No. 1 x Exhaust manifold converter 12 122 9 Oil level gage guide x Water by−pass pipe No. 1 9.0 92 80 in.⋅lbf Intake manifold x Cylinder head 30 306 22 Drive plate & ring gear (A/T) x Crankshaft 98 1,000 72 Flywheel sub−assy (M/T) x Crankshaft 130 1,330 96 Starter assy x Automatic transaxle assy 39 398 29 Starter assy x Manual transaxle assy 39 398 29 Engine mounting insulator LH x Automatic transaxle assy 95 969 70 Engine mounting insulator LH x Manual transaxle assy 143 1,459 105 Engine mounting insulator RH x Engine mounting bracket RH 95 969 70 Engine mounting insulator FR x Engine mounting bracket FR 87 888 64 Engine mounting bracket rear No. 2 x Engine lateral control rod (M/T) 89 910 66 Vane pump assy x Timing chain cover 43 439 32 Frame side plate x Front frame assy Bolt A 85 867 63 Frame side plate x Body Bolt B 32 326 24 Front suspension member brace rear x Front frame assy Bolt C 85 867 63 Front suspension member brace rear x Body Bolt D 32 326 24 Steering intermediate shaft 35 357 26 Drive plate & ring gear x Torque converter 41 418 30 Front suspension arm sub−assy lower No. 1 x Lower ball joint 75 764 55 Tie rod assy x Steering knuckle 49 500 36 Speed sensor front LH (w/ ABS) x Steering knuckle 8.0 82 71 in.⋅lbf Speed sensor front RH (w/ ABS) x Steering knuckle 8.0 82 71 in.⋅lbf Front axle hub LH nut x Front drive shaft 294 3,000 217 Front stabilizer link assy x Front suspension 74 755 55 5.0 51 44 in.⋅lbf 22 Turn 90
220 Turn 90
16 Turn 90
33 332 24 Air cleaner assy x Body Balanceshaft housing x Stiffening crankcase assy Stiffening crankcase assy x Cylinder block 1st 2nd WhereEverybodyKnowsYourName 03−20 SERVICE SPECIFICATIONS − ENGINE MECHANICAL Part Tightened N⋅m kgf⋅cm ft⋅lbf w/ head taper screw plug No. 1 x Cylinder block 26 265 19 Oil control valve filter x Cylinder block 30 306 22 25 255 18 79 Turn 90
806 Turn 90
58 Turn 90
Camshaft timing gear assy x Camshaft 54 551 40 Camshaft timing sprocket x Camshaft 54 551 40 Camshaft bearing cap No. 1 x Cylinder head 30 301 22 Camshaft bearing cap No. 2 x Cylinder head 30 301 22 Camshaft bearing cap No. 3 x Cylinder head 9.0 92 80 in.⋅lbf Oil pump assy x Stiffening crankcase assy 19 194 14 Chain tensioner plate x Stiffening crankcase assy 12 122 9 Oil pump drive sprocket x Oil pump 30 301 22 Chain vibration damper No. 1 x Cylinder head 9.0 92 80 in.⋅lbf Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.⋅lbf Chain tensioner slipper x Cylinder block 19 194 14 9.0 92 80 in.⋅lbf 9.0 21 43 9.0 92 214 438 92 80 in.⋅lbf 15 32 80 in.⋅lbf 9.0 92 80 in.⋅lbf Oil pan drain plug x Oil pan 25 250 18 Water pump assy x Cylinder block 9.0 92 80 in.⋅lbf Water pump pulley x Water pump assy 26 265 19 Cylinder block water drain cock x Stiffening crankcase assy Cylinder head x Cylinder block 1st 2nd Timing chain guide x Crankshaft bearing cap No. 1 Timing chain cover (See page 14−75) Bolt A Bolt B Bolt C Nut Oil pan x Stiffening crankcase assy Crankshaft position sensor x Timing chain cover 9.0 92 80 in.⋅lbf Crankshaft pulley x Crankshaft 170 1,733 125 Chain tensioner assy No. 1 x Timing chain cover 9.0 92 80 in.⋅lbf Camshaft position sensor x Cylinder head 9.0 92 80 in.⋅lbf Cylinder head cover x Cylinder head 11 110 8 Oil filter union x Stiffening crankcase assy 30 306 22 Spark plug x Cylinder head 19 194 14 Ventilation valve x Cylinder head cover 19 194 14 Front suspension brace x Body 80 816 59 Stud bolt (See page 14−108) Bolt A Bolt B Bolt C Bolt D 5 5 10 10 51 51 97 97 44 in.⋅lbf 44 in.⋅lbf 84 in.⋅lbf 84 in.⋅lbf Stud bolt (See page 14−120) Stud bolt A Stud bolt B Stud bolt C 5.0 10 5.0 51 97 51 44 in.⋅lbf 84 in.⋅lbf 44 in.⋅lbf Crankshaft bearing cap x Cylinder block 1st 2nd 20 40 204 408 15 29 Connecting rod cap x Connecting rod 1st 2nd 25 Turn 90
250 Turn 90
18 Turn 90
WhereEverybodyKnowsYourName 03−21 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1MZ−FE/3MZ−FE Part Tightened N⋅m kgf⋅cm ft⋅lbf 20 204 15 39 20 398 204 39 15 Oil pressure switch assy x Cylinder block 15 152 11 Compressor mounting bracket No.1 x Cylinder block 25 255 18 Generator bracket No. 1 x Cylinder block 58 591 43 Pump bracket x Cylinder head 32 326 24 Drive shaft bearing bracket x Cylinder block 64 653 47 Exhaust manifold converter sub−assy No. 2 x Cylinder head 49 500 36 Exhaust manifold heat insulator No. 2 x Cylinder head 8.5 87 75 in.⋅lbf Exhaust manifold converter sub−assy RH x Cylinder head 49 500 36 Intake manifold x Cylinder head 15 153 11 Ignition coil assy x Cylinder head cover 8.0 82 71 in.⋅lbf Intake air surge tank x Intake manifold 28 286 21 Surge tank stay bolt 20 204 15 Engine hanger No. 2 x Cylinder head 39 398 29 Engine hanger No. 1 x Intake air surge tank 39 398 29 Manifold stay No. 2 x Exhaust manifold converter sub−assy 49 500 36 Manifold stay No. 2 x Automatic transaxle assy 49 500 36 Engine mounting insulator RH x Engine mounting bracket 95 969 70 Engine mounting insulator LH x Automatic transaxle assy 95 969 70 Engine mounting insulator FR x Automatic transaxle assy 87 887 64 Vane pump assy x Pump bracket 43 439 32 Vane pump assy x Engine mounting bracket 43 439 32 Bolt A Bolt B Nut 85 32 32 867 326 326 63 24 24 Bolt C Bolt D Nut 85 32 32 867 326 326 63 24 24 Compressor and magnetic clutch x Compressor mounting bracket No.1 (See page 14 14−164) 164) Bolt Nut 25 26 250 260 18 19 43 18 8.0 438 184 82 32 13 71 in.⋅lbf Generator bracket No. 2 x Transverse engine engine mounting bracket 28 286 21 Intermediate shaft sub−assy 35 357 26 Drive plate & ring gear x Torque converter 41 418 30 Flywheel housing under cover x Automatic transaxle assy 7.8 80 69 in.⋅lbf Front suspension arm x Lower ball joint 75 764 55 Tie rod end x Steering knuckle 49 500 36 Front axle hub nut x Front drive shaft 294 2,998 217 Front stabilizer link assy x Front suspension 74 755 55 V−bank cover x Cylinder head cover 7.9 81 70 in.⋅lbf Engine mounting stay No. 2 RH x Engine engine mounting bracket 64 653 47 64 23 653 235 47 17 5.4 55 48 in.⋅lbf Engine hanger No. 2 x Cylinder head Knock sensor x Cylinder block 1MZ−FE 3MZ−FE Frame side rail plate sub−assembly x Front frame assy (See page age 14 164) 14−164) Front suspension member brace rear x Front frame assy (See page age 14 164) 14−164) Generator belt adjusting bar x Cylinder block (See page 14−164) Engine moving control rod (See page age 14−164) Camshaft sub−gear x Main gear Nut A Bolt B Bolt C Bolt A Bolt B WhereEverybodyKnowsYourName 03−22 SERVICE SPECIFICATIONS − ENGINE MECHANICAL Part Tightened N⋅m kgf⋅cm ft⋅lbf 8.0 82 71 in.⋅lbf 8.0 20 43 82 204 439 71 in.⋅lbf 15 32 8.0 82 71 in.⋅lbf 8.0 82 71 in.⋅lbf 8.0 20 82 204 71 in.⋅lbf 15 Oil strainer sub−assy x Oil pan sub−assy 8.0 82 71 in.⋅lbf Oil pan sub−assy No. 2 x Oil pan sub−assy 8.0 82 71 in.⋅lbf Oil pan drain plug x Oil pan sub−assy No. 2 45 459 33 8.0 82 71 in.⋅lbf 54 Turn 90
19 551 Turn 90
189 40 Turn 90
14 Camshaft bearing cap x Cylinder head 16 163 12 Timing belt plate x Oil pump assy 8.0 82 71 in.⋅lbf Water pump assy x Cylinder block 8.0 82 71 in.⋅lbf Oil level gage guide x Cylinder block 8.0 82 71 in.⋅lbf Oil filter union x Cylinder block 30 306 22 Timing belt idler bracket x Cylinder block 28 286 21 Timing belt No. 3 cover x Cylinder head 8.5 87 76 in.⋅lbf Camshaft timing pulley x Camshaft 125 1,275 92 Timing belt idler sub−assy No. 2 x Timing belt idler bracket 43 438 32 Timing belt idler sub−assy No. 1 x Cylinder block 34 347 25 Chain tensioner assy No. 1 x Oil pump assy 27 280 20 Transverse engine engine mounting bracket x Cylinder block 28 286 21 Timing belt No. 2 cover x Timing belt No. 3 cover 8.5 87 76 in.⋅lbf Timing belt No. 1 cover x OIl pump assy 8.5 87 76 in.⋅lbf Crankshaft pulley x Crankshaft 215 2,192 159 Camshaft position sensor x Cylinder head 8.0 82 71 in.⋅lbf Cylinder head cover x Cylinder head 8.0 82 71 in.⋅lbf Spark plug x Cylinder head 18 184 13 Vane pump assy x Adjusting strut 43 439 32 Generator x Generator bracket 58 591 43 Generator x Adjusting bar 18 184 13 Front suspension brace upper x Body 80 816 59 Water outlet x Cylinder head 15 153 11 Exhaust manifold heat insulator No. 2 x Exhaust manifold LH 8.5 87 55 in.⋅lbf Exhaust pipe support bracket No. 1 x Automatic transaxle assy 21 214 15 Drive plate & ring gear sub−assy x Crankshaft 83 846 61 w/ head straight screw plug No. 1 x Cylinder head 44 449 32 Engine rear oil seal retainer x Cylinder block Oil pump assy x Cylinder block (See page 14−186) 10 mm head 12 mm head 14 mm head Crank position sensor x Oil pump assy Oil pan baffle plate x Oil pan sub−assy Oil pan an sub−assy x Cylinder block (See page age 14−186) 10 mm head 12 mm head Water inlet housing x Cylinder block Cylinder head x Cylinder block 12 pointed head 1st 2nd Recessed head w/ head straight screw plug No. 2 x Cylinder head 44 449 32 12 pointed head 1st 2nd 6 pointed head 22 Turn 90
27 224 Turn 90
275 16 Turn 90
20 1st 2nd 25 Turn 90
250 Turn 90
18 Turn 90
Cylinder block w/ head straight screw No. 1 plug x Cylinder block 30 306 22 Cylinder block w/ head straight screw No. 2 plug x Cylinder block 50 510 37 Cylinder block w/head straight screw No. 3 plug x Cylinder block 30 306 22 Main bearing cap x Cylinder block Connecting rod cap x Connecting rod WhereEverybodyKnowsYourName 03−23 SERVICE SPECIFICATIONS Part Tightened − ENGINE MECHANICAL N⋅m kgf⋅cm ft⋅lbf Water seal plate x Cylinder block 18 184 13 Cylinder block water drain cock sub−assy x Cylinder block 39 398 29 WhereEverybodyKnowsYourName 03−2 SERVICE SPECIFICATIONS − STANDARD BOLT 0307L−02 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 − 60 145 290 540 850 − 52 in.·lbf 10 21 39 61 − 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 − 75 175 360 670 1,050 − 65 in.·lbf 13 26 48 76 − 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 − 90 210 440 810 1,250 − 78 in.·lbf 15 32 59 90 − 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 − 120 290 590 1,050 1,700 − 9 21 43 76 123 − 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 WhereEverybodyKnowsYourName 03−24 SERVICE SPECIFICATIONS − EXHAUST EXHAUST 030EV−03 TORQUE SPECIFICATION 2AZ−FE Part Tightened Exhaust pipe damper (A/T) x Exhaust pipe assy center Exhaust pipe assy center x Exhaust pipe assy tail N⋅m kgf⋅cm ft⋅lbf 19 194 14 56 571 41 19.5 199 14 Exhaust pipe assy front x Exhaust pipe assy center 56 571 41 Exhaust pipe assy front x Exhaust manifold converter sub assy 62 633 46 Exhaust pipe No. 1 support bracket x Exhaust pipe assy front 33 337 24 Exhaust pipe No. 1 support bracket x Exhaust pipe assy front 33 337 24 Heated oxygen sensor x Exhaust pipe assy front 44 449 32 N⋅m kgf⋅cm ft⋅lbf Exhaust pipe assy center x Exhaust pipe assy tail 56 571 41 Exhaust pipe assy front x Exhaust manifold RH 62 633 47 Exhaust pipe assy front x Exhaust manifold converter No. 2 62 633 47 Exhaust pipe assy front x Exhaust pipe assy center 56 571 41 Exhaust pipe No. 1 support bracket x Body 33 337 24 Floor panel brace rear x Body 20 204 15 Exhaust pipe No. 1 support bracket x Exhaust pipe support bracket No. 1 33 337 24 Heated oxygen sensor x Exhaust pipe assy front 44 449 32 Floor panel brace rear x Body 1MZ−FE/3MZ−FE Part Tightened WhereEverybodyKnowsYourName 03−25 SERVICE SPECIFICATIONS − COOLING COOLING 030EW−03 SERVICE DATA 2AZ−FE Thermostat Valve opening temperature Valve lift at 95
C (203
F) Radiator cap sub−assy Specified opening pressure Cooling fan Standard amperage 80 to 84
C (176 to 183
F) 10 mm (0.394 in.) or more 78 to 122 kPa (0.80 to 1.25 kgf/cm2, 11.2 to 17.6 psi) at 20
C (68
F) 4.9 to 8.5 A 1MZ−FE/3MZ−FE Thermostat Valve opening temperature Valve lift at 95
C (203
F) Radiator cap sub−assy Specified opening pressure Cooling fan Standard amperage 80 to 84
C (176 to 183
F) 10 mm (0.394 in.) or more 69.0 to 112.8 kPa (0.70 to 1.15 kgf/cm2, 10.0 to 16.4 psi) at 20
C (68
F) 8.0 to 12.0 A WhereEverybodyKnowsYourName 03−26 SERVICE SPECIFICATIONS − COOLING 030EX−04 TORQUE SPECIFICATION 2AZ−FE N⋅m kgf⋅cm ft⋅lbf Cylinder block drain cock plug x Drain cock Part Tightened 13 130 10 Water pump x Cylinder block 9.0 92 80 in.⋅lbf Water pump pulley x Water pump 26 265 19 Water inlet x Cylinder block 9.0 92 80 in.⋅lbf Fan assy w/ motor x Radiator assy 5.0 51 44 in.⋅lbf Radiator support upper x Body 14 142 10 Air cleaner inlet x Body 5.0 51 44 in.⋅lbf Oil cooler assy x Radiator tank lower 8.3 85 73 in.⋅lbf Oil coler pipe x Oil cooler assy 14.7 150 11 N⋅m kgf⋅cm ft⋅lbf Cylinder block drain cock plug x Drain cock 13 130 10 Water pump assy x Cylinder block 8 82 71 in.⋅lbf Timing belt Idler sub−assy No.2 x Cylinder block 43 438 32 Engine mounting bracket RH x Cylinder block 28 286 21 Generator bracket No. 2 x Cylinder block 28 286 21 71 in.⋅lbf 1MZ−FE/3MZ−FE Part Tightened Water inlet x Cylinder block 8 82 Water inlet pipe x Water inlet 20 204 15 Fan assy w/ motor x Radiator assy 5.0 51 44 in.⋅lbf Radiator support upper x body 14 142 10 Air cleaner inlet x Body 5.0 51 44 in.⋅lbf Oil cooler assy x Radiator tank lower 8.3 85 74 in.⋅lbf Oil coler pipe x Oil cooler assy 14.7 150 11 WhereEverybodyKnowsYourName 03−27 SERVICE SPECIFICATIONS − LUBRICATION LUBRICATION 030EY−03 SERVICE DATA 2AZ−FE Oil pressure at idle speed at 3,000 rpm Oil pump Specified side clearance Specified tip clearance Specified body clearance 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 245 to 539 kPa (2.5 to 5.5 kgf⋅cm2, 36 to 78 psi) or more 0.030 to 0.160 mm (0.0012 to 0.0063 in.) 0.080 to 0.350 mm (0.0031 to 0.0138 in.) 0.100 to 0.325 mm (0.0039 to 0.0128 in.) 1MZ−FE/3MZ−FE Oil pressure Oil pump Specified side clearance Specified tip clearance Specified body clearance at idle speed at 3,000 rpm 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 245 to 539 kPa (2.5 to 5.5 kgf⋅cm2, 36 to 78 psi) 0.060 to 0.300 mm (0.0024 to 0.0118 in.) 0.250 to 0.500 mm (0.0098 to 0.0128 in.) 0.030 to 0.150 mm (0.0012 to 0.0059 in.) WhereEverybodyKnowsYourName 03−28 SERVICE SPECIFICATIONS − LUBRICATION 030EZ−04 TORQUE SPECIFICATION 2AZ−FE N⋅m kgf⋅cm ft⋅lbf Oil pressure switch x Cylinder head Part Tightened 15 152 11 Oil drain plug x Oil pan sub−assy 25 255 18 Oil pump assy x Cylinder block 19 194 14 Chain tensioner plate x Stiffening crankcase assy 12 122 9 Oil pump drive sprocket x Oil pump 30 301 22 Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.⋅lbf Chain tensioner slipper x Cylinder block 19 194 14 9.0 21 43 9.0 92 214 438 92 80 in.⋅lbf 15 32 80 in.⋅lbf 59.5 607 44 54 551 40 95 87 969 888 70 64 Steering gear return hose clamp 8.0 80 69 in.⋅lbf Engine mounting insulator FR x Engine mounting bracket FR 87 888 64 Engine lateral control rod x Bracket 89 910 66 Oil pan sub−assy x Stiffening crankcase assy 9.0 92 80 in.⋅lbf Timing chain cover (see page 17−8) Bolt A Bolt B Bolt C Nut V−ribbed belt tensioner assy x Timing chain cover Engine mounting bracket RH x Cylinder block Engine mounting insulator RH (see page 17−8) Bolt A Bolt B Crankshaft position sensor x Timing chain cover 9.0 92 80 in.⋅lbf Crankshaft pulley x Crankshaft 170 1,733 125 Ignition coil assy x Cylinder head 9.0 92 80 in.⋅lbf Engine mounting bracket No. 2 RH x Timing chain cover 52 531 38 Engine mounting stay No. 2 RH x Cylinder head 64 653 47 Engine moving control rod w/ bracket x Fender apron RH 64 653 47 Oil pump cover x Oil pump 8.8 90 78 in.⋅lbf Oil pump strainer x Oil pump 8.8 90 78 in.⋅lbf N⋅m kgf⋅cm ft⋅lbf Oil pressure switch x Cylinder block 15 152 11 Oil drain plug x Oil pump sub−assy No. 2 25 255 18 Bolt A Bolt B Bolt C 8 20 43 82 199 439 71 in.⋅lbf 14 32 8 82 71 in.⋅lbf 10 mm head 12 mm head 14 mm head 8.0 20 37 82 203 379 71 in.⋅lbf 15 27 Oil strainer sub−assy x Main bearing cap 8 82 71 in.⋅lbf Oil pan sub−assy No. 2 x Oil pan sub−assy No. 1 8 82 71 in.⋅lbf 1MZ−FE/3MZ−FE Part Tightened Oil pump assy x Cylinder block (see page 17−32) Crankshaft position sensor x Oil pump assy Oil pan sub−assy x Cylinder block Engine engine mounting bracket RH (See page 17−32) Bolt A Nut B Bolt C 54 54 43 550 550 439 40 40 32 Engine mounting insulator RH (see page 17−32) Nut A Nut B 95 87 969 887 70 64 Engine mounting insulator FR (see page 17−32) Bolt A Nut B 87 52 887 531 64 38 Oil level gage guide x Cylinder block 8 82 71 in.⋅lbf Compressor mounting bracket No. 1 x Cylinder block 25 250 18 Timing belt idler sub−assy No. 1 x Cylinder block 34 347 25 WhereEverybodyKnowsYourName 03−29 SERVICE SPECIFICATIONS Part Tightened − LUBRICATION N⋅m kgf⋅cm ft⋅lbf Compressor and magnetic clutch x Compressor mounting bracket 25 250 18 Generator bracket No. 2 x Transverse engine engine mounting bracket 28 286 21 Front suspension brace upper center x Body 80 816 59 Oil pump cover x Oil pump 10 105 8 Oil pump relief valve x Oil pump 49 500 36 WhereEverybodyKnowsYourName 03−3 SERVICE SPECIFICATIONS − STANDARD BOLT 0307M−02 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more WhereEverybodyKnowsYourName 03−30 SERVICE SPECIFICATIONS − IGNITION IGNITION 030F0−03 SERVICE DATA 2AZ−FE Spark plug Recommended spark plug Electrode gap Camshaft position sensor Resistance Crank position sensor Resistance DENSO NGK Standard Maximum SK20R11 IFR6A11 1.0 − 1.1mm (0.039 − 0.043 in.) 1.3 mm (0.051 in.) at cold at hot 835 − 1,400Ω 1,060 − 1,645Ω at cold at hot 985 − 1,600Ω 1,265 − 1,890Ω 1MZ−FE/3MZ−FE Spark plug Recommended spark plug Electrode gap Camshaft position sensor Resistance Crank position sensor Resistance DENSO NGK Standard Maximum SK20R11 IFR6A11 1.0−1.1mm (0.039−0.043 in.) 1.3mm (0.051 in.) at cold at hot 835−1400Ω 1060−1645Ω at cold at hot 1630−2740Ω 2065−3225Ω WhereEverybodyKnowsYourName 03−31 SERVICE SPECIFICATIONS − IGNITION 030F1−03 TORQUE SPECIFICATION 2AZ−FE N⋅m kgf⋅cm ft⋅lbf Spark plug x Cylinder head cover Part Tightened 19 194 14 Ignition coil x Cylinder head cover 9.0 92 80 in.⋅lbf 1MZ−FE/3MZ−FE N⋅m kgf⋅cm ft⋅lbf Spark plug x Cylinder head cover Part Tightened 25 255 18.5 Ignition coil x Cylinder head cover 8.0 82 71 in.⋅lbf WhereEverybodyKnowsYourName 03−32 SERVICE SPECIFICATIONS − STARTING & CHARGING STARTING & CHARGING 030F2−03 SERVICE DATA 2AZ−FE: Starter assy Specified current Starter relay Specified condition Starter armature assy Depth Starter commutator end frame assy Brush length Magnetic switch resistance Starter armature resistance Voltage regulator Generator brush holder assy Brush length Generator rotor assy Open circuit Slip ring diameter 90 A or less at 11.5 V 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Standard 3.1 mm (0.122 in.) Maximum 3.8 mm (0.150 in.) Standard 9.0 mm (0.354 in.) Minimum 4.0 mm (0.158 in.) Terminal 50 − C Terminal 50 − Switch body Below 1 Ω Below 2 Ω Segments Below 1 Ω Commutator − Coil core 10 kΩ or higher Regulating voltage Standard amperage 13.2 to 14.8 V 10 A or less Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) Resistance 2.3 to 2.7 Ω at 20
C (68
F) Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) 1MZ−FE/3MZ−FE: Starter assy Specified current Starter relay Specified condition Starter armature assy Depth Starter commutator end frame assy Brush length Magnetic switch resistance Starter armature resistance Voltage regulator Generator brush holder assy Brush length Generator rotor assy Open circuit Slip ring diameter 90 A or less at 11.5 V 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Standard 3.1 mm (0.122 in.) Maximum 3.8 mm (0.150 in.) Standard 9.0 mm (0.354 in.) Minimum 4.0 mm (0.158 in.) Terminal 50 − C Terminal 50 − Switch body Below 1 Ω Below 2 Ω Segments Below 1 Ω Commutator − Coil core 10 kΩ or higher Regulating voltage Standard amperage 13.2 to 14.8 V 10 A or less Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) Resistance 2.3 to 2.7 Ω at 20
C (68
F) Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) WhereEverybodyKnowsYourName 03−33 SERVICE SPECIFICATIONS − STARTING & CHARGING 030F3−03 TORQUE SPECIFICATION 2AZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf 39 398 29 Starter wire x Starter assy 13 130 9 Air cleaner inlet x Body 7.0 71 62 in.⋅lbf Air cleaner bracket x Body 12 122 9 Air cleaner case sub−assy x Air cleaner bracket 5.0 51 44 in.⋅lbf Air cleaner case sub−assy x Body 5.0 51 44 in.⋅lbf Air cleaner cap sub−assy x Air cleaner case sub−assy 5.0 51 44 in.⋅lbf Battery clamp sub−assy x Body 5.5 56 49 in.⋅lbf Battery clamp sub−assy x Battery clamp bolt 5.5 56 49 in.⋅lbf Terminal x Battery 3.5 36 31 in.⋅lbf Commutator end frame assy x Starter drive housing assy 6.0 61 53 in.⋅lbf Magnetic switch assy x Starter drive housing assy 7.5 76 66 in.⋅lbf 10 102 7 21 52 214 530 15 38 80 in.⋅lbf Starter x Transaxle housing Lead wire x Terminal C Generator assy x Engine M8 M10 Wiring harness clamp 9 92 Generator wire x Generator assy 9.8 100 7 Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator rectifier end frame x Drive end frame assy generator 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Generator pulley x Generator rotor assy 110 1,122 81 1MZ−FE/3MZ−FE: N⋅m kgf⋅cm ft⋅lbf Starter assy x Transaxle housing Part Tightened 37 380 26 Starter wire x Starter assy 9.8 100 7 Air cleaner inlet No. 1 x Body 7.0 71 62 in.⋅lbf Air cleaner bracket x Body 12 122 9 Air cleaner case sub−assy x Air cleaner bracket 5.0 51 44 in.⋅lbf Air cleaner case sub−assy x Body 5.0 51 44 in.⋅lbf Air cleaner cap sub−assy x Air cleaner case sub−assy 5.0 51 44 in.⋅lbf Air cleaner inlet No. 2 x Body 7.0 71 62 in.⋅lbf Battery clamp sub−assy x Body 5.5 56 49 in.⋅lbf Battery clamp sub−assy x Battery clamp bolt 5.5 56 49 in.⋅lbf Terminal x Battery 3.5 36 31 in.⋅lbf Commutator end frame assy x Starter drive housing assy 6.0 61 53 in.⋅lbf Magnetic switch assy x Starter drive housing assy 7.5 76 66 in.⋅lbf Lead wire x Terminal C 10 102 7 Generator assy x Generator bracket No. 1 58 592 43 Generator assy x Generator belt adjusting bar 18 184 13 Generator wire x Generator assy 9.8 100 7 Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator rectifier end frame x Drive end frame assy generator 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Generator pulley x Generator rotor assy 111 1,127 82 WhereEverybodyKnowsYourName 03−34 SERVICE SPECIFICATIONS − FRONT SUSPENSION FRONT SUSPENSION 032CP−01 SERVICE DATA Vehicle height 1MZ−FE COMFORT 1MZ−FE PREMIUM (USA, Canada) 1MZ−FE PREMIUM (Mexico) Front: A − B Rear: D − C Front: A − B Rear: D − C Front: A − B Rear: D − C 3MZ−FE SPORT 2AZ−FE COMFORT (USA, Canada) 2AZ−FE COMFORT (Mexico) Front: A − B Rear: D − C Front: A − B Rear: D − C Front: A − B Rear: D − C 2AZ−FE PREMIUM Front: A − B Rear: D − C Front: A − B Rear: D − C 2AZ−FE SPORT 0

12’ (0

0.2
, 0
2 mm, 0
0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Toe−in (total) Front wheel alignment Wheel angle 15 inch (USA, Canada) 15 inch (Mexico) 16 inch (USA, Canada) 16 inch (Mexico) Inside wheel Outside wheel: Reference Inside wheel Outside wheel: Reference Inside wheel Outside wheel: Reference Inside wheel Outside wheel: Reference 39°04’ ± 2° (39.07° ± 2°) 33°44’ (33.73°) 39°30’ ± 2° (39.50° ± 2°) 34°02’ (34.03°) 36°39’ ± 2° (36.65° ± 2°) 32°11’ (32.18°) 37°00’ ± 2° (37.00° ± 2°) 32°28’ (32.47°) USA, Canada: −0°43’ ± 45’ (−0.72° ± 0.75°) Mexico: −0°33’ ± 45’ (−0.55° ± 0.75°) Right−left error 45’ (0.75°) or less Camber Caster 3MZ−FE 1MZ−FE Except SPORT (USA, Canada) 1MZ−FE Except SPORT (Mexico) 2AZ−FE SPORT 2AZ−FE Except SPORT (USA, Canada) 2AZ−FE Except SPORT (Mexico) Right−left error Steering axis inclination Front suspension 120 mm (4.72 in.) 46 mm (1.81 in.) 119 mm (4.69 in.) 47 mm (1.85 in.) 106 mm (4.17 in.) *1 101 mm (3.98 in.) 33 mm (1.30 in.) *1 25 mm (0.98 in.) 120 mm (4.72 in.) 48 mm (1.89 in.) 119 mm (4.69 in.) 45 mm (1.77 in.) 106 mm (4.17 in.) *1 101 mm (3.98 in) 33 mm (1.30 in.) *1 25 mm (0.98 in.) 120 mm (4.72 in.) 45 mm (1.77 in.) 120 mm (4.72 in.) 48 mm (1.89 in.) 2°39’ ± 45’ (2.65° ± 0.75°) 2°37’ ± 45’ (2.62° ± 0.75°) 2°33’ ± 45’ (2.55° ± 0.75°) 2°43’ ± 45’ (2.72° ± 0.75°) 2°39’ ± 45’ (2.65° ± 0.75°) 2°36’ ± 45’ (2.60° ± 0.75°) 45’ (0.75°) or less USA, Canada: 11°27’ ± 45’ (11.45° ± 0.75°) Mexico: 11°05’ ± 45’ (11.08° ± 0.75°) Right−left error 45’ (0.75°) or less Lower ball joint turning torque 0.98 − 3.43 N·m (10 − 35 kgf·cm, 8.7 − 30 in.·lbf) Stabilizer bar link ball joint turning torque 0.05 − 1.96 N·m (0.5 − 20 kgf·cm, 0.4 − 17.4 in.·lbf) A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 set bolt center C: Ground clearance of strut rod set bolt center D: Ground clearance of rear wheel center *1: HI UP WhereEverybodyKnowsYourName 03−35 SERVICE SPECIFICATIONS − FRONT SUSPENSION 032CQ−01 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Tie rod end lock nut 74 755 55 Steering knuckle x Shock absorber 210 2,141 155 Hub nut 103 1,050 76 Suspension support x Body TMC made: 80 816 59 Suspension support x Body TMMK made: 85 867 63 Suspension support x Piston rod 49 500 36 Speed sensor wire harness bracket set bolt (w/ ABS) 18.8 192 14 Flexible hose x Shock absorber (w/o ABS) 18.8 192 14 200 206 2,039 2,101 148 152 Transverse engine engine mounting insulator set nut 87 887 64 Transverse engine engine mounting insulator x Bracket (MT) 64 653 47 Stabilizer bar bracket x Suspension member 19 194 14 Stabilizer bar link set nut 74 755 55 Lower ball joint assy x Front suspension arm no.1 75 765 55 Lower suspension arm set bolt Front side: Rear side: WhereEverybodyKnowsYourName 03−36 SERVICE SPECIFICATIONS − REAR SUSPENSION REAR SUSPENSION 030FH−02 SERVICE DATA 0
22’
11’ (0.3

0.2
), 4
2 mm (0.16
0.08 in.) Toe−in (total) Rear wheel alignment Rear suspension No.2 lower suspension arm length difference 1.5 mm (0.06 in.) or less USA, Canada: −1°16’ ± 45’ (−1.27° ± 0.75°) Mexico: −1°09’ ± 45’ (−1.15° ± 0.75°) Right−left error 45’ (0.75°) or less Camber Stabilizer bar link ball joint turning torque 0.05 − 1.0 N·m (0.5 − 10 kgf·cm, 0.4 − 8.7 in.·lbf) WhereEverybodyKnowsYourName 03−37 SERVICE SPECIFICATIONS − REAR SUSPENSION 030FG−02 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Shock absorber x Body 39 400 29 Shock absorber x Rear axle carrier 255 2,600 188 Flexible hose x Shock absorber 19 194 14 ABS speed sensor wire harness x Shock absorber 5.5 56 49 in⋅lbf Piston rod set nut 49 500 36 Shock absorber x Stabilizer bar link 39 400 29 Rear suspension member x Rear suspensio arm assy No. 1 LH 100 1,020 74 55 38 561 387 41 28 Rear suspension arm assy No. 1 x Rear axle carrier 100 1,020 74 Rear suspension arm assy No. 2 x Rear axle carrier 100 1,020 74 Stabilizer bar bracket 19 195 14 Rear suspension member x Body A, B C Stabilizer bar x Stabilizer bar link 39 400 29 Strut rod x Body 113 1,150 83 Strut rod x Rear axle carrier 113 1,152 83 Parking brake cable x Body 5.4 55 48 in.⋅lbf Hub nut 103 1,050 76 WhereEverybodyKnowsYourName 03−38 SERVICE SPECIFICATIONS − TIRE & WHEEL TIRE & WHEEL 032CR−01 SERVICE DATA Cold tire inflation pressure Tire size: P205/65R15 92T Tire size: P205/65R15 92H Tire size: 205/65R15 94V Tire size: P215/60R16 94V Front, Rear Front, Rear Front, Rear Front, Rear 200 kPa (2.0 kgf/cm2, 29 psi) Tire size: P215/55R17 93V Front, Rear 210 kPa (2.1 kgf/cm2, 30 psi) Tire runout 1.0 mm (0.039 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less WhereEverybodyKnowsYourName 03−39 SERVICE SPECIFICATIONS − DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 030EJ−02 SERVICE DATA Front axle hub bearing Backlash Front axle hub bearing Deviation Maximum: 0.05 mm (0.0020 in.) Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing Backlash Rear axle hub bearing Deviation Maximum: 0.07 mm (0.0027 in.) Maximum: 0.05 mm (0.0020 in.) WhereEverybodyKnowsYourName 03−4 SERVICE SPECIFICATIONS − ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 030EL−04 SERVICE DATA 2AZ−FE: Throttle body Standard throttle valve opening percentage 60% or more Accelerator pedal position sensor Intake air flow meter assy Resistance Camshaft timing oil control valve assy Resistance Accelerator pedal rod assy Resistance Standard voltage 0.6 to 1.0 V 4 (THA) − 5 (E2) at −20
C (−4
F) at 20
C (68
F) at 60
C (140
F) 13.6 to 18.4 kΩ 2.21 to 2.69 kΩ 0.493 to 0.667 kΩ at 20
C (68
F) 2 (VPA2) − 3 (EP1) 5 (VPA1) − 1 (EP2) 6 (VCP1) − 3 (EP1) 4 (VCP2) − 1 (EP2) Throttle body assy Resistance at 20
C (68
F) 2 (M+) − 1 (M−) 5 (VC) − 3 (E2) E.F.I. engine coolant temperature sensor Resistance Knock sensor Resistance Approx. 20
C (68
F) Approx. 80
C (176
F) at 20
C (68
F) EFI relay Specified condition C/OPN relay Specified condition 6.9 to 7.9 Ω 5.0 kΩ or less 5.0 kΩ or less 2.25 to 4.75 kΩ 2.25 to 4.75 kΩ 0.3 to 100 kΩ 1.2 to 3.2 kΩ 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ 120 to 280 kΩ 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1MZ−FE/3MZ−FE: Throttle body Standard throttle valve opening percentage 60% or more Accelerator pedal position sensor Intake air flow meter assy Resistance Camshaft timing oil control valve assy Resistance Accelerator pedal rod assy Resistance Throttle body assy Resistance Standard voltage 0.6 to 1.0 V 4 (THA) − 5 (E2) at −20
C (−4
F) at 20
C (68
F) at 60
C (140
F) 13.6 to 18.4 kΩ 2.21 to 2.69 kΩ 0.493 to 0.667 kΩ at 20
C (68
F) 2 (VPA2) − 3 (EP1) 5 (VPA1) − 1 (EP2) 6 (VCP1) − 3 (EP1) 4 (VCP2) − 1 (EP2) at 20
C (68
F) 2 (M+) − 1 (M−) 5 (VC) − 3 (E2) 6.9 to 7.9 Ω 5.0 kΩ or less 5.0 kΩ or less 2.25 to 4.75 kΩ 2.25 to 4.75 kΩ 0.3 to 100 kΩ 2.0 to 4.0 kΩ WhereEverybodyKnowsYourName 03−5 SERVICE SPECIFICATIONS E.F.I. engine coolant temperature sensor Resistance − ENGINE CONTROL SYSTEM Approx. 20
C (68
F) Approx. 80
C (176
F) 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ Knock sensor (1MZ−FE) Resistance terminal − body 10 kΩ or higher Knock sensor (3MZ−FE) Resistance at 20
C (68
F) 120 to 280 kΩ EFI relay Specified condition C/OPN relay Specified condition 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3−5 3−5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) WhereEverybodyKnowsYourName 03−40 SERVICE SPECIFICATIONS − DRIVE SHAFT / PROPELLER SHAFT / AXLE 030EK−02 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Front wheel set nut 103 1,050 76 Lower ball joint x Lower suspension arm 75 765 55 Tie rod end x Steering knuckle 49 500 36 Axle hub x Front drive shaft 294 2,998 217 Front drive shaft center bearing set bolt 32 330 24 Front speed sensor set bolt (w/ ABS) 8.0 82 71 Front flexible hose and speed sensor wire harness x Shock absorber (w/ ABS) 19 192 13 Front flexible hose x Shock absorber (w/o ABS) 19 192 13 Rear wheel set nut 103 1,050 76 Rear flexible hose x Shock absorber 19 192 14 Shock absorber x Rear axle carrier 255 2,600 188 Rear axle hub set bolt 80 816 59 Rear axle carrier x Brake caliper (Rear disc brake) 62 630 46 Rear wheel brake cylinder x Brake tube (Rear drum brake) 15 155 11 Lower ball joint x Steering knuckle 123 1,254 91 WhereEverybodyKnowsYourName 03−41 SERVICE SPECIFICATIONS − BRAKE BRAKE 030FQ−07 SERVICE DATA Brake pedal height (from asphalt sheet) 144.1 − 154.1 mm (5.673 − 6.067 in.) Brake pedal freeplay Pedal free play: Stop lamp switch clearance 1 − 6 mm (0.04 − 0.24 in.) 0.5 − 2.5 mm (0.020 − 0.098 in.) Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf) Brake booster push rod to piston clearance (w/ SST) More than 63 mm (2.48 in.) Clearance: 0 mm (0 in.) Front brake pad thickness Standard thickness: Minimum thickness: 12.0 mm (0.472 in.) 1.0 mm (0.039 in.) Front brake disc thickness Standard thickness: Minimum thickness: 28.0 mm (1.102 in.) 26.0 mm (1.024 in.) Front brake disc runout Maximum disc runout: 0.05 mm (0.0020 in.) Rear brake pad thickness Standard thickness: Minimum thickness: 10.0 mm (0.394 in.) 1.0 mm (0.039 in.) Rear disc brake thickness Standard thickness: Minimum thickness: 12.0 mm (0.472 in.) 10.5 mm (0.413 in.) Rear brake disc runout Rear brake drum inside diameter Rear drum brake shoe lining thickness Maximum disc runout: 0.15 mm (0.0059 in.) Standard inside diameter: Minimum inside diameter: 228.0 mm (8.976 in.) 230.6 mm (9.079 in.) Standard thickness: Minimum thickness: 5.0 mm (0.197 in.) 1.0 mm (0.039 in.) WhereEverybodyKnowsYourName 03−42 SERVICE SPECIFICATIONS − BRAKE 030FR−08 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Bleeder plug 8.3 85 73 in.⋅lbf Brake booster clevis lock nut 26 265 19 37 375 27 Stop lamp lock nut 26 265 19 Brake pedal support assy x Reinforcement 20 204 15 Brake pedal sub−assy set bolt Normal type brake pedal: Brake pedal support assy x Body 13 130 9 19.1 194 14 Brake pedal support assy x Accelerator pedal assy Accelerator & brake pedal: 12 122 8.8 Master cylinder piston stopper bolt 7 Brake pedal support assy x Body Accelerator & brake pedal: 10 100 Brake master cylinder x Brake booster w/o VSC: 13 130 9 Brake line union nut 15 155 11 Vacuum hose bracket set bolt 5.4 55 48 in.⋅lbf Wheel nut 103 1,050 76 Front brake cylinder mounting x Steering knuckle 107 1,090 79 Front brake cylinder x Front brake cylinder mounting 34 350 25 Front brake cylinder x Flexible hose 29 300 22 TMC made: TMMK made: 61.8 47 630 475 46 34 Rear disc brake cylinder slide pin x Rear disc brake cylinder mounting TMC made (Upper side): TMC made (Lower side): TMMK made: 34.3 39.2 43 350 400 440 25 29 32 Rear disc brake cylinder x Flexible hose 29.4 300 22 10 100 7 5.4 8.0 55 82 48 in.⋅lbf 71 in.⋅lbf Brake actuator bracket x Body 19 194 14 Brake actuator assy x Actuator bracket (w/ VSC) 5.4 55 48 in.⋅lbf Brake actuator bracket x Body 19 194 14 Proportioning valve assy x Body 5.4 55 48 in.⋅lbf Proportioning valve assy x Brake line 15.2 155 11 8.0 82 71 in.⋅lbf 5.0 18.8 51 192 44 in.⋅lbf 14 Rear axle hub set bolt 80 816 59 Yawrate sensor x Body 12.5 127 9 Rear disc brake cylinder mounting set bolt Rear drum brake wheel cylinder x Backing plate Brake actuator assy x Actuator bracket (w/o VSC) DENSO made: BOSCH made: Front speed sensor x Steering knuckle Front speed sensor wire harness clamp x shock absorber Bolt A: Bolt B: WhereEverybodyKnowsYourName 03−43 SERVICE SPECIFICATIONS − PARKING BRAKE PARKING BRAKE 030FS−01 SERVICE DATA Parking brake pedal travel at 300 N (31 kgf, 68.3 lbf): 3 − 6 clicks Parking brake lever travel at 200 N (20 kgf, 44.1 lbf): 6 − 9 clicks Rear brake disc inside diameter Standard inside diameter: Maximum inside diameter: 170 mm (6.69 in.) 171 mm (6.73 in.) Standard thickness: Minimum thickness: 2.0 mm (0.079 in.) 1.0 mm (0.039 in.) Parking brake shoe lining thickness Parking brake shoe clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.) WhereEverybodyKnowsYourName 03−44 SERVICE SPECIFICATIONS − PARKING BRAKE 030FT−01 TORQUE SPECIFICATION Part Tightened Wheel nut Parking brake cable lock nut Parking pedal type: Parking lever type: Parking brake lever set bolt Parking brake control pedal set bolt N⋅m kgf⋅cm ft⋅lbf 103 1,050 76 5.4 5.0 55 51 48 in.⋅lbf 44 in.⋅lbf 12.5 128 9 29 39 398 Console box mounting set bolt 12.5 128 9 Parking brake cable No. 1 x Turn buckle 5.4 55 48 in.⋅lbf Parking brake cable No. 3 x Backing plate 7.8 80 69 in.⋅lbf Parking brake cable heart insulator set nut 5.4 55 48 in.⋅lbf Parking brake cable No. 4 x Body 12.5 128 9 WhereEverybodyKnowsYourName 03−45 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION / TRANSAXLE 0305K−24 SERVICE DATA U151E (1MZ−FE) Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag Engine idle speed (A/C OFF) Drive plate runout Torque converter runout Differential oil seal drive in depth Shift schedule D position (Throttle valve fully open) (Throttle valve fully closed) 3 position (Throttle valve fully open) 2 position (Throttle valve fully open) L position (Throttle valve fully open) Lock−up point D position 5th gear 4th gear D position N → D position N → R position N position Max. Max. LH side RH side 372 to 412 kPa (3.8 to 4.2 kgf⋅cm2, 54 to 60 psi) 672 to 742 kPa (6.8 to 7.5 kgf⋅cm2, 97 to 106 psi) 931 to 1,031kPa (9.5 to 10.5 kgf⋅cm2, 135 to 150 psi) 1,768 to 1,968 kPa (18.0 to 20 kgf⋅cm2, 256 to 285 psi) 2,400
150 rpm Less than 1.2 seconds Less than 1.5 seconds 700
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 0
0.5 mm (0
0.020 in.) 1→2 2→3 3→4 4→5 5→4 4→3 3→2 2→1 4→5 5→4 45 to 52 km/h (28 to 32 mph) 85 to 94 km/h (53 to 58 mph) 137 to 151 km/h (85 to 94 mph) 193 to 209 km/h (120 to 130 mph) 187 to 203 km/h (116 to 126 mph) 131 to 145 km/h (81 to 90 mph) 80 to 88 km/h (50 to 55 mph) 37 to 44 km/h (23 to 27 mph) 43 to 49 km/h (27 to 30 mph) 34 to 40 km/h (21 to 25 mph) 1→2 2→3 4→3 3→2 2→1 45 to 52 km/h (28 to 32 mph) 85 to 94 km/h (53 to 58 mph) 136 to 151 km/h (85 to 94 mph) 80 to 88 km/h (50 to 55 mph) 37 to 44 km/h (23 to 27 mph) 1→2 3→2 2→1 45 to 52 km/h (28 to 32 mph) 88 to 96 km/h (55 to 60 mph) 37 to 44 km/h (23 to 27 mph) 2→1 38 to 45 km/h (24 to 28 mph) Throttle valve opening 5% Lock−up ON Lock−up OFF Lock−up ON Lock−up OFF 69 to 77 km/h (43 to 48 mph) 68 to 75 km/h (42 to 47 mph) 96 to 105 km/h (60 to 65 mph) 90 to 98 km/h (56 to 61 mph) U151E (3MZ−FE) Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution D position 372 to 412 kPa (3.8 to 4.2 kgf⋅cm2, 54 to 60 psi) 672 to 742 kPa (6.8 to 7.5 kgf⋅cm2, 97 to 106 psi) 931 to 1,031kPa (9.5 to 10.5 kgf⋅cm2, 135 to 150 psi) 1,768 to 1,968 kPa (18.0 to 20 kgf⋅cm2, 256 to 285 psi) 2,240
150 rpm WhereEverybodyKnowsYourName 03−46 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION / TRANSAXLE U151E (3MZ−FE) Time lag Engine idle speed (A/C OFF) Drive plate runout Torque converter runout Differential oil seal drive in depth Shift schedule D position (Throttle valve fully open) (Throttle valve fully closed) 3 position (Throttle valve fully open) 2 position (Throttle valve fully open) L position (Throttle valve fully open) Lock−up point D position 5th gear 4th gear N → D position N → R position N position Max. Max. LH side RH side Less than 1.2 seconds Less than 1.5 seconds 700
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 0
0.5 mm (0
0.020 in.) 1→2 2→3 3→4 4→5 5→4 4→3 3→2 2→1 4→5 5→4 39 to 47 km/h (24 to 29 mph) 79 to 88 km/h (49 to 55 mph) 128 to 143 km/h (80 to 89 mph) 186 to 203 km/h (116 to 126 mph) 179 to 196 km/h (111 to 122 mph) 124 to 138 km/h (77 to 86 mph) 74 to 83 km/h (46 to 52 mph) 35 to 41 km/h (22 to 25 mph) 44 to 50 km/h (27 to 31 mph) 34 to 40 km/h (21 to 25 mph) 1→2 2→3 4→3 3→2 2→1 39 to 47 km/h (24 to 29 mph) 79 to 88 km/h (49 to 55 mph) 127 to 141 km/h (79 to 88 mph) 74 to 83 km/h (46 to 52 mph) 35 to 41 km/h (22 to 25 mph) 1→2 3→2 2→1 39 to 47 km/h (24 to 29 mph) 82 to 90 km/h (51 to 56 mph) 35 to 41 km/h (22 to 25 mph) 2→1 38 to 45 km/h (24 to 28 mph) Throttle valve opening 5% Lock−up ON Lock−up OFF Lock−up ON Lock−up OFF 70 to 78 km/h (43 to 48 mph) 68 to 76 km/h (42 to 47 mph) 96 to 105 km/h (60 to 65 mph) 93 to 102 km/h (58 to 63 mph) U250E (2AZ−FE) Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag Engine idle speed (A/C OFF) Drive plate runout Torque converter runout Differential oil seal drive in depth D position N → D position N → R position N position Max. Max. LH side RH side 372 to 412 kpa (3.8 to 4.2 kgf⋅cm2, 54 to 60 psi) 672 to 742 kpa (6.8 to 7.5 kgf⋅cm2, 97 to 106 psi) 931 to 1,031 kpa (9.5 to 10.5 kgf⋅cm2, 135 to 150 psi) 1,768 to 1,968 kpa (18.0 to 20 kgf⋅cm2, 256 to 285 psi) 2,350
150 rpm Less than 1.2 seconds Less than 1.5 seconds 700
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 0
0.5 mm (0
0.020 in.) WhereEverybodyKnowsYourName 03−47 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION / TRANSAXLE U250E (2AZ−FE) Shift schedule D position (Throttle valve fully open) (Throttle valve fully closed) 3 position (Throttle valve fully open) 2 position (Throttle valve fully open) L position (Throttle valve fully open) Lock−up point D position 5th gear 4th gear Flex lock−up point D position 5th gear 4th gear 1→2 2→3 3→4 4→5 5→4 4→3 3→2 2→1 4→5 5→4 45 to 53 km/h (28 to 33 mph) 87 to 97 km/h (54 to 60 mph) 137 to 153 km/h (85 to 95 mph) 196 to 215 km/h (122 to 134 mph) 189 to 208 km/h (117 to 129 mph) 129 to 144 km/h (80 to 89 mph) 79 to 88 km/h (49 to 55 mph) 32 to 38 km/h (20 to 24 mph) 66 to 74 km/h (41 to 46 mph) 35 to 42 km/h (22 to 26 mph) 1→2 2→3 4→3 3→2 2→1 45 to 53 km/h (28 to 33 mph) 87 to 97 km/h (54 to 60 mph) 137 to 153 km/h (85 to 95 mph) 79 to 88 km/h (49 to 55 mph) 32 to 38 km/h (20 to 24 mph) 1→2 3→2 2→1 45 to 53 km/h (28 to 33 mph) 87 to 97 km/h (54 to 60 mph) 32 to 38 km/h (20 to 24 mph) 2→1 39 to 45 km/h (24 to 28 mph) Throttle valve opening 5% Lock−up ON Lock−up OFF Lock−up ON Lock−up OFF 74 to 83 km/h (46 to 52 mph) 73 to 81 km/h (45 to 50 mph) 74 to 84 km/h (46 to 52 mph) 73 to 81 km/h (45 to 50 mph) Throttle valve opening 5% Lock−up ON Lock−up OFF Lock−up ON Lock−up OFF 55 to 62 km/h (34 to 39 mph) 54 to 62 km/h (34 to 39 mph) 39 to 47 km/h (24 to 29 mph) 39 to 45 km/h (24 to 28 mph) WhereEverybodyKnowsYourName 03−48 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION / TRANSAXLE 0305L−25 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 6.9 70 61 in.⋅lbf 5.4 55 48 in.⋅lbf Control shaft lever x Control shaft 13 130 9 Shift control cable x Control shaft lever 15 150 10 A bolt B bolt C bolt 64 46 37 653 470 377 47 34 27 A bolt B bolt C bolt 64 44 46 653 449 470 47 32 34 41 418 30 Engine mounting bracket FR x Transaxle 64 653 47 Oil filler tube x Transaxle 5.5 56 49 in.⋅lbf Control cable bracket x Transaxle 12 122 9 Oil cooler tube clamp x Control cable bracket 5.4 55 48 in.⋅lbf Oil cooler inlet tube x Transaxle 34 350 25 Oil cooler outlet tube x Transaxle 34 350 25 Starter x Transaxle 37 377 27 Starter wire x starter 9.8 100 87 in.⋅lbf Wire harness x Transaxle 13 139 9 Control cable clamp x Transaxle 12 122 9 Wire harness clamp x Transaxle 8.4 86 74 in.⋅lbf Revolution sensor x Transaxle (U151E) 11 110 8 Revolution sensor NC sensor x Transaxle (U250E) 8.8 90 78 in.⋅lbf Park/neutral position osition switch Nut Bolt Transaxle housing x Engine block (U151E) Transaxle housing x Engine block (U250E) Torque converter clutch x Drive plate Revolution sensor NT sensor x Transaxle (U250E) 11 110 8 Drain plug x Oil pan 49 500 36 Transmission wire x Transaxle 5.4 55 48 in.⋅lbf ATF temperature sensor x Valve body 6.6 67 58 in.⋅lbf Oil pan x Transaxle 7.8 80 69 in.⋅lbf 11 6.6 110 67 8 58 in.⋅lbf Valve body x transaxle 11 110 8 Oil strainer x Valve body 11 110 8 Floor shift assy x Body 12 122 9 Control cable x Body 4.9 50 43 in.⋅lbf Transmission case cover x Automatic transaxle 12 122 9 7.8 21 80 214 69 in.⋅lbf 16 Solenoid valve x Valve body A, B bolt C, D bolt Flywheel housing under cover x Automatic transaxle (U151E) Bolt Nut WhereEverybodyKnowsYourName 03−49 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION / TRANSAXLE MANUAL TRANSMISSION / TRANSAXLE 030FO−03 SERVICE DATA Transmission case oil seal driven in depth 3.5
0.5 mm (0.138
0.020 in.) Front transaxle case cover oil seal drive in depth 0
0.5 mm (0
0.020 in.) Manual transaxle assy 5th gear thrust clearance Standard clearance 0.10 to 0.65 mm (0.0039 to 0.0256 in.) 5th gear radial clearance Standard clearance 0.009 to 0.050 mm (0.0004 to 0.0020 in.) Reverse idler gear sub−assy inside diameter Reverse idler gear shaft outer diameter Standard inside diameter Maximum inside diameter 20.056 to 20.074 mm (0.7896 to 0.7903 in.) 20.074 mm (0.7903 in.) Standard outer diameter Minimum outer diameter 19.984 to 20.000 mm (0.7868 to 0.7874 in.) 19.984 mm (0.7868 in.) Transmission hub sleeve No.3 groove − thickness of the claw part on gear shift fork No.3 Standard clearance 5th gear inside diameter Standard inside diameter Maximum inside diameter 0.15 to 0.35 mm (0.0059 to 0.0138 in.) 34.981 to 34.997 mm (1.3772 to 1.3778 in.) 34.997 mm (1.3778 in.) Control shaft cover bimetal formed bush clearance 0.081 to 0.149 mm (0.0032 to 0.0059 in.) Front transaxle case cover oil seal driven in depth 0
0.5 mm (0
0.020 in.) Transmission case oil seal driven in depth 3.5
0.5 mm (0.138
0.020 in.) Output shaft rear bearing clearance 3.8 to 4.4 mm (0.150 to 0.173 in.) Output shaft bearing preload New bearing Used bearing Output shaft rear bearing shim thickness 0 1 2 3 4 5 6 7 8 9 A B C D E F G H J K L M N P Q Front differential case tapered roller bearing preload New bearing Used bearing 0.8 to 1.6 N⋅m (8.16 to 16.32 kgf⋅cm, 7.1 to 14.2 in.⋅lbf) 0.5 to 1.0 N⋅m (5.10 to 10.20 kgf⋅cm, 4.4 to 8.9 in.⋅lbf) 1.30 mm (0.0512 in.) 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 0.8 to 1.6 N⋅m (8.16 − 16.32 kgf⋅cm, 7.1 to 14.2 in.⋅lbf) 0.5 to 1.0 N⋅m (5.10 − 10.20 kgf⋅cm, 4.4 to 8.9 in.⋅lbf) WhereEverybodyKnowsYourName 03−50 SERVICE SPECIFICATIONS Front differential case shim RR thickness − MANUAL TRANSMISSION / TRANSAXLE 0 1 2 3 4 5 6 7 8 9 A B C D E F G H 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in. ) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) Front differential case oil seal clearance 1 to 2 mm (0.0394 to 0.0787 in.) Input shaft front bearing clearance 4.28 to 4.60 mm (0.1685 to 0.1811 in.) Reverse restrict pin clearance 12.5 to 13.5 mm (0.492 to 0.531 in.) Transmission clutch hub No.3 snap ring clearance 0.1 mm or less (0.0039 in. or less) Transmission clutch hub No.3 snap ring thickness a b c d e f g h j 1.75 to 1.80 mm (0.0689 to 0.0709 in.) 1.80 to 1.85 mm (0.0709 to 0.0728 in.) 1.85 to 1.90 mm (0.0728 to 0.0748 in.) 1.90 to 1.95 mm (0.0748 to 0.0768 in.) 1.95 to 2.00 mm (0.0768 to 0.0787 in.) 2.00 to 2.05 mm (0.0787 to 0.0807 in.) 2.05 to 2.10 mm (0.0807 to 0.0827 in.) 2.10 to 2.15 mm (0.0827 to 0.0846 in.) 2.15 to 2.20 mm (0.0846 to 0.0866 in.) 5th gear radial clearance Standard clearance 0.009 to 0.050 mm (0.0004 to 0.0020 in.) 5th gear thrust clearance Standard clearance 0.10 to 0.65 mm (0.0039 to 0.0260 in.) 4th gear thrust clearance Standard clearance 0.10 to 0.57 mm (0.0039 to 0.0224 in.) 3rd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 4th gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 3rd gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) Input shaft assy Input shaft run out Maximum run out: 0.03 mm (0.0012 in.) Input shaft standard outer diameter A B C 35.984 to 36.000 mm (1.4167 to 1.4173 in.) 35.984 to 36.000 mm (1.4167 to 1.4173 in.) 27.957 to 27.972 mm (1.1007 to 1.1013 in.) Input shaft minimum outer diameter A B C 35.984 mm (1.4167 in.) 35.984 mm (1.4167 in.) 27.957 mm (1.1007 in.) 4th gear inside diameter Standard inside diameter Maximum inside diameter 42.009 to 42.025 mm (1.6539 to 1.6545 in.) 42.025 mm (1.6545 in.) 3rd gear inside diameter Standard inside diameter Maximum inside diameter 43.009 to 43.025 mm (1.6933 to 1.6939 in.) 43.025 mm (1.6939 in.) Between the 4th gear spline end and synchronizer outer ring back clearance 0.75 to 1.65 mm (0.0295 to 0.0650 in.) Between the 3rd gear spline end and synchronizer outer ring back clearance 0.65 to 1.75 mm (0.0256 to 0.0689 in.) Transmission hub sleeve No.3 groove − thickness of the claw part on gear shift fork No.1 Standard clearance 0.11 to 0.69 mm (0.0043 to 0.0272 in.) Transmission clutch hub No.2 snap ring clearance 0.1 mm or less (0.0039 in. or less) Standard clearance WhereEverybodyKnowsYourName 03−51 SERVICE SPECIFICATIONS − Transmission clutch hub No.2 snap ring thickness MANUAL TRANSMISSION / TRANSAXLE H J K L M N P Input shaft rear radial ball bearing snap ring clearance Standard clearance Input shaft rear radial ball bearing snap ring thickness 1 2 3 4 5 6 7 8 2.30 to 2.35 mm (0.0906 to 0.0925 in.) 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 2.40 to 2.45 mm (0.0945 to 0.0965 in.) 2.45 to 2.50 mm (0.0965 to 0.0984 in.) 2.50 to 2.55 mm (0.0984 to 0.1004 in.) 2.55 to 2.60 mm (0.1004 to 0.1024 in.) 2.60 to 2.65 mm (0.1024 to 0.1043 in.to 0.1 mm or less (0.0039 in. or less) 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 2.40 to 2.45 mm (0.0945 to 0.0965 in.) 2.45 to 2.50 mm (0.0965 to 0.0984 in.) 2.50 to 2.55 mm (0.0984 to 0.1004 in.) 2.55 to 2.60 mm (0.1004 to 0.1024 in.) 2.60 to 2.65 mm (0.1024 to 0.1043 in.) 2.65 to 2.70 mm (0.1043 to 0.1063 in.) 2.70 to 2.75 mm (0.1063 to 0.1083 in.) 3rd gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 4th gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 3rd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 4th gear thrust clearance Standard clearance 0.10 to 0.57 mm (0.0039 to 0.0224 in.) 1st gear thrust clearance Standard clearance 0.25 to 0.40 mm (0.0098 to 0.0157 in.) 2nd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Output shaft assy 1st gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 2nd gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) Output shaft run out Maximum run out 0.03 mm (0.0012 in.) Output shaft standard outer diameter A B 37.610 to 37.626 mm (1.4807 to 1.4813 in.) 34.502 to 34.512 mm (1.3583 to 1.3587 in.) Output shaft minimum outer diameter A B 37.610 mm (1.4807 in.) 34.502 mm (1.3702 in.) 2nd gear inside diameter Standard inside diameter Maximum inside diameter 50.009 to 50.025 mm (1.9689 to 1.9695 in.) 50.025 mm (1.9695 in.) 1st gear inside diameter Standard inside diameter Maximum inside diameter 51.009 to 51.025 (2.0082 to 2.0089 in.) 51.025 mm (2.0089 in.) Between the 2nd gear while and synchronizer ring No.2 back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.) Between the 1st gear while and synchronizer ring set No.1 back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.) Reverse gear groove − thickness of the claw part on gear shift fork No.1 clearance Standard clearance 0.15 to 0.35 mm (0.0059 to 0.0138 in.) 2nd gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 1st gear radial clearance KOYO made NSK made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) 0.009 to 0.051 mm (0.0004 to 0.0020 in.) 2nd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 1st gear thrust clearance Standard clearance 0.25 to 0.40 mm (0.0098 to 0.0157 in.) Front differential side gear backlash Standard backlash 0.10 to 0.20 mm (0.0039 to 0.0079 in.) Front differential pinion thrust washer thickness Minimum thickness 0.9 mm (0.035 in.) Front differential pinion shaft No.1 thickness Minimum thickness 17.975 mm (0.70768 in.) Front differential side gear backlash Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Differential case assy Front differential side gear thrust washer thickness 1 2 3 4 1.00 mm (0.0394 in.) 1.10 mm (0.0433 in.) 1.20 mm (0.0472 in.) 1.30 mm (0.0512 in.) WhereEverybodyKnowsYourName 03−52 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION / TRANSAXLE Shift & select lever shaft assy Control shaft cover bimetal formed bush drive in depth 0
0.25 mm (0
0. 010 in.) Control shaft cover oil seal drive in depth 28.5
0.50 mm (1.122
0. 020 in.) Shift lever slotted pin clearance to the shift lever inner assy −0.5 to 0.5 mm (−0.0197 to 0.0197 in.) Shift lever slotted pin clearance to the shift lever inner No.2 5.8 to 6.8 mm (0.228 to 0.268 in.) WhereEverybodyKnowsYourName 03−53 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION / TRANSAXLE 030FP−03 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Hub nut 103 1,050 76 Floor shift lever assembly x Body 12 122 9 Floor shift cable transmission control shift clamp x Body 5.0 51 44 in.⋅lbf Floor shift cable transmission control shift retainer x Body 5.0 51 44 in.⋅lbf Gear shift fork No. 1 set bolt 24 245 18 Reverse shift arm bracket assy x Manual transaxle case 17 173 13 Reverse restrict pin plug 13 133 9.6 Oil receiver pipe No. 1 x Manual transmission case 17 175 13 Clutch tube bracket set bolt 17 173 13 Reverse idler gear shaft bolt 30 306 22 Gear shift fork No. 3 shift fork bolt 24 244 17 Manual transmission output shaft rear set nut 123 1,250 90 Drain plug sub−assy 49 500 36 Manual transmission filler plug 49 500 36 Back up lamp switch assy x Manual transmission case 40 410 30 Manual transmission breather plug x Manual transmission case 49 500 36 Lock ball assy No. 1 x Manual transmission case 29 300 22 Control shaft cover set bolt 20 200 14 Control shift lever x Shift & select lever shaft 6.4 65 57 in.⋅lbf Selecting ballcrank assy x Manual transmission case 20 204 15 Release fork support x Manual transaxle case 47 480 35 64 46 44 653 470 449 47 34 32 Engine mounting insulator LH x Manual transaxle 64 653 47 Exhaust pipe support bracket No. 1 set bolt 19 194 14 Manual transmission case protector x Manual transaxle 18 184 13 Engine mounting bracket FR x Manual transaxle 64 653 47 Starter assy x Manual transaxle 39 398 29 Wire harness clamp bracket x Manual transaxle 8.4 86 74 in.⋅lbf Engine wire No. 3 x Manual transaxle 9.6 98 85 in.⋅lbf Transmission case x Manual transaxle case 29 296 21 Manual transaxle case x Transmission case 29 296 21 Bearing retainer RR x Transmission case 43 438 32 Manual transaxle x Engine Bolt A Bolt B Bolt C Manual transaxle case receiver x Manual transaxle case 7 71 62 in.⋅lbf Gear shift head No.1 x Gear shift fork shaft No.2 24 245 18 Gear shift fork No.1 x Gear shift fork shaft No.1 24 245 18 Reverse shift arm bracket x Manual transaxle case 17 173 13 Reverse restrict pin plug x Transmission case 13 133 9.6 Oil receiver pipe No.1 x Transmission case 17 173 13 Oil receiver pipe No.2 x Transmission case 17 173 13 Clutch tube bracket x Transmission case 17 173 13 Reverse idler gear shaft bolt x Transmission case 30 306 22 Transmission clutch hub No.3 gear shift fork shaft x input shaft 24 245 18 Manual transmission output rear set nat. x Output shaft 123 1,254 91 Drain (MTM) plug sub−assy x Transmission case 49 500 36 Manual transmission filler plug x Transmission case 49 500 36 Back up lamp switch assy x Transmission case 40 408 30 Manual transmission breather plug x Transmission case 49 500 36 Lock ball assy No.1 x Transmission case 29 296 21 WhereEverybodyKnowsYourName 03−54 SERVICE SPECIFICATIONS Part Tightened − MANUAL TRANSMISSION / TRANSAXLE N⋅m kgf⋅cm Control shift cover x Transmission case 20 204 15 Control shift lever x Shift & select lever assy 6.4 65 57 in.⋅lbf Selecting bell crank assy x Transmission case 20 204 15 Selecting bellcrank support x Selecting bellcrank No.2 plate washer 12 122 9 Release fork support x Manual transaxle case 47 480 35 Front differential ring gear x Front differential case 106 1,081 78 WhereEverybodyKnowsYourName ft⋅lbf 03−55 SERVICE SPECIFICATIONS − CLUTCH CLUTCH 030EF−05 SERVICE DATA Pedal height from asphalt sheet 159.0 to 169.0 mm (6.260 to 6.654 in.) Clutch pedal free play 5.0 to 15.0 mm (0.197 to 0591 in.) Clutch pedal push rod play at pedal top 1.0 to 5.0 mm (0.039 to 0.197 in.) Slotted spring pin protrusion Maximum 1.5 to 3.5 mm (0.059 to 0.138 in.) Disc rivet head depth Maximum 0.3 mm (0.012 in.) Disc runout Minimum 0.8 mm (0.031 in.) Diaphragm spring finger wear Maximum depth: Maximum width: Flywheel runout 0.5 mm (0.020 in.) 6.0 mm (0.236 in.) Maximum 0.1 mm (0.004 in.) Diaphragm spring finger wear Maximum depth Clutch release point from pedal full stroke end position 0.5 mm (0.020 in.) 25 mm (0.98 in.) or more WhereEverybodyKnowsYourName 03−56 SERVICE SPECIFICATIONS − CLUTCH 030EG−04 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Clutch pedal sub−assy x Clutch pedal support 39 398 29 Clutch pedal support set bolt x Body 19 195 14 Cylinder push rod clevis lock nut 26 260 19 Clutch master cylinder assy x Clutch pedal support 12 120 9 Clutch master cylinder assy x Flexible hose tube 15 155 11 Master cylinder bleeder plug 8.3 85 73 in.⋅lbf Release cylinder bleeder plug 8.3 85 73 in.⋅lbf Clutch release cylinder assy x Transaxle housing 12 120 9 Clutch accumulator assy x Clutch release cylinder assy 12 120 9 Clutch release cylinder assy x flexible hose tube 15 155 11 Clutch cover assy x Flywheel 19 195 14 Release fork support x Transaxle assy 47 480 35 Clutch start switch assy set nut 16 160 12 WhereEverybodyKnowsYourName 03−6 SERVICE SPECIFICATIONS − ENGINE CONTROL SYSTEM 030EM−04 TORQUE SPECIFICATION 2AZ−FE: N⋅m kgf⋅cm ft⋅lbf Throttle body assy x Intake manifold Part Tightened 30 306 22 Knock sensor x Cylinder block sub−assy 20 199 14 Intake manifold x Cylinder head sub−assy 30 306 22 ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 7.5 76 66 in.⋅lbf N⋅m kgf⋅cm ft⋅lbf 1MZ−FE/3MZ−FE: Part Tightened Front suspension upper brace center x Body 80 815 59 V−bank cover sub−assy x Cylinder head cover sub−assy LH (w/ Performance Rod) 7.9 81 70 in.⋅lbf Throttle body assy x Intake air connector 11 112 8 Air cleaner cap sub−assy x Air cleaner case sub−assy 5.0 51 44 in.⋅lbf Knock sensor x Cylinder block sub−assy 1MZ−FE 39 398 29 Knock sensor x Cylinder block sub−assy 3MZ−FE 20 199 14 Water outlet x Cylinder head sub−assy 15 153 11 Water outlet x Cylinder head LH 15 153 11 Intake manifold x Cylinder head sub−assy 15 153 11 Intake manifold x Cylinder head LH 15 153 11 Ground cable x Intake manifold 8.4 86 74 in.⋅lbf ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 7.5 76 66 in.⋅lbf WhereEverybodyKnowsYourName 03−7 SERVICE SPECIFICATIONS − FUEL FUEL 030EN−04 SERVICE DATA 2AZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm2, 21 psi) or more Fuel injector Resistance Injection volume Difference between each cylinder Fuel leakage Fuel pump Resistance at 20
C (68
F) 13.4 to 14.2Ω 76 to 91 cm2 (4.6 to 5.5 cu in.) per 15 seconds 15 cm3 (0.9 cu in.) or less 1 drop or less per 12 minutes at 20
C (68
F) 0.2 to 3.0 Ω 1MZ−FE/3MZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm2, 21 psi) or more Fuel injector Resistance Injection volume Difference between each cylinder Fuel leakage Fuel pump Resistance at 20
C (68
F) 13.4 to 14.2Ω 60 to 73 cm2 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less 1 drop or less per 12 minutes at 20
C (68
F) 0.2 to 3.0 Ω WhereEverybodyKnowsYourName 03−8 SERVICE SPECIFICATIONS − FUEL 030EO−03 TORQUE SPECIFICATION 2AZ−FE: N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe x Cylinder head Part Tightened 20 204 15 Fuel tank bent tube set plate x Fuel tank assy 5.9 60 52 in.⋅lbf Fuel main tube support x Fuel tank assy 5.4 55 48 in.⋅lbf Fuel tank band sub−assy No. 1 RH x Body 39 400 29 Fuel tank band sub−assy No. 1 LH x Body 39 400 29 Fuel tank protector lower center x Fuel tank assy 5.4 55 48 in.⋅lbf Packing brake cable assy No. 2 x Body 5.4 55 48 in.⋅lbf Packing brake cable assy No. 3 x Body 5.4 55 48 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 56 571 41 Exhaust pipe assy center x Exhaust pipe assy tail 56 571 41 Floor panel brace rear x Body 20 199 14 1MZ−FE/3MZ−FE: N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe sub−assy x Intake manifold Part Tightened 10 102 7 Fuel delivery pipe No. 2 x Intake manifold 10 102 7 Fuel pipe No. 2 union bolt x Fuel delivery pipe No. 2 33 331 24 Fuel pressure pulsation damper assy x Fuel delivery pipe sub−assy 33 331 24 Fuel pipe sub−assy No. 1 x Intake manifold 20 199 14 Surge tank stay No. 2 x Intake air surge tank 20 199 14 Surge tank stay No. 2 x Cylinder head 20 199 14 Surge tank stay No. 1 x Intake air surge tank 20 199 14 Surge tank stay No. 1 x Cylinder head 20 199 14 Engine hunger No. 1 x Intake air surge tank 20 199 14 Engine hunger No. 1 x Cylinder head 20 199 14 Pressure feed tube assy x Engine hunger No. 1 7.8 80 69 in.⋅lbf Intake air surge tank x Intake manifold 28 286 21 Emission control valve set x Emission control valve bracket 8.0 80 71 in.⋅lbf Fuel tank bent tube set plate x Fuel tank assy 5.9 60 52 in.⋅lbf Fuel main tube support x Fuel tank assy 5.4 55 48 in.⋅lbf Fuel tank band sub−assy No. 1 RH x Body 39 400 29 Fuel tank band sub−assy No. 1 LH x Body 39 400 29 Fuel tank protector lower center x Fuel tank assy 5.4 55 48 in.⋅lbf Packing brake cable assy No. 2 x Body 5.4 55 48 in.⋅lbf Packing brake cable assy No. 3 x Body 5.4 55 48 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 56 571 41 Exhaust pipe assy center x Exhaust pipe assy tail 56 571 41 Floor panel brace rear x Body 20 199 14 WhereEverybodyKnowsYourName 03−9 SERVICE SPECIFICATIONS − EMISSION CONTROL EMISSION CONTROL 030EP−04 SERVICE DATA 2AZ−FE: VSV for CCV Resistance VSV for EVAP Resistance Air fuel ratio sensor Resistance Heated oxygen sensor (Bank 1 Sensor 2) Resistance at 20
C (68
F) at 100
C (212
F) 1−2 1 − Body ground 2 − Body ground 25 to 30 Ω 32 to 40 Ω 26 to 30 Ω at 20
C (68
F) 10 kΩ or higher 10 kΩ or higher 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 0.8 to 1.4 Ω at 20
C (68
F) 1.8 to 3.2 Ω at 800
C (1,472
F) 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20
C (68
F) 23 to 32 Ω at 800
C (1,472
F) 1MZ−FE/3MZ−FE: VSV for CCV Resistance VSV for EVAP Resistance Air fuel ratio sensor Resistance Heated oxygen sensor (Bank 1 Sensor 2) Resistance Heated oxygen sensor (Bank 2 Sensor 2) Resistance at 20
C (68
F) at 100
C (212
F) 1−2 1 − Body ground 2 − Body ground 25 to 30 Ω 32 to 40 Ω 26 to 30 Ω at 20
C (68
F) 10 kΩ or higher 10 kΩ or higher 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 0.8 to 1.4 Ω at 20
C (68
F) 1.8 to 3.2 Ω at 800
C (1,472
F) 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20
C (68
F) 23 to 32 Ω at 800
C (1,472
F) 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20
C (68
F) 23 to 32 Ω at 800
C (1,472
F) WhereEverybodyKnowsYourName 42−1 CLUTCH − CLUTCH SYSTEM (From July, 2003) CLUTCH SYSTEM (From July, 2003) 4202B−05 PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely causes of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspected Area Engine mounting (Loosen) Clutch disc (Runout is excessive) Clutch disc (Oily) Clutch disc (Worn out) Clutch disc torsion rubber (Damaged) Clutch disc (Glazed) Diaphragm spring (Out of tip alignment) See page Clutch grabs/chatters 1. 2. 3. 4. 5. 6. 7. Clutch pedal is spongy 1. Clutch line (Air in line) 2. Master cylinder cup (Damaged) 3. Release cylinder rubber(Damaged) − 42−9 30−2 Clutch is noisy 1. Release bearing (Worn, dirty, or damaged) 2. Clutch disc torsion rubber (Damaged) 42−15 42−15 Clutch slips 1. 2. 3. 4. 5. 6. Clutch pedal (Free play is out of adjustment) Clutch disc (Oily) Clutch disc (Worn out) Diaphragm spring (Damaged) Pressure plate (Distortion) Flywheel (Distortion) 42−7 42−15 42−15 42−15 42−15 − Clutch does not disengage 1. Clutch pedal (Free play is out of adjustment) 2. Clutch line (Air in line) 3. Master cylinder cup (Damaged) 4. Release cylinder cup (Damaged) 5. Clutch disc (Out of true) 6. Clutch disc (Runout is excessive) 7. Clutch disc (Lining broken) 8. Clutch disc (Dirty or burned) 9. Clutch disc (Oily) 10.Clutch disc (Lack of spline grease) 42−7 − 42−9 30−2 42−15 42−15 42−15 42−15 42−15 42−15 WhereEverybodyKnowsYourName − 42−15 42−15 42−15 42−15 42−15 42−15 42−12 CLUTCH − CLUTCH RELEASE CYLINDER ASSY CLUTCH RELEASE CYLINDER ASSY (From July, 2003) 42027−05 OVERHAUL 1. (a) (b) D31468 DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Remove the bolt and separate the tube clamp bracket. Using SST, disconnect the 2 flexible hose tubes. SST 09023−00101 HINT: Use a container to catch the fluid. 2. REMOVE CLUTCH ACCUMULATOR ASSY (a) Remove the 2 bolts and flexible hose bracket No.2. (b) Remove the 2 nuts and the clutch accumulator assy. 3. REMOVE CLUTCH RELEASE CYLINDER ASSY (a) Remove the 2 bolts and clutch release cylinder assy. 4. REMOVE CLUTCH RELEASE CYLINDER KIT (a) Remove the boot from the cylinder body. (b) Remove the push rod from the cylinder body. (c) Remove the piston from the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (d) Remove the spring from the cylinder body. (e) Remove the bleeder plug cap from the bleeder plug. 5. REMOVE RELEASE CYLINDER BLEEDER PLUG 6. INSTALL RELEASE CYLINDER BLEEDER PLUG Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) 7. (a) (b) INSTALL CLUTCH RELEASE CYLINDER KIT Install the bleeder plug cap to the bleeder plug. Install a new spring to the cylinder body. (c) Coat the piston with lithium soap base glycol grease, as shown in the illustration. (d) Install the piston to the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (e) Install the push rod to the cylinder body. (f) Install the boot to the cylinder body. CL0672 WhereEverybodyKnowsYourName 42−13 CLUTCH 8. (a) 9. (a) (b) (B) D31468 10. (a) (b) 12. 13. CLUTCH RELEASE CYLINDER ASSY INSTALL CLUTCH RELEASE CYLINDER ASSY Install the clutch release cylinder assy with the 2 bolts. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) (A) 11. (a) − INSTALL CLUTCH ACCUMULATOR ASSY Install the clutch accumulator assy with the 2 nuts and the bolt. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) Install the flexible hose bracket No.2 with the 2 bolts. Torque: Bolt A: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) Bolt B: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Using SST, connect the 2 flexible hose tubes. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) Install the tube clamp bracket with the bolt. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with clutch fluid and bleed the clutch system. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR WhereEverybodyKnowsYourName 42−14 CLUTCH − CLUTCH ACCUMULATOR ASSY CLUTCH ACCUMULATOR ASSY (From July, 2003) 4207K−02 REPLACEMENT 1. (a) (b) D31469 HINT: Use a container to catch the fluid. 2. REMOVE CLUTCH ACCUMULATOR ASSY (a) Remove the 2 bolts and flexible hose bracket No.2. (b) Remove the 2 nuts and clutch accumulator assy. 3. (a) (A) (b) (B) D31469 4. (a) (b) 5. (a) 6. 7. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Remove the bolt and separate the tube clamp bracket. Using SST, disconnect the 3 flexible hose tubes. SST 09023−00101 INSTALL CLUTCH ACCUMULATOR ASSY Install the clutch accumulator assy with the 2 nuts. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) Install the flexible hose bracket No.2 with the 2 bolts. Torque: Bolt A: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) Bolt B: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Using SST, connect the 3 flexible hose tubes to the clutch accumulator assy. SST 09023−00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) Install the tube clamp bracket with the bolt. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with brake fluid and bleed the clutch system. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 ft⋅lbf) CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR WhereEverybodyKnowsYourName 42−15 CLUTCH − CLUTCH UNIT CLUTCH UNIT 4202F−03 OVERHAUL 1. 2. REMOVE MANUAL TRANSAXLE ASSY (SEE PAGE 41−11) REMOVE CLUTCH RELEASE FORK BOOT 3. REMOVE CLUTCH RELEASE BEARING ASSY 4. REMOVE CLUTCH RELEASE FORK SUB−ASSY 5. REMOVE RELEASE BEARING HUB CLIP 6. REMOVE RELEASE FORK SUPPORT (a) Remove the release fork support from the manual transaxle assy. 7. Matchmarks REMOVE CLUTCH COVER ASSY (a) D08941 8. Place the matchmarks on the clutch cover assy with the one on the flywheel sub−assy. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the set bolts and pull off the clutch cover assy. NOTICE: Do not drop the clutch disc assy. REMOVE CLUTCH DISC ASSY NOTICE: Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub−assy away from oil and foreign attachment. 9. INSPECT CLUTCH DISC ASSY (a) Using vernier calipers, measure the rivet head depth. Maximum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc assy. Q06032 WhereEverybodyKnowsYourName 42−16 CLUTCH − CLUTCH UNIT (b) Install the clutch disc assy to the transaxle assy. NOTICE: Take care not to insert the clutch disc assy in the wrong direction (c) Using a dial indicator, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc assy. Transaxle Side D25721 10. A INSPECT CLUTCH COVER ASSY B (a) Using vernier calipers, inspect the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) If necessary, replace clutch cover assy. C57466 D25281 11. INSPECT FLYWHEEL SUB−ASSY (a) Using a dial indicator, inspect the flywheel sub−assy runout. Maximum runout: 0.1 mm (0.004 in.) If necessary, replace the flywheel sub−assy. D08943 12. INSPECT CLUTCH RELEASE BEARING ASSY (a) Turn the release bearing assy by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and required no cleaning or lubrication. If necessary, replace the release bearing assy. N00414 WhereEverybodyKnowsYourName 42−17 CLUTCH 13. − CLUTCH UNIT INSTALL CLUTCH DISC ASSY (a) Insert SST in the clutch disc assy, then insert them in the flywheel sub−assy. SST 09301−00220 NOTICE: Take care not to insert clutch disc assy in the wrong direction. Flywheel Side SST D08944 3 Matchmarks 7 6 1, 4 14. INSTALL CLUTCH COVER ASSY (a) Align the matchmarks on the clutch cover assy and flywheel sub−assy. Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top. Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf) (b) 2 SST 5 D08945 HINT:

Following the order in the illustration, tighten the bolts at a time evenly. Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts. 15. (a) INSPECT AND ADJUST CLUTCH COVER ASSY Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum non−alignment: 0.5 mm (0.020 in.) If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment. SST 09333−00013 SST D08946 16. INSTALL RELEASE FORK SUPPORT (a) 17. Install the release fork support to the manual transaxle assy. Torque: 47 N⋅m (480 kgf⋅cm, 35 ft⋅lbf) INSTALL RELEASE BEARING HUB CLIP (a) Install the release bearing hub clip to the release bearing assy. WhereEverybodyKnowsYourName 42−18 CLUTCH Q05807 − CLUTCH UNIT 18. INSTALL CLUTCH RELEASE FORK SUB−ASSY (a) Apply release hub grease to the release fork and release bearing assy contact, release fork and push rod contact and release fork pivot points. Sealant: Part No. 08887−01806, RELEASE HUB GREASE or equivalent Install the release fork to the release bearing assy. INSTALL CLUTCH RELEASE BEARING ASSY (b) 19. (a) 20. 21. Apply the clutch spline grease to the input shaft spline. Sealant: Part No. 08887−01706, CLUTCH SPLINE GREASE or equivalent (b) Install the release fork with release bearing assy to the manual transaxle assy. NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly. INSTALL CLUTCH RELEASE FORK BOOT INSTALL MANUAL TRANSAXLE ASSY (SEE PAGE 41−11) WhereEverybodyKnowsYourName 42−19 CLUTCH − CLUTCH START SWITCH ASSY CLUTCH START SWITCH ASSY 42028−05 ON−VEHICLE INSPECTION 1. (a) CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch assy. Clutch Start Switch Assy D26283 WhereEverybodyKnowsYourName 42−2 CLUTCH − CLUTCH PEDAL SUB−ASSY CLUTCH PEDAL SUB−ASSY 4202C−03 REPLACEMENT 1. 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE PAGE 71−16) REMOVE COMBINATION METER ASSEMBLY (SEE PAGE 71−29) REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (SEE PAGE 71−16) REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH (SEE PAGE 71−16) REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Remove the clip and hole pin. 2. 3. 4. 6. (a) (b) REMOVE CLUTCH PEDAL ASSY Disconnect the clutch start switch clamp and connector. Remove the bolt, 2 nuts and clutch pedal assy. 7. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING (a) (b) Using a small screwdriver, remove the E−ring. Remove the compression spring. 8. REMOVE CLUTCH PEDAL SUB−ASSY (a) (b) Remove the clutch pedal spring. Mount the clutch pedal assy in a soft jaw vise. D26294 D26274 D26275 WhereEverybodyKnowsYourName 42−3 CLUTCH − CLUTCH PEDAL SUB−ASSY (c) Remove the bolt, nut and clutch pedal sub−assy from clutch pedal support. 9. REMOVE CLUTCH PEDAL BUSH (a) Remove the 2 bushes from the clutch pedal sub−assy. 10. REMOVE CLUTCH PEDAL TURNOVER BUSH 11. REMOVE OVER CENTER SPRING CAP 13. REMOVE CLUTCH PEDAL NO.1 CUSHION D26276 D26277 Over Center Spring Cap Clutch Pedal Turnover Bush D26278 12. REMOVE CLUTCH PEDAL PAD D26280 WhereEverybodyKnowsYourName 42−4 CLUTCH − CLUTCH PEDAL SUB−ASSY 14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH (a) Using a hexagon wrench (8 mm) and hammer, remove the clevis bush from the clutch pedal sub−assy. 15. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH D26279 (a) Apply MP grease to inside of a new bush. (b) Install the clevis bush to the clutch pedal sub−assy. HINT: Install the clevis bush from the right side of the vehicle. MP Grease D26281 16. INSTALL CLUTCH PEDAL NO.1 CUSHION 17. INSTALL CLUTCH PEDAL PAD Over Center Spring Cap 18. INSTALL OVER CENTER SPRING CAP 19. INSTALL CLUTCH PEDAL TURNOVER BUSH (a) (b) Apply MP grease to inside of a new bush. Install the bush to the clutch pedal sub−assy. 20. INSTALL CLUTCH PEDAL BUSH (a) (b) Apply MP grease to both side of 2 new bushes. Install the 2 bushes to the clutch pedal sub−assy. Clutch Pedal Turnover Bush MP Grease MP Grease D26278 D26277 WhereEverybodyKnowsYourName 42−5 CLUTCH − CLUTCH PEDAL SUB−ASSY 21. INSTALL CLUTCH PEDAL SUB−ASSY (a) Install the clutch pedal sub−assy to the clutch pedal support with the bolt and nut. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) HINT: Install the bolt from the right side of the vehicle. D26276 (b) Install the clutch pedal spring. 22. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (a) Apply MP grease to the contact surface of the bush and spring. Install the compression spring. Using needle nose pliers, install the E−ring. D26275 (b) (c) MP Grease 23. (a) (b) D26288 INSTALL CLUTCH PEDAL ASSY Install the clutch pedal assy with the bolt and 2 nuts. Torque: Bolt: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf) Nut: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) Connect the clutch start switch clamp and connector. 24. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Apply MP grease to the contact surface of the hole pin and bush. Connect the clevis to the clutch pedal assy with the hole pin. (b) MP Grease D26271 HINT: Install the hole pin from the left side of the vehicle. (c) Install the clip to the hole pin. WhereEverybodyKnowsYourName 42−6 CLUTCH − CLUTCH PEDAL SUB−ASSY 25. INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH 26. INSTALL INSTRUMENT PANEL SUB−ASSY UPPER 27. INSTALL COMBINATION METER ASSEMBLY (SEE PAGE 71−29) INSTALL INSTRUMENT CLUSTER FINISH PANEL (SEE PAGE 71−16) INSPECT AND ADJUST CLUTCH PEDAL SUB−ASSY (SEE PAGE 42−7) INSPECT CLUTCH START SWITCH ASSY (SEE PAGE 42−19) 28. 29. 30. WhereEverybodyKnowsYourName 42−20 CLUTCH − CLUTCH START SWITCH ASSY 42029−07 INSPECTION 5.0
0.5 mm (0.197
0.020 in.) 1. INSPECT CLUTCH START SWITCH ASSY (a) Check the continuity between terminals when the switch is ON and OFF. Switch position Condition ON (pushed) Continuity OFF (free) No continuity CL0477 WhereEverybodyKnowsYourName 42−21 CLUTCH − CLUTCH START SWITCH ASSY 4202A−03 REPLACEMENT 1. REMOVE CLUTCH START SWITCH ASSY (a) (b) Disconnect the clutch start switch assy connector. Remove the nut and clutch start switch assy from the clutch pedal support. INSTALL CLUTCH START SWITCH ASSY 2. (a) D26284 (b) 3. Install the clutch start switch assy with the nut. Torque: 16 N⋅m (160 kgf⋅cm, 12 ft⋅lbf) Connect the clutch start switch assy connector. INSPECT CLUTCH START SWITCH ASSY (SEE PAGE 42−19) WhereEverybodyKnowsYourName 42−7 CLUTCH − CLUTCH PEDAL SUB−ASSY 4202D−03 ADJUSTMENT Push Rod Play and Free Play Adjust Point 1. INSPECT AND ADJUST CLUTCH PEDAL SUB−ASSY (a) Turn over the floor carpet. (b) Check that the pedal height is correct. Pedal height from asphalt sheet: 159.0 to 169.0 mm (6.260 − 6.654 in.) Adjust the pedal height. (1) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. Torque: 26 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) Check that the pedal free play and push rod play are correct. (1) Depress the pedal until the clutch resistance begin to be felt. Pedal free play: 5.0 to 15.0 mm (0.197 − 0591 in.) (2) Gently depress the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 − 5.0 mm (0.039 − 0.197 in.) (c) (d) Pedal Height Adjust Point Push Rod Play Pedal Height D26287 (e) Adjust the pedal free play and push rod play. (1) Remove the instrument panel sub−assy upper. (2) Remove the instrument panel insert sub−assy lower LH. (3) Disconnect the air duct. (4) Loosen the lock nut and turn the push rod until the free play and push rod play are correct. (5) Tighten the lock nut. (6) After adjusting the pedal free play, check the pedal height. (7) Connect the air duct. (8) Install the instrument panel insert sub−assy lower LH. (9) Install the instrument panel sub−assy upper. (f) Check the clutch release point. (1) Pull the parking brake lever and install wheel stopper. (2) Start the engine and idle the engine. (3) Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. Pedal Free Play CL0102 25 mm (0.98 in.) or more Release Point Full Stroke End Position CL0512 WhereEverybodyKnowsYourName 42−8 CLUTCH − CLUTCH PEDAL SUB−ASSY (4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operations.
Check pedal height.
Check push rod play and pedal free play.
Bleed the clutch line.
Check the clutch cover assy and disc assy. WhereEverybodyKnowsYourName 42−9 CLUTCH − CLUTCH MASTER CYLINDER ASSY CLUTCH MASTER CYLINDER ASSY 4202E−07 OVERHAUL 1. 2. 3. 4. DRAIN CLUTCH FLUID REMOVE BRAKE MASTER CYLINDER SUB−ASSY (SEE PAGE 27−4) REMOVE BRAKE BOOSTER ASSY (SEE PAGE 26−19) DISCONNECT CLUTCH RESERVOIR TUBE (a) Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder assy. HINT: Use a container to catch the fluid. 5. SST DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, disconnect the flexible hose tube. HINT: Use a container to catch the fluid. SST 09023−00101 D26293 6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) 7. Remove the clip and hole pin. REMOVE CLUTCH MASTER CYLINDER ASSY (a) Remove the 2 nuts and clutch master cylinder assy. 8. REMOVE CLUTCH MASTER CYLINDER KIT (a) Using a pin punch (φ 5 mm) and hammer, drive out the slotted spring pin. Remove the inlet union and grommet. Loosen the lock nut, and remove the push rod clevis. Remove the lock nut from the push rod. Remove the boot from the cylinder body. (b) (c) (d) (e) D05850 WhereEverybodyKnowsYourName 42−10 CLUTCH − CLUTCH MASTER CYLINDER ASSY (f) D26270 While pushing the piston rod, using snap ring pliers, remove the snap ring. (g) Remove the push rod from the cylinder body. NOTICE: The piston may pop up out of the cylinder body. Therefore, slowly remove the push rod from the cylinder body. (h) Remove the stop plate from the push rod. (i) Remove the piston with spring from the cylinder. NOTICE: Be careful not to damage the inside of the cylinder body. 9. INSTALL CLUTCH MASTER CYLINDER KIT (a) Coat parts with lithium soap base glycol grease, shown in the illustration. (b) Install the piston with spring into the cylinder. NOTICE: Be careful not to damage the inside of the cylinder body. (c) Install the stop plate to the push rod. (d) Install the push rod to the cylinder body. CL0528 (e) (f) (g) (h) (i) While pushing the piston rod, using snap ring pliers, install the snap ring. Install the boot to the cylinder body. Install the lock nut to the push rod. Temporarily install the push rod clevis with the lock nut to the push rod. Install the inlet union and a new grommet. D26270 (j) Protrusion 1.5 − 3.5 mm (0.059 − 0.138 in.) Using a pin punch (φ 5 mm) and hammer, drive in the slotted spring pin. D05852 10. INSTALL CLUTCH MASTER CYLINDER ASSY (a) Install the clutch master cylinder assy with the 2 nuts. Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf) WhereEverybodyKnowsYourName 42−11 CLUTCH D26271 CLUTCH MASTER CYLINDER ASSY 11. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Apply MP grease to the contact surface of the hole pin and bush. Connect the clevis to the clutch pedal assy with the hole pin. (b) MP Grease − HINT: Install the hole pin from the left side of the vehicle. (c) Install the clip to the hole pin. 12. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE (a) SST Using SST, connect the flexible hose tube. Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) SST 09023−00101 D26293 13. CONNECT CLUTCH RESERVOIR TUBE (a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assy. NOTICE: Connect the clutch reservoir tube so that it will not be twisted. 14. INSTALL BRAKE BOOSTER ASSY (SEE PAGE 26−19) 15. INSTALL BRAKE MASTER CYLINDER SUB−ASSY (SEE PAGE 27−4) 16. BLEED MASTER CYLINDER SST 09023−00100 17. BLEED BRAKE LINE (SEE PAGE 30−8) 18. BLEED CLUTCH PIPE LINE (a) Fill the brake reservoir tank with clutch fluid and bleed clutch system. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) 19. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 30−29) 20. INSPECT AND ADJUST CLUTCH PEDAL SUB−ASSY (SEE PAGE 42−7) 21. CHECK BRAKE FLUID LEAKAGE 22. CHECK CLUTCH FLUID LEAKAGE 23. CHECK FLUID LEVEL IN RESERVOIR WhereEverybodyKnowsYourName 17−1 LUBRICATION − LUBRICATION SYSTEM (2AZ−FE)(From July, 2003) LUBRICATION SYSTEM (2AZ−FE)(From July, 2003) 1701Z−10 ON−VEHICLE INSPECTION 1. (a) CHECK ENGINE OIL LEVEL Warm up the engine, stop the engine and wait for 5 minutes. The oil level should be between the dipstick’s low level mark and full level mark. If the oil level is low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 2. (a) Recommended Viscosity (SAE) 5W−30
C −29 −18
F −20 0 −7 20 4 40 16 60 27 38 80 100 A66623 CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: ILSAC multigrade engine oil is recommended. SAE 5W−30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 3. REMOVE OIL PRESSURE SWITCH ASSY (a) Disconnect the oil pressure switch connector. (b) Remove the oil pressure switch. Oil Pressure Switch B11410 4. (a) Oil Pressure Gauge INSTALL OIL PRESSURE GAUGE Install the oil pressure gauge. B11411 5. WARM UP ENGINE WhereEverybodyKnowsYourName 17−2 LUBRICATION 6. LUBRICATION SYSTEM (2AZ−FE)(From July, 2003) CHECK OIL PRESSURE Specification: Item Oil Pressure Idle 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf⋅cm2, 36 to 78 psi) or more INSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Install the oil pressure switch. Torque: 15 N⋅m (152 kgf⋅cm, 11 ft⋅lbf) NOTICE: A50082 Do not start the engine for at least 1 hour after installation of the switch. (d) Connect the oil pressure switch connector. START ENGINE AND CHECK FOR ENGINE OIL LEAKS Adhesive 8. − 7. (a) (b) WhereEverybodyKnowsYourName 17−20 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 1701W−09 OVERHAUL 1. (a) REMOVE OIL PUMP STRAINER SET Remove the 2 nuts and oil pump strainer. 2. (a) (b) REMOVE OIL PUMP RELIEF VALVE Using a socket wrench (27mm), remove the plug. Remove the valve spring and relief valve. 3. (a) REMOVE OIL PUMP COVER Remove the 5 bolts and oil pump cover. B11430 A52074 B11431 4. (a) INSPECT OIL PUMP RELIEF VALVE Check the relief valve. (1) Coat the valve with engine oil and check that the valve falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assy. B11419 WhereEverybodyKnowsYourName 17−21 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 5. (a) Driven Rotor Drive B11420 Driven Rotor Grooves Drive Tips INSPECT OIL PUMP ROTOR Check the clearance between the drive and driven rotor. (1) Place a precision straight edge on the top surface of the drive. Insert a feeler gauge between the bottom edge of the precision straight edge and the top surface of the driven rotor. Measure the clearance. Specified clearance: 0.030 to 0.160 mm (0.0012 to 0.0063 in.) If the clearance is greater than the maximum, replace the oil pump assy. (b) Check the clearance between the drive tips and driven rotor grooves. (1) Insert a feeler gauge between each drive tip and driven rotor groove. Measure the clearance. Specified tip clearance: 0.080 to 0.350 mm (0.0031 to 0.0138 in.) If the tip clearance is greater than the maximum, replace the oil pump assy. B11421 (c) Check the clearance between the driven rotor and body. (1) Insert a feeler gauge between the driven rotor and body. Measure the clearance. Specified body clearance: 0.100 to 0.325 mm (0.0039 to 0.0128 in.) (d) Remove the oil pump rotors. If the body clearance is greater than the maximum, replace the oil pump assy. B11422 6. REMOVE OIL PUMP ROTOR 7. (a) (b) INSTALL OIL PUMP ROTOR Coat the drive rotor and driven rotors with engine oil. Place the drive and driven rotors into the pump body with the marks facing the pump body cover side. B11423 WhereEverybodyKnowsYourName 17−22 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 8. (a) INSTALL OIL PUMP COVER Install the pump body cover with the 5 bolts. Torque: 8.8 N⋅m (90 kgf⋅cm, 79 in.⋅lbf) 9. (a) (b) (c) INSTALL OIL PUMP RELIEF VALVE Coat the relief valve with engine oil. Insert the relief valve and spring into the pump body hole. Using a socket wrench (27 mm), install the plug. 10. (a) (b) INSTALL OIL PUMP STRAINER SET Place a new gasket on the oil pump. Install the oil strainer with the 2 nuts. Torque: 8.8 N⋅m (90 kgf⋅cm, 79 in.⋅lbf) B11431 A52074 B11430 WhereEverybodyKnowsYourName 17−23 LUBRICATION − LUBRICATION SYSTEM (1MZ−FE/3MZ−FE) LUBRICATION SYSTEM (1MZ−FE/3MZ−FE) 17020−10 ON−VEHICLE INSPECTION 1. (a) CHECK ENGINE OIL LEVEL Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick’s low level mark and full level mark. If the oil level is low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 2. (a) Recommended Viscosity (SAE) 5W−30
C −29 −18
F −20 0 −7 20 4 40 16 60 27 38 80 100 A66623 CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SL, Energy−Conserving or ILSAC, multigrade engine oil is recommended. SAE 5W−30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 3. REMOVE OIL PRESSURE SWITCH ASSY (a) Disconnect the oil pressure switch connector. (b) Using a 24 mm deep socket wrench, remove the oil pressure switch. 4. (a) INSTALL OIL PRESSURE GAUGE Install the oil pressure gauge. Oil Pressure Switch A52637 Oil Pressure Gauge B04132 5. WARM UP ENGINE WhereEverybodyKnowsYourName 17−24 LUBRICATION 6. LUBRICATION SYSTEM (1MZ−FE/3MZ−FE) CHECK OIL PRESSURE Specification: Item Oil Pressure Idle 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf⋅cm2, 36 to 78 psi) or more INSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N⋅m (152 kgf⋅cm, 11 ft⋅lbf) A50082 NOTICE: Do not start the engine for at least 1 hour after installation of the switch. (d) Connect the oil pressure switch connector. START ENGINE AND CHECK FOR ENGINE OIL LEAKS Adhesive 8. − 7. (a) (b) WhereEverybodyKnowsYourName 17−25 LUBRICATION − OIL FILTER SUB−ASSY (1MZ−FE/3MZ−FE) OIL FILTER SUB−ASSY (1MZ−FE/3MZ−FE) 1701H−08 REPLACEMENT 1. REMOVE ENGINE UNDER COVER RH CAUTION:
Prolonged and repeated contact of mineral oil with the skin will deplete the skin’s natural fats, leading to dryness, irritation and dermatitis. In addition, used engine oil contains harmful contaminants which may cause skin cancer.
Wear protective clothing and gloves to minimize the length and frequency of contact between the skin and used oil. If contact does occur wash your skin thoroughly with soap and water or waterless hand cleaner. Do not use gasoline, thinners or solvents to wash the skin.
In order to preserve the environment, dispose of used oil and used oil filters only at designated disposal site. 2. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 3. (a) REMOVE OIL FILTER SUB−ASSY Using SST, remove the oil filter. SST 09228−07501 4. (a) (b) (c) INSTALL OIL FILTER SUB−ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten the oil filter an additional 3/4 turn. SST 09228−07501 SST A51980 (d) 3/4 turn A52007 5. (a) (b) ADD ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) Fill with fresh engine oil. Specification: Item Capacity Drain and refill w/ oil filter change 4.7 liters (5.0 US qts, 4.1 lmp. qts) Drain and refill w/o oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts) Dry fill (c) 5.5 liters (5.8 US qts, 4.8 lmp. qts) Install the oil filler cap. WhereEverybodyKnowsYourName 17−26 LUBRICATION 6. 7. − OIL FILTER SUB−ASSY (1MZ−FE/3MZ−FE) INSPECT CHECK FOR ENGINE OIL LEAKS INSTALL ENGINE UNDER COVER RH WhereEverybodyKnowsYourName 17−27 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) OIL PUMP ASSY (1MZ−FE/3MZ−FE) 170HG−02 COMPONENTS 23 (235, 17) 64 (653, 47) 7.9 (81, 70 in.·lbf) V−Bank Cover Engine Moving Control Rod V Belt No. 1 Vane Pump V Belt Engine Mounting Stay No. 2 RH 26 (260, 19) Vane Pump Assy 25 (250, 18) Generator Bracket No. 2 28 (286, 21) 56 (571, 41) 18 (184, 13) 8.0 (82, 71 in.·lbf) Generator Assy
Gasket Front Fender Apron Seal RH Exhaust Pipe Assy Front
Gasket 62 (633, 46) Engine Under Cover RH Engine Under Cover LH

56 (571, 41)
Gasket 62 (633, 46) Front Exhaust Pipe No. 1 Support Bracket
N⋅m (kgf⋅cm, ft⋅lbf) 33 (337, 24) : Specified torque
Non−reusable part A90194 WhereEverybodyKnowsYourName 17−28 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) Timing Belt 8.5 (87, 75 in.⋅lbf) Timing Belt No. 2 Cover Timing Belt Guide No. 2 Engine Mounting Bracket RH 28 (286, 21) Timing Belt No. 1 Cover 220 (2,250, 162) 8.5 (87, 75 in.⋅lbf) Crankshaft Pulley Engine Wire Protector 27 (280, 20) Timing Belt Tensioner Assy N·m (kgf·cm, ft·lbf) : Specified torque A78353 WhereEverybodyKnowsYourName 17−29 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) Timing Belt No. 3 Cover Gasket Collar 8.5 (87, 75 in.⋅lbf) Bushing x6 43 (438, 32) Camshaft Timing Pulley Timing Belt Idler Sub−assy No. 2 125 (1,275, 92) Engine Wire Timing Belt Idler Sub−assy No. 1 34 (347, 25) Crankshaft Timing Pulley Timing Belt Plate 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque A78396 WhereEverybodyKnowsYourName 17−30 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) Oil Pump Assy 43 (439, 32) Compressor Mounting Bracket No. 1 20 (203, 15)
O−ring 8.0 (82, 71 in.⋅lbf) 20 (204, 15) Crankshaft Position Sensor 8.0 (82, 71 in.⋅lbf)
Oil Pump Seal 20 (204, 15) Oil Pan Sub−assy 20 (204, 15) 8.0 (82, 71 in.⋅lbf) 20 (204, 15) 20 (204, 15) 8.0 (82, 71 in.⋅lbf) 20 (204, 15)
Gasket 20 (204, 15) 37 (379, 27) Oil Strainer Sub−assy Flywheel Housing Under Cover 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf)
Gasket 7.8 (80, 69 in.⋅lbf) 45 (459, 33) Oil Pan Drain Plug 8.0 (82, 71 in.⋅lbf) A86170 A86564 N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part Oil Pan Sub−assy No. 2 A91353 WhereEverybodyKnowsYourName 17−31 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) Oil Pump Cover 10 (102, 7) x 10 Driven Rotor Drive Rotor Oil Pump Assy Oil Pump Relief Valve Oil Pump Relief Valve Spring 49 (500, 36) Oil Pump Relief Valve Plug N·m (kgf·cm, ft·lbf) : Specified torque WhereEverybodyKnowsYourName A80109 17−3 LUBRICATION − OIL FILTER SUB−ASSY (2AZ−FE)(From July, 2003) OIL FILTER SUB−ASSY (2AZ−FE)(From July, 2003) 1701X−07 REPLACEMENT CAUTION:
Prolonged and repeated contact of mineral oil with the skin will deplete the skin’s natural fats, leading to dryness, irritation and dermatitis. In addition, used engine oil contains harmful contaminants which may cause skin cancer.
Wear protective clothing and gloves to minimize the length and frequency of contact between the skin and used oil. If contact does occur wash your skin thoroughly with soap and water or waterless hand cleaner. Do not use gasoline, thinners or solvents to wash the skin.
In order to preserve the environment, dispose of used oil and used oil filters only at designated disposal site. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. (a) 3. (a) (b) SST REMOVE OIL FILTER SUB−ASSY Using SST, remove the oil filter. SST 09228−06501 INSTALL OIL FILTER SUB−ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. B11412 (c) (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten the oil filter an additional 3/4 turn. SST 09228−06501 SST B11413 4. (a) (b) ADD ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) Fill with fresh engine oil. Specification: Item Capacity Drain and refill w/ oil filter change Drain and refill w/o oil filter change Dry fill (c) 3.8 liters (4.0 US qts, 3.3 lmp. qts) 3.6 liters (3.8 US qts, 3.2 lmp. qts) 4.5 liters (4.88 US qts, 4.0 lmp. qts) Install the oil filler cap. WhereEverybodyKnowsYourName 17−4 LUBRICATION 5. − OIL FILTER SUB−ASSY (2AZ−FE)(From July, 2003) INSPECT CHECK FOR ENGINE OIL LEAKS WhereEverybodyKnowsYourName 17−32 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) 170HH−02 REPLACEMENT 1. 2. 3. 4. (a) 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE OIL Install a new gasket after draining engine oil. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) REMOVE V BELT NO. 1 (See page 14−140) REMOVE VANE PUMP V BELT (See page 14−140) REMOVE ENGINE MOVING CONTROL ROD (See page 14−164) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14−164) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14−186) REMOVE TIMING BELT NO.1 COVER (See page 14−186) REMOVE TIMING BELT NO.2 COVER (See page 14−186) REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14−186) REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REMOVE EXHAUST PIPE ASSY FRONT REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 19. (a) SEPARATE COMPRESSOR AND MAGNETIC CLUTCH Remove the 2 bolts, nut and the drive belt adjusting bar bracket. (b) Remove the 2 nuts, the generator bracket adjusting bar with wire harness clamp bracket. Disconnect the compressor, magnetic clutch connector and the wire harness clamp. E34923 (c) A36746 WhereEverybodyKnowsYourName 17−33 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) (d) Remove the 3 bolts, the compressor and magnetic clutch. HINT: Hang up the hoses instead of detaching. E34925 20. 21. 22. (a) 23. 24. REMOVE TIMING BELT IDLER SUB−ASSY NO.2 (See page 14−186) REMOVE CAMSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT IDLER SUB−ASSY NO.1 Using a 10 mm socket hexagon wrench, remove the timing belt idler and plate washer. REMOVE CRANKSHAFT TIMING PULLEY (See page 14−186) REMOVE TIMING BELT NO.3 COVER (See page 14−186) 25. (a) REMOVE COMPRESSOR MOUNTING BRACKET NO.1 Remove the 2 bolts and mounting bracket. A36749 26. (a) REMOVE OIL LEVEL GAGE GUIDE Remove the bolt and gage guide. WhereEverybodyKnowsYourName 17−34 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) 27. (a) SEPARATE ENGINE MOUNTING INSULATOR FR Remove the 3 nuts and bolt. Then separate the engine mounting insulator. NOTICE: Do not remove the engine mounting insulator. A60458 28. (a) REMOVE ENGINE MOUNTING INSULATOR RH Remove the bolt and disconnect the power steering return hose clamp from the frame. (b) (c) A86600 Remove the 4 nuts. Prepare a jack. Place a wooden block on the jack and set the jack under the engine. Remove the engine mounting insulator. (d) Raise the jack and lift up the engine. Then remove the engine mounting insulator RH. NOTICE: Be careful not to damage the contact surfaces of the oil pan. 29. (a) REMOVE ENGINE MOUNTING BRACKET RH Remove the 4 bolts, nut and bracket. A52015 WhereEverybodyKnowsYourName 17−35 LUBRICATION 30. (a) − OIL PUMP ASSY (1MZ−FE/3MZ−FE) REMOVE OIL PAN SUB−ASSY NO.2 Remove the 10 bolts, 2 nuts and oil pan. A36750 (b) A00019 31. (a) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, cut through the sealer and remove oil pan No. 2. SST 09032−00100 NOTICE:
Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
Do not damage the flange portion of oil pan No.2 during removal. REMOVE OIL STRAINER SUB−ASSY Remove the bolt and 2 nuts, and remove the oil strainer and gasket. 32. (a) REMOVE OIL PAN SUB−ASSY Remove the 2 bolts and the flywheel housing under cover. (b) Uniformly loosen the 17 bolts and 2 nuts. Remove the bolts and nuts. A78379 A36754 WhereEverybodyKnowsYourName 17−36 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) (c) Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan shown in the illustration. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. A32940 P20034 33. (a) (b) REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. 34. (a) (b) (c) REMOVE OIL PUMP ASSY Remove the 9 bolts. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap. Remove the O−ring. A51990 35. (a) SST A62376 INSTALL OIL PUMP ASSY Using SST and a hammer, install a new oil seal. Tap the surface of the SST with the hammer until the oil seal’s surface is flush with oil pump body edge. SST 09223−00010 NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the oil pump body edge and the oil seal free from contamination. (b) Apply a small amount of MP grease to the oil seal lip. (c) Remove any old seal packing material from the contact surface. (d) Apply a light coat of engine oil to a new O−ring and place it on the cylinder block. A36784 WhereEverybodyKnowsYourName 17−37 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) (e) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration. Seal packing: Part No. 08226−00080 or equivalent NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing the oil pump. B A C Seal Packing Seal Packing A Seal Width 2 to 3 mm B C A90857 (f) Align the key of the oil pump drive gear with the key way located on the crankshaft, and slide the oil pump into place. (g) Install the oil pump by tightening the 9 bolts uniformly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A 20 N⋅m (203 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C A36785 A B C A A B A A A A51990 36. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) WhereEverybodyKnowsYourName 17−38 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) 37. (a) (b) INSTALL OIL PAN SUB−ASSY Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (diameter 3 to Region ”X” Region ”Y” 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes in the region ”X”.
Apply seal packing to the inner side of the bolt holes in the region ”Y”. B A
Install the oil pan within 3 minutes after applying seal packing. Seal Packing B A
Do not expose the seal to engine oil for at least 2 hours after installing the oil pan. (c) Install the oil pan No.1 by tightening the oil pan’s 17 bolts and 2 nuts uniformly. Seal Width Torque: 3 to 4 mm 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for 10 mm head A78726 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for 12 mm head 37 N⋅m (379 kgf⋅cm, 27 ft⋅lbf) for 14 mm head (d) Install the flywheel housing under cover with the 2 bolts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) 38. INSTALL OIL STRAINER SUB−ASSY (a) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 39. (a) (b) INSTALL OIL PAN SUB−ASSY NO.2 Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing the oil pan. (c) Install the oil pan with the 10 bolts and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Seal Packing A A B Seal Width 4 to 5 mm B A78727 WhereEverybodyKnowsYourName 17−39 LUBRICATION A C − OIL PUMP ASSY (1MZ−FE/3MZ−FE) 40. INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) for bolt A 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) for nut B 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C 41. INSTALL ENGINE MOUNTING INSULATOR RH Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for nut A 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for nut B 42. INSTALL ENGINE MOUNTING INSULATOR FR Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for bolt A 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) for nut B B A A A52939 A86600 A B B B A60458 43. (a) 44. 45. 46. (a) 47. INSTALL OIL LEVEL GAGE GUIDE Install a new O−ring, bolt and gage guide. Torque: 8 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL COMPRESSOR MOUNTING BRACKET NO.1 Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) INSTALL TIMING BELT NO.3 COVER (See page 14−186) INSTALL TIMING BELT IDLER SUB−ASSY NO.1 Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) INSTALL TIMING BELT IDLER SUB−ASSY NO.2 (See page 14−186) WhereEverybodyKnowsYourName 17−40 LUBRICATION 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. − OIL PUMP ASSY (1MZ−FE/3MZ−FE) INSTALL CAMSHAFT TIMING PULLEY (See page 14−186) INSTALL COMPRESSOR AND MAGNETIC CLUTCH Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 15−7) INSTALL EXHAUST PIPE ASSY FRONT (See page 15−7) INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET (See page 15−7) INSPECT TIMING BELT (See page 14−186) INSTALL TIMING BELT (See page 14−186) INSTALL TIMING BELT GUIDE NO.2 INSTALL TIMING BELT NO.2 COVER (See page 14−186) INSTALL TIMING BELT NO.1 COVER (See page 14−186) INSTALL CRANKSHAFT PULLEY (See page 14−186) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 in.⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14−164) INSTALL ENGINE MOVING CONTROL ROD (See page 14−164) INSTALL VANE PUMP V BELT (See page 14−140) INSTALL V BELT NO. 1 (See page 14−140) INSPECT DRIVE BELT TENSION (See page 14−136) INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) ADD ENGINE OIL INSPECT CHECK FOR ENGINE OIL LEAKS INSTALL FRONT WHEEL RH CHECK FOR EXHAUST GAS LEAKS WhereEverybodyKnowsYourName 17−41 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) 1701I−08 OVERHAUL 1. (a) REMOVE OIL PUMP RELIEF VALVE Remove the plug, spring and relief valve. 2. (a) (b) INSPECT OIL PUMP RELIEF VALVE Apply a light coat of engine oil. Check that the valve falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assy. A33002 3. (a) INSPECT OIL PUMP COVER Remove the 10 screws and the oil pump cover. 4. INSPECT OIL PUMP ROTOR (a) Apply a light coat of engine oil to the oil pump rotor set and place them into the oil pump body. Check that the rotors revolve smoothly. If the result is not as specified, replace the oil pump assy. (b) Check the clearance between the drive tips and driven rotor grooves. (1) Insert a feeler gauge between each drive tip and driven rotor groove. Measure the clearances. Specified tip clearance: 0.060 to 0.300 mm (0.0024 to 0.0118 in.) If the tip clearance is greater than the maximum, replace the oil pump assy. A33003 (c) Check the clearance between the driven rotor and body. (1) Insert a feeler gauge between the driven rotor and body. Measure the clearance. Specified body clearance: 0.250 to 0.500 mm (0.0098 to 0.0128 in.) If the body clearance is greater than the maximum, replace the oil pump assy. A33004 WhereEverybodyKnowsYourName 17−42 LUBRICATION − OIL PUMP ASSY (1MZ−FE/3MZ−FE) (d) A33005 5. Check the clearance between the drive and driven rotor. (1) Place a precision straight edge on the top surface of the drive. Insert a feeler gauge between the bottom edge of the precision straight edge and the top surface of the driven rotor. Measure the clearance. Specified side clearance: 0.030 to 0.150 mm (0.0012 to 0.0059 in.) If the side clearance is greater than the maximum, replace the oil pump assy. REMOVE OIL PUMP ROTOR Marks 6. (a) INSTALL OIL PUMP ROTOR Apply a light coat of engine oil to the oil pump gear set and place it into the pump body with the marks facing the pump body cover side. A51993 7. (a) 8. (a) (b) INSTALL OIL PUMP COVER Install the oil pump cover with the 10 screws. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) INSTALL OIL PUMP RELIEF VALVE Apply a light coat of engine oil to the relief valve, and insert the relief valve and spring into the pump body hole. Install the plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) WhereEverybodyKnowsYourName 17−5 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) OIL PUMP ASSY (2AZ−FE)(From July, 2003) 170HI−02 COMPONENTS Engine Moving Control Rod w/ Bracket 64 (653, 47) Engine Cover Sub−assy No. 1 52 (531, 38) Engine Mounting Bracket No. 2 RH Fan and Generator V Belt 64 (653, 47) Engine Mounting Stay No. 2 RH 49 (439, 36) Vane Pump Assy 52 (531, 38) 21 (214, 15) Generator Assy Front Fender Apron Seal LH 56 (571, 41)
Gasket Exhaust Pipe Assy Front Engine Under Cover RH
Gasket Engine Under Cover LH
Exhaust Pipe No. 1 Support Bracket 62 (633, 46) Exhaust Pipe No. 1 Support Bracket N⋅m (kgf⋅cm, ft⋅lbf)
Non−reusable part : Specified torque 33 (337, 24)
33 (337, 24) A92852 WhereEverybodyKnowsYourName 17−6 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 9.0 (92, 80 in.⋅lbf) Engine Wire Ignition Coil Assy Cylinder Cover Sub−assy Chain Tensioner Assy No. 1
Gasket 11 (110, 8) Timing Chain or 9.0 (92, 80 in.⋅lbf) Belt Cover Sub−assy
Gasket V−ribbed Belt Tensioner Assy 9.0 (92, 80 in.⋅lbf) 59.5 (607, 44) 43 (438, 32)
Oil Seal Crankshaft Position Sensor Chain Sub−assy Crankshaft Timing 21 (214, 15) Gear or Sprocket 170 (1,733, 125) Chain Timing Tensioner Crankshaft Pully Chain Guide Slipper 19 (194, 14) 9.0 (92, 80 in.⋅lbf) Crankshaft Position Chain Vibration Damper No. 1 Sensor Plate No. 1 Chain Tensioner 9.0 (92, 80 in.⋅lbf) Spring
Gasket Oil Pump Assy No. 2 Chain Sub−assy x2 12 (122, 9) Oil Pump Drive Shaft N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part x 12 9.0 (92, 80 in.⋅lbf) Oil Pan Sub−assy Sprocket 30 (306, 22) Oil Pump Driven Shaft Sproket 19 (194, 14) WhereEverybodyKnowsYourName A89785 17−7 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) Oil Pump Strainer Set 8.8 (90, 78 in.⋅lbf) 8.8 (90, 78 in.⋅lbf) Driven Rotor Oil Pump Relief Valve Spring
Gasket Oil Pump Cover Drive Rotor Oil Pump Assy Oil Pump Relief Valve Plug Oil Pump Relief Valve N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A87112 17−8 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 170HJ−03 REPLACEMENT 1. 2. 3. 4. 5. (a) 6. REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) REMOVE EXHAUST PIPE ASSY FRONT 7. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and control rod. A59888 8. REMOVE ENGINE MOUNTING STAY NO.2 RH 9. REMOVE ENGINE MOUNTING BRACKET NO.2 RH 10. REMOVE FAN AND GENERATOR V BELT (See page 14−5) 11. REMOVE ENGINE COVER SUB−ASSY NO.1 12. DISCONNECT ENGINE WIRE 13. REMOVE GENERATOR ASSY (See page 19−17) 14. REMOVE VANE PUMP ASSY (See page 51−8) NOTICE: Do not disconnect the hose. 15. REMOVE IGNITION COIL ASSY 16. DISCONNECT VENTILATION HOSE 17. DISCONNECT VENTILATION HOSE NO.2 18. (a) (b) REMOVE CYLINDER HEAD COVER SUB−ASSY Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover. A52450 19. 20. 21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14−7) REMOVE CRANKSHAFT PULLEY (See page 14−47) REMOVE CRANKSHAFT POSITION SENSOR WhereEverybodyKnowsYourName 17−9 LUBRICATION 22. (a) − OIL PUMP ASSY (2AZ−FE)(From July, 2003) REMOVE OIL PAN SUB−ASSY Remove the 12 bolts and 2 nuts. A64641 (b) Insert the blade of SST between the crankcase and oil pan, cut through applied sealer and remove the oil pan. SST 09032−00100 NOTICE: Do not damage the contact surface of the cylinder block and oil pan. A00019 23. REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14−47) 24. (a) REMOVE V−RIBBED BELT TENSIONER ASSY Remove the bolt labeled A and the bolt labeled B. Then remove the tensioner. 25. (a) REMOVE ENGINE HANGER NO.1 Install the engine hanger No. 1 and No. 2 with their respective bolts, as shown in the illustration. Parts No.: A B A52478 Engine Hanger No.1 Engine Hanger No.2 A52507 Engine hanger No. 1 12281−28010 Engine hanger No. 2 12282−28010 Bolt 91512−61020 Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf) 26. REMOVE ENGINE MOUNTING INSULATOR (a) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. WhereEverybodyKnowsYourName 17−10 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) (b) Remove the bolt and disconnect the engine mounting insulator FR. (c) M/T: Remove the bolt and disconnect the engine lateral control rod. (d) Remove the bolt and disconnect the steering gear return hose clamp from the frame. (e) Remove the 4 nuts from the engine mounting insulator RH. Prepare a jack. Place a wooden block on the jack and set the jack under the engine. Remove the engine mounting insulator. Raise the jack and lift up the engine. Then remove the engine mounting insulator RH. A59880 M/T A60825 A59901 (f) (g) A59900 27. (a) REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket RH. A52481 WhereEverybodyKnowsYourName 17−11 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 28. REMOVE TIMING CHAIN OR BELT COVER SUB−ASSY (a) Remove the stud bolt for drive belt tensioner from the cylinder block. (b) Remove the 14 bolts and 2 nuts. (c) Pry out the timing chain cover using a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. A92183 29. 30. 31. 32. 33. (a) (b) REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 REMOVE CHAIN TENSIONER SLIPPER REMOVE CHAIN VIBRATION DAMPER NO.1 REMOVE CHAIN SUB−ASSY REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Remove the bolt and timing chain guide. Remove the timing gear or sprocket. 34. (a) REMOVE NO.2 CHAIN SUB−ASSY Turn the crankshaft counterclockwise 90
and turn the cutout of the oil pump drive shaft gear to the top. (b) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Put a bar (φ 4 mm (0.16 in.)) in the adjusting hole of the oil pump drive shaft gear to temporarily lock the gear in position. Remove the nut. B11424 (c) Groove A52509 WhereEverybodyKnowsYourName 17−12 LUBRICATION Bolt − OIL PUMP ASSY (2AZ−FE)(From July, 2003) (d) (e) Remove the bolt, chain tensioner plate and spring. Remove the oil pump drive shaft gear and chain. 35. (a) REMOVE OIL PUMP ASSY Remove the 3 bolts and pump. Spring Chain Tensioner Plate B11415 A32684 36. (a) (b) INSTALL OIL PUMP ASSY Place a new gasket on the cylinder block. Install the pump with the 3 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 37. (a) (b) INSTALL NO.2 CHAIN SUB−ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft gear to the top. (c) Align the mark links (yellow colored links) with the timing marks of the gear as shown in the illustration. Insert the gears and chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump drive shaft gear with the a nut. B11424 Mark Link Timing Mark (d) (e) Timing Mark Mark Link A52510 WhereEverybodyKnowsYourName 17−13 LUBRICATION Chain Tensioner Plate − OIL PUMP ASSY (2AZ−FE)(From July, 2003) (f) Inset the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) (g) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Put a bar (φ 4 mm (0.16 in.)) in the adjusting hole of the oil pump drive shaft gear to temporarily lock the gear in position. Install the nut. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Bolt A91029 (h) Groove A52512 (i) 90
Rotate the crankshaft clockwise 90
, and align the crankshaft key to the top. A36525 38. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) WhereEverybodyKnowsYourName 17−14 LUBRICATION 39. (a) − OIL PUMP ASSY (2AZ−FE)(From July, 2003) INSTALL CHAIN SUB−ASSY Set the No.1 cylinder to TDC/compression. (1) Align the timing marks of the camshaft timing sprockets and bearing caps (No. 1 and No. 2). Timing Marks Timing Marks A53018 (2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A52505 (b) Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing sprocket. (c) Using SST, tap in the sprocket. SST 09309−37010 Timing Mark Mark Link A52523 SST A13337 WhereEverybodyKnowsYourName 17−15 LUBRICATION (d) Mark Links Timing Marks Timing Mark − OIL PUMP ASSY (2AZ−FE)(From July, 2003) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket, and install the chain. A52513 40. INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 41. (a) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Install the sensor plate with the F mark facing outward. A53064 Seal Packing Seal Packing A90854 42. INSTALL TIMING CHAIN OR BELT COVER SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the chain cover. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply a continuous bead of seal packing (diameter: 2 mm (0.099 in.)), as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent WhereEverybodyKnowsYourName 17−16 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) (c) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)), as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent (d) Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for nut Install the stud bolt to the drive belt tensioner. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) Seal Packing 4 mm (0.16 in.) A A A−A 3 to 4 mm 2.5 mm (0.098 in.) A92184 Nut Nut C C C C C (e) B B B C B B B B B A92183 43. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14−47) 44. (a) INSTALL V−RIBBED BELT TENSIONER ASSY Install the tensioner with the bolt and nut. Torque: 59.5 N⋅m (607 kgf⋅cm, 44 ft⋅lbf) A52478 WhereEverybodyKnowsYourName 17−17 LUBRICATION − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 45. (a) INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N⋅m (551 kgf⋅cm, 41 ft⋅lbf) 46. (a) INSTALL ENGINE MOUNTING INSULATOR Raise the engine and install the engine mounting insulator RH. Install the engine mounting insulator RH with the 4 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for bolt A 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf) for bolt B A52481 A (b) B B B A59900 (c) Install the bolt and disconnect the steering gear return hose clamp from the frame. Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf) (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf) (e) M/T: Install the engine lateral control rod with the bolt. Torque: 89 N⋅m (910 kgf⋅cm, 66 ft⋅lbf) A59901 A59880 M/T A60825 WhereEverybodyKnowsYourName 17−18 LUBRICATION 6 mm (0.24 in.) Seal Packing A92185 − OIL PUMP ASSY (2AZ−FE)(From July, 2003) 47. INSTALL OIL PAN SUB−ASSY NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan. (b) Apply a continuous bead of seal packing in the shape of bead (diameter: 3 to 4 mm (0.157 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826−00080 or equivalent (c) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 48. (a) INSTALL CRANKSHAFT POSITION SENSOR Install the bolt and sensor. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Confirm the wire harness of the sensor is placed as shown in the illustration. A64641 Wire Harness (b) Clamp Rib A52071 49. (a) INSTALL CRANKSHAFT PULLEY Install the crankshaft pulley (see page 14−47). (b) Disconnect the plunger knock pin. (1) Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook. Disconnect Turn Hook Pin A89786 WhereEverybodyKnowsYourName 17−19 LUBRICATION − (2) OIL PUMP ASSY (2AZ−FE)(From July, 2003) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Plunger Push Turn 50. 51. 52. 53. 54. 55. 56. 57. A89787 INSTALL CYLINDER HEAD COVER SUB−ASSY (See page 14−47) INSTALL IGNITION COIL ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL VANE PUMP ASSY (See page 51−8) INSTALL GENERATOR ASSY (See page 19−17) INSTALL ENGINE WIRE INSTALL FAN AND GENERATOR V BELT (See page 14−5) INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 58. (a) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET Install the engine mounting control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A59888 59. 60. 61. 62. INSTALL EXHAUST PIPE ASSY FRONT (See page 15−3) INSTALL FRONT WHEEL RH ADD ENGINE OIL INSPECT CHECK FOR ENGINE OIL LEAKS WhereEverybodyKnowsYourName 66−1 WIPER & WASHER − WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM 6604P−01 PRECAUTION 1. (a) (b) PRECAUTION OF WASHER NOZZLE ADJUSTMENT Do not clean or adjust the washer nozzle with a safety pin etc. because; (1) the washer nozzle tip is made of resin and could be damaged. (2) adjustment is not necessary because the washer nozzle is spray type. In case the washer nozzle is clogged with wax etc., remove the objects and clean the nozzle hole with a soft resin brush etc. WhereEverybodyKnowsYourName 66−10 WIPER & WASHER − WINDSHIELD WIPER SWITCH ASSY WINDSHIELD WIPER SWITCH ASSY 6604V−01 REPLACEMENT 1. REMOVE STEERING COLUMN COVER (See Page 50−9) 2. REMOVE WINDSHIELD WIPER SWITCH ASSY (a) (b) Claw E57797 Disconnect the connector. Using a screwdriver, release the claw and pull out the windshield wiper switch assy. NOTICE: Pressing the claw hard breaks the claw. HINT: Tape the screwdriver tip before use. WhereEverybodyKnowsYourName 66−2 WIPER & WASHER − WIPER AND WASHER SYSTEM 6604Q−01 PROBLEM SYMPTOMS TABLE 1. WIPER AND WASHER SYSTEM Symptom Suspect Area See page Front wipers do not operate. 1. IG1 Relay 2. WIPER Fuse 3. Front Wiper Switch 4. Wire Harness − − 66−4 − Front wipers do not operate in LO or HI. 1. Front Wiper Switch 2. Front Wiper Motor 3. Wire Harness 66−4 66−4 − Front wipers do not operate in INT. 1. Front Wiper Switch 2. Front Wiper Motor 3. Wire Harness 66−4 66−4 − Front Washer motor does not operate. 1. WIPER Fuse 2. Front Washer Switch 3. Front Washer Motor 4. Wire Harness − 66−4 65−2 − Front Wipers do not operate when washer switch in ON. 1. Front Wiper Switch 2. Front Wiper Motor 3. Wire Harness 66−4 66−4 − Washer fluid does not operate. 1. Washer Hose and Nozzle
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong.
The wiper blade is in contact with the body. 1. Wiper Motor (wiper arm and blade set position) WhereEverybodyKnowsYourName − 66−6 66−3 WIPER & WASHER − WIPER AND WASHER SYSTEM 6604R−01 ON−VEHICLE INSPECTION 1. (a) 1 2 WASHER MOTOR Operation Check (1) Pour the water into the washer jar with the washer motor and the pump installed to the washer jar assy. (2) Connect the battery (+) to terminal 2 of the washer motor and the pump, the battery (−) to terminal 1 of the washer motor and the pump. Check that the water comes out from the washer jar. E56397 WhereEverybodyKnowsYourName 66−4 WIPER & WASHER − WIPER AND WASHER SYSTEM 6604S−01 INSPECTION 1. WINDSHIELD WIPER SWITCH ASSY (a) Continuity Check (1) Check the continuity of each terminal of the connector. Standard: Front Wiper Switch Switch position Tester connection Specified condition MIST 7 (+1) − 17 (+B) Continuity OFF 16 (+S) − 7 (+1) Continuity INT 16 (+S) − 7 (+1) Continuity LO 7 (+1) − 17 (+B) Continuity HI 17 (+B) − 8 (+2) Continuity Switch position Tester connection Specified condition OFF − No continuity ON 11 (WF) − 2 (EW) Continuity E34825 Front Washer Switch (b) FAST: Intermittent Operation Check (1) Connect the voltmeter (+) terminal to terminal 7 (+1) of the connector, the voltmeter (−) terminal to terminal 2 (EW) of the connector. (2) Connect the battery (+) to terminal 17 (+B) of the connector, the battery (−) to terminal 2 (EW) and 16 (+S) of the connector. (3) Turn the wiper switch to INT. (4) Connect the battery (+) to terminal 16 (+S) of the connector for 5 seconds. (5) Connect the battery (−) to terminal 16 (+S) of the connector. Operate the intermittent wiper relay and check voltage between terminal 7 (+1) and terminal 2 (EW). Connect the battery (−) to terminal 16 (+S) SLOW: Connect the battery (−) to terminal 16 (+S) 7 (+1) ⇔ 2 (EW) Voltage between terminals 1.6
1 seconds 10.7
5 seconds E56399 WhereEverybodyKnowsYourName 66−5 WIPER & WASHER (c) Voltage between terminal 7 (+1) and 5 (EW): ON OFF 10 − 14 V 0V Approx. 0.3 seconds Approx. 2.2 seconds I32848 2. (a) (b) E34081 (c) − Operation Check (Front Wiper) (1) Turn the wiper switch to OFF. (2) Connect the battery (+) to terminal 17 (+B) of the connector, the battery (−) to terminal 16 (+S) and 2 (EW) of the connecter. (3) Connect the voltmeter (+) terminal to terminal 7 (+1) of the connector, and the voltmeter (−) terminal to terminal 2 (EW) of the connector. Turn the washer switch to ON and OFF, and check voltage between terminal 7 (+1) and terminal 2 (EW). WINDSHIELD WIPER MOTOR ASSY LO Operation Check (1) Connect the battery (+) to terminal 1 (+1) of the connector, the battery (−) to terminal 5 (E) of the connector, and check that the motor operates at low speed (LO). HI Operation Check (1) Connect the battery (+) to terminal 4 (+2) of the connector, the battery (−) to terminal 5 (E) of the connector, and check that the motor operates at high speed (HI). Automatic Stop Operation Check (1) Connect the battery (+) to terminal 1 (+1) of the connector, the battery (−) to terminal 5 (E) of the connector. With the motor being rotated at low speed (LO), disconnect terminal 1 (+1) to stop the wiper motor operation at any position except the automatic stop position. (2) Connect terminals 1 (+1) and 3 (S), and the battery (+) to terminal 2 (B) to restart the motor operation at low speed. SST 09843−18040 (3) Automatic Stop Position WIPER AND WASHER SYSTEM Check the automatic stop position. 4
+5
−10
E57881 WhereEverybodyKnowsYourName 66−6 WIPER & WASHER − WINDSHIELD WIPER MOTOR ASSY WINDSHIELD WIPER MOTOR ASSY 6604T−01 REPLACEMENT 1. REMOVE FRONT WIPER ARM HEAD CAP 2. REMOVE FR WIPER ARM LH (a) 3. Operate the wiper and stop the windshield wiper motor assy at the automatic stop position. REMOVE FR WIPER ARM RH 4. REMOVE COWL TOP VENTILATOR LOUVER SUB−ASSY (a) Remove the 6 clips and cowl top ventilator louver sub assy. 5. REMOVE WIPER LINK ASSY (a) (b) Disconnect the connector. Remove the 4 bolts and wiper link assy. 6. REMOVE WINDSHIELD WIPER MOTOR ASSY (a) Disengage the meshing of rod at the clank arm pivot of the windshield wiper motor assy. (b) Remove the 3 bolts and windshield wiper motor assy from the windshield wiper link assy. Clips E59224 E57801 E57802 HINT: Turning the crank arm by hand prior to the operation will be able to remove the wiper motor easier. E57804 WhereEverybodyKnowsYourName 66−7 WIPER & WASHER − WINDSHIELD WIPER MOTOR ASSY 7. INSTALL WINDSHIELD WIPER MOTOR ASSY (a) (b) Apply grease to the clank arm pivot of the windshield wiper motor assy. Install the windshield wiper motor assy with the 3 bolts to the windshield wiper link assy. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 8. INSTALL WIPER LINK ASSY (a) (b) Install the windshield wiper link assy with the 4 bolts. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) Connect the connector. 9. INSTALL FR WIPER ARM RH (a) Operate the wiper, and stop the windshield wiper motor assy at the automatic stop position. (b) Scrape off the serration part of the wiper arm with a round file or equivalent. Clean the wiper pivot serration with the wire brush. E57801 (c) Wiper Arm Serration Wiper Pivot Serration Wire Brush E58837 (d) Align the FR wiper blade front end with the mark and install the FR wiper arm RH with the nut. Torque: 20.1 N⋅m (205 kgf⋅cm, 15 ft⋅lbf) Installation Position Mark E58529 WhereEverybodyKnowsYourName 66−8 WIPER & WASHER Installation Position Mark WINDSHIELD WIPER MOTOR ASSY 10. INSTALL FR WIPER ARM LH (a) (b) Clean the wiper pivot serration with the wire brush. Align the FR wiper blade front tip with the mark and install the FR wiper arm LH with the nut. Torque: 20.1 N⋅m (205 kgf⋅cm, 15 ft⋅lbf) Operate the wiper while running the water or the washer fluid over the window, and check the wiping condition and that the wiper does not hit against the vehicle body. (c) E58528 − WhereEverybodyKnowsYourName 66−9 WIPER & WASHER − WIPER RUBBER LH WIPER RUBBER LH 6604U−01 REPLACEMENT 1. REMOVE FR WIPER BLADE LH (a) Remove the FR wiper blade LH from the front wiper arm LH. NOTICE: Do not fold down the front wiper arm with the front wiper blade being removed from it. 2. REMOVE WIPER RUBBER LH (a) (b) Remove the FR wiper rubber LH from the FR wiper blade LH. Remove the 2 wiper rubber backing plates from the wiper rubber LH. 3. INSTALL WIPER RUBBER LH (a) Install the 2 wiper rubber backing plates to the wiper rubber LH. NOTICE: Be careful to observe and keep direction of curvature for correct replacement. I30020 (b) Install the wiper rubber LH so that the head part (Longer side) of the wiper rubber faces the arm axle side. NOTICE:
Push in the front wiper blade into the grooves of the wiper rubber to engage them completely.
Put back the wiper arm of passenger side before driver side wiper arm is put back. E57398 WhereEverybodyKnowsYourName 15−1 EXHAUST − EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) 150B4−01 COMPONENTS PZEV Rear Exhaust Pipe No. 1 Support Bracket Front Floor Heat Insulator No. 1 Parking Brake Cable Heat Insulator Fuel Tank Protector Lower Center Main Muffler Heat Insulator Exhaust Pipe No. 4 Support Bracket Sub−assy 33 (337, 24) 5.4 (55, 48 in.⋅lbf)
Gasket Exhaust Pipe Support No. 4 62 (632, 46) 22 (224, 16) Heated Oxygen Sensor (Bank 1 Sensor 3) 44 (449, 32) 5.4 (55, 48 in.⋅lbf) Front Exhaust Pipe No. 1 Support Bracket Exhaust Pipe Assy Tail 33 (337, 24) Exhaust Pipe Assy Front 39 (398, 29)
Gasket 56 (571, 41) Exhaust Pipe Assy Center 33 (337, 24) Floor Panel Brace Rear 44 (449, 32) Heated Oxygen Sensor (Bank 1 Sensor 2) Exhaust Pipe Damper N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Exhaust Pipe Support No. 4
Gasket Tailpipe Baffle 19.5 (199, 14) 19 (194, 14) 56 (571, 41) A90542 WhereEverybodyKnowsYourName 15−2 EXHAUST − EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) Except PZEV Rear Exhaust Pipe No. 1 Support Bracket Front Floor Heat Insulator No. 1 Exhaust Pipe Support No. 4 Parking Brake Cable Heat Insulator Fuel Tank Protector Lower Center Main Muffler Heat Insulator Exhaust Pipe No. 4 Support Bracket Sub−assy 22 (224, 16) 4.9 (50, 43 in.⋅lbf)
Gasket 33 (337, 24) 62 (632, 46) Front Exhaust Pipe No. 1 Support Bracket 5.4 (55, 48 in.⋅lbf) Exhaust Pipe Assy Front 5.4 (55, 48 in.⋅lbf) 39 (398, 29) Exhaust Pipe Support No. 4 33 (337, 24) Exhaust Pipe Assy Tail
Gasket 56 (571, 41) Exhaust Pipe Assy Center Floor Panel Brace Rear 44 (449, 32) Heated Oxygen Sensor (Bank 1 Sensor 2) 33 (337, 24)
Gasket A/T Exhaust Pipe Damper N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part Tailpipe Baffle 19.5 (199, 14) 19 (194, 14) 56 (571, 41) A85553 WhereEverybodyKnowsYourName 15−3 EXHAUST − EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) 150B0−02 REPLACEMENT 1. (a) 2. (a) 3. (a) (b) (c) 4. (a) (b) 5. (a) 6. (a) 7. (a) 8. (a) 9. (a) REMOVE FLOOR PANEL BRACE REAR Remove the 2 bolts and panel brace. REMOVE EXHAUST PIPE DAMPER (A/T) Remove the 2 bolts and damper. REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts, 2 nuts and pipe center from the pipe front. Remove the 2 nuts and pipe center from the pipe tail. Remove the pipe center from the 2 pipe supports. Bank 1 sensor 2: REMOVE HEATED OXYGEN SENSOR Disconnect the sensor connector. Remove the sensor. Bank 1 sensor 3: REMOVE HEATED OXYGEN SENSOR Disconnect the sensor from the front pipe. REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET Remove the 2 nuts and front support bracket. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET Remove the 2 bolts and rear support bracket. REMOVE EXHAUST PIPE ASSY FRONT Remove the 2 nuts and pipe front. REMOVE EXHAUST PIPE ASSY TAIL Remove the pipe tail from the 3 pipe supports. 10. (a) REMOVE TAIL PIPE BAFFLE Using a plastic hammer, tap the baffle uniformly to remove it. 11. (a) INSTALL TAIL PIPE BAFFLE Align the keyway of the baffle with the key location on the pipe. Using a plastic hammer, tap the baffle to install it. A85551 Key Location (b) Keyway A85552 12. (a) 13. (a) INSTALL EXHAUST PIPE ASSY TAIL Install the pipe to the 3 pipe supports. INSTALL EXHAUST PIPE ASSY FRONT Install a new gasket and the pipe front to the manifold converter with the 2 nuts. Torque: 62 N⋅m (632 kgf⋅cm, 46 ft⋅lbf) WhereEverybodyKnowsYourName 15−4 EXHAUST − EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) 14. INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the rear support bracket with the 2 bolts. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) NOTICE: Do not install the bracket facing the wrong direction. Bracket Pipe Assy Front 15. (a) 16. (a) (b) 17. (a) A60823 INSTALL FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET Install the front support bracket with the 2 nuts. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) Bank 1 sensor 2: INSTALL HEATED OXYGEN SENSOR Install the sensor. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) Connect the sensor connector. Bank 1 sensor 3: INSTALL HEATED OXYGEN SENSOR Install the sensor. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) HINT:

18. (a) (b) Before installing the sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. After installing the sensor, check that the sensor wire is not twisted. If it is twisted, remove the sensor and reinstall it. INSTALL EXHAUST PIPE ASSY CENTER Install a new gasket and the pipe center to the pipe front with the 2 bolts and 2 nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) Install a new gasket and the pipe center to the pipe tail with the 2 nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) 19. (a) INSTALL EXHAUST PIPE DAMPER (A/T) Install the damper with the 2 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) NOTICE: Do not install the damper facing the wrong direction. Exhaust Pipe Damper Exhaust Pipe Assy Center A60822 20. (a) 21. INSTALL FLOOR PANEL BRACE REAR Install the brace with the 2 bolts. Torque: 19.5 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) CHECK FOR EXHAUST GAS LEAKS WhereEverybodyKnowsYourName 15−5 EXHAUST − EXHAUST PIPE ASSY (2AZ−FE)(From July, 2003) If the exhaust pipe is loose, tighten it. If damaged, replace it. WhereEverybodyKnowsYourName 15−6 EXHAUST − EXHAUST PIPE ASSY (1MZ−FE/3MZ−FE) EXHAUST PIPE ASSY (1MZ−FE/3MZ−FE) 150B1−02 COMPONENTS Rear Exhaust Pipe No. 1 Support Bracket Front Floor Heat Insulator No. 1 Exhaust Pipe Support No. 4 Parking Brake Cable Heat Insulator Fuel Tank Protector Lower Center Main Muffler Heat Insulator Exhaust Pipe No. 4 Support Bracket Sub−assy 4.9 (50, 43 in.⋅lbf) 22 (224, 16)
Gasket 33 (337, 24) Heated Oxygen Sensor (Bank 2 Sensor 2) 39 (398, 29) 5.4 (55, 48 in.⋅lbf) 44 (449, 32) Exhaust Pipe Assy Front 5.4 (55, 48 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) Exhaust Pipe Support No. 4 62 (632, 46)
Gasket
Gasket 44 (449, 32) 62 (632, 46) Heated Oxygen Sensor (Bank 1 Sensor 2) 33 (337, 24) 56 (571, 41) Front Exhaust Pipe No. 1 Support Bracket Exhaust Pipe Assy Center Exhaust Pipe Assy Tail Tailpipe Baffle 33 (337, 24) Floor Panel Brace Rear N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part 19.5 (199, 14) WhereEverybodyKnowsYourName 56 (571, 41) A85548 15−7 EXHAUST − EXHAUST PIPE ASSY (1MZ−FE/3MZ−FE) 150B2−02 REPLACEMENT 1. (a) (a) (b) Bank 1 sensor 2 and bank 2 sensor 2: REMOVE HEATED OXYGEN SENSOR Disconnect the 2 sensor connectors. Remove the 2 sensors. (b) A85550 2. (a) 3. (a) 4. (a) 5. (a) (b) (c) 6. (a) (b) (c) 7. (a) REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET Remove the 2 nuts and front support bracket. REMOVE FLOOR PANEL BRACE REAR Remove the 2 bolts and brace. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET Remove the 2 bolts and rear support bracket. REMOVE EXHAUST PIPE ASSY FRONT Remove the 2 nuts holding the manifold converter No. 2 to the pipe front. Remove the 2 bolts holding the manifold converter RH to the pipe front. Remove the 2 bolts and 2 nuts holding the center to the pipe front. Then remove the pipe front. REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 nuts from the pipe tail. Remove the pipe center from the 2 pipe supports. Remove the gasket between the pipe center and pipe tail. REMOVE EXHAUST PIPE ASSY TAIL Remove the pipe tail from the 3 pipe supports. 8. (a) REMOVE TAIL PIPE BAFFLE Using a plastic hammer, tap the baffle uniformly to remove it. A85551 WhereEverybodyKnowsYourName 15−8 EXHAUST 9. (a) Key Location (b) − EXHAUST PIPE ASSY (1MZ−FE/3MZ−FE) INSTALL TAIL PIPE BAFFLE Align the keyway of the baffle with the key location on the pipe assy tail. Using a plastic hammer, tap the baffle to install it. Keyway A85552 10. (a) 11. (a) (b) (c) 12. (a) (b) (c) (d) INSTALL EXHAUST PIPE ASSY TAIL Install the pipe tail to the 3 pipe supports. INSTALL EXHAUST PIPE ASSY CENTER Install a new gasket between the pipe center and pipe tail. Install the pipe center to the 2 exhaust pipe supports. Install the pipe center with the 2 nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) INSTALL EXHAUST PIPE ASSY FRONT Install 3 new gaskets to the pipe front. Install the pipe front to the manifold converter RH with the 2 bolts. Torque: 62 N⋅m (632 kgf⋅cm, 46 ft⋅lbf) Install the pipe front to the manifold converter No. 2 with the 2 nuts. Torque: 62 N⋅m (632 kgf⋅cm, 46 ft⋅lbf) Install the pipe front to the pipe center with the 2 bolts and 2 nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) 13. INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the rear support bracket with the 2 bolts. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) NOTICE: Do not install the bracket facing the wrong direction. Bracket Pipe Assy Front 14. (a) A60823 INSTALL FLOOR PANEL BRACE REAR Install the floor panel brace with the 2 bolts. Torque: 19.5 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) 15. INSTALL FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the front support bracket with the 2 nuts. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) NOTICE: Do not install the support bracket facing the wrong direction. A85549 WhereEverybodyKnowsYourName 15−9 EXHAUST − EXHAUST PIPE ASSY (1MZ−FE/3MZ−FE) 16. Bank 1 sensor 2 and bank 2 sensor 2: INSTALL HEATED OXYGEN SENSOR (a) Install the 2 sensors. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) (b) Connect the 2 sensor connectors. 17. CHECK FOR EXHAUST GAS LEAKS If the exhaust pipe is loose, tighten it. If damaged, replace it. WhereEverybodyKnowsYourName 27−1 REAR SUSPENSION − REAR SUSPENSION SYSTEM REAR SUSPENSION SYSTEM 2701I−14 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page Bottoming 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn) − 27−4 27−4 Sways/pitches 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 3. Shock absorber (Worn) 28−1 27−16 27−4 1. 2. 3. 4. 28−1 28−1 27−4 26−5 27−3 30−2 Rear wheel shimmy Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) 5. Hub bearing (Worn) 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) Abnormal tire wear 3. Shock absorber (Worn) 4. Suspension parts (Worn) WhereEverybodyKnowsYourName 28−1 26−5 27−3 27−4 − 27−10 REAR SUSPENSION − REAR SUSPENSION ARM ASSY NO.1 LH REAR SUSPENSION ARM ASSY NO.1 LH 2705Z−06 REPLACEMENT HINT: COMPONENTS: See page 27−2 1. REMOVE REAR WHEEL 2. REMOVE EXHAUST PIPE ASSY CENTER (a) 1MZ−FE / 3MZ−FE engine: See page 15−7 (b) 2AZ−FE engine: See page 15−3 3. REMOVE STABILIZER BAR REAR (See page 27−16) 4. SEPARATE STRUT ROD ASSY REAR (See page 27−18) 5. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt, nut and rear suspension arm No. 2 (outer side) from the rear carrier. HINT: Keep the nut fixed while loosening and removing the bolt. B53735 6. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH HINT: Separate the RH side by the procedures with the LH side. 7. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt, nut and rear suspension arm No. 1 (outer side) from rear axle carrier. HINT: Keep the nut fixed while loosening and removing the bolt. B53736 8. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Separate the RH side by the procedures with the LH side. WhereEverybodyKnowsYourName 27−11 REAR SUSPENSION − REAR SUSPENSION ARM ASSY NO.1 LH 9. (a) (b) REMOVE REAR SUSPENSION MEMBER SUB−ASSY Support the rear suspension member with a jack. Remove the 4 nuts, 2 bolts and 4 retainers from the rear suspension member. 10. (a) (b) REMOVE REAR SUSPENSION ARM ASSY NO.1 LH Lower the rear suspension member. Remove the bolt and lower suspension arm No. 1. 11. (a) INSTALL REAR SUSPENSION ARM ASSY NO.1 LH Install the lower suspension No. 1 with the bolt, nut and temporary tighten the bolt. (b) Set suspension arm in the position shown in the illustration and fully tighten the bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) B53742 B53744 B53744 38 mm (1.5 in.) B53747 HINT: Install the lower suspension No. 1 so that the bracket leans toward the front of the vehicle, as shown in the illustration. Front B53748 WhereEverybodyKnowsYourName 27−12 REAR SUSPENSION C C B A − REAR SUSPENSION ARM ASSY NO.1 LH 12. (a) (b) INSTALL REAR SUSPENSION MEMBER SUB−ASSY Support the rear suspension member with a jack. Install the rear suspension member with the 4 nuts, 2 bolts and 4 retainers. Torque: A, B: 55 N⋅m (561 kgf⋅cm, 41 ft⋅lbf) C: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf) 13. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Connect the rear suspension arm No. 1 (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt and nut. B A B53742 (a) HINT: Insert the bolt from the front side of the vehicle and temporarily install the bolt. B53736 14. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Temporarily tighten the RH side by the procedures with the LH side. 15. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Connect the rear suspension arm No. 2 (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt. HINT: Insert the bolt from the rear side of the vehicle and temporarily install the bolt. B53735 16. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Temporarily tighten the RH side by the procedures with the LH side. 17. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (See page 27−18) 18. (a) STABILIZE SUSPENSION Jack up the rear axle carrier, placing a wood block between them. Apply load to the suspension so that the installed bolt of the suspension arm assy No. 1 (vehicle side) is horizontally aligned with the center of the rear axle hub. C91813 WhereEverybodyKnowsYourName 27−13 REAR SUSPENSION 19. (a) − REAR SUSPENSION ARM ASSY NO.1 LH FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Fully tighten the bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) HINT: Keep the nut fixed while tightening the bolt. C82996 20. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Fully tighten the RH side by the procedures with the LH side. 21. (a) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Fully tighten the bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) HINT: Keep the nut fixed while tightening the bolt. C82997 22. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Fully tighten the RH side by the procedures with the LH side. 23. FULLY TIGHTEN STRUT ROD ASSY REAR (See page 27−18) 24. INSTALL STABILIZER BAR REAR (See page 27−16) 25. INSTALL EXHAUST PIPE ASSY CENTER (a) 1MZ−FE / 3MZ−FE engine: See page 15−7 (b) 2AZ−FE engine: See page 15−3 26. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 27. INSPECT REAR WHEEL ALIGNMENT (See page 27−3) WhereEverybodyKnowsYourName 27−14 REAR SUSPENSION − REAR SUSPENSION ARM ASSY NO.2 LH REAR SUSPENSION ARM ASSY NO.2 LH 27060−06 REPLACEMENT HINT: COMPONENTS: See page 27−2 1. REMOVE REAR WHEEL 2. REMOVE EXHAUST PIPE ASSY CENTER (a) 1MZ−FE / 3MZ−FE engine: See page 15−7 (b) 2AZ−FE engine: See page 15−3 3. REMOVE STABILIZER BAR REAR (See page 27−16) 4. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (See page 27−10) 5. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Separate the RH side by the procedures with the LH side. 6. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (See page 27−10) 7. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH HINT: Separate the RH side by the procedures with the LH side. 8. SEPARATE STRUT ROD ASSY REAR (See page 27−18) 9. REMOVE REAR SUSPENSION MEMBER SUB−ASSY (See page 27−10) 10. (a) REMOVE REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt and disconnect the rear suspension arm No. 2 (inner side). (b) Remove the bolt, nut and the rear suspension arm No. 2 (outer side) from rear axle carrier. C82992 HINT: Keep the nut fixed while loosening and removing the bolt. C82993 WhereEverybodyKnowsYourName 27−15 REAR SUSPENSION − REAR SUSPENSION ARM ASSY NO.2 LH 11. (a) INSTALL REAR SUSPENSION ARM ASSY NO.2 LH Install the rear suspension arm No. 2 (inner side) with the bolt and temporarily tighten the bolt. (b) Set the suspension arm in the position in the illustration and fully tighten the bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) C82992 38 mm (1.5 in.) B53747 12. INSTALL REAR SUSPENSION MEMBER SUB−ASSY (See page 27−10) 13. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (See page 27−10) 14. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Temporarily tighten the RH side by the procedures with the LH side. 15. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (See page 27−10) 16. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Temporarily tighten the RH side by the procedures with the LH side. 17. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (See page 27−18) 18. INSTALL STABILIZER BAR REAR (See page 27−16) 19. STABILIZE SUSPENSION (See page 27−10) 20. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (See page 27−10) 21. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Fully tighten the RH side by the procedures with the LH side. 22. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (See page 27−10) 23. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Fully tighten the RH side by the procedures with the LH side. 24. FULLY TIGHTEN STRUT ROD ASSY REAR (See page 27−18) 25. INSTALL EXHAUST PIPE ASSY CENTER (a) 1MZ−FE / 3MZ−FE engine: See page 15−7 (b) 2AZ−FE engine: See page 15−3 26. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 27. INSPECT REAR WHEEL ALIGNMENT (See page 27−3) WhereEverybodyKnowsYourName 27−16 REAR SUSPENSION − STABILIZER BAR REAR STABILIZER BAR REAR 27061−04 REPLACEMENT HINT: COMPONENTS: See page 27−2 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSY LH (a) Remove the 2 nuts and stabilizer bar link. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C91816 3. REMOVE REAR STABILIZER LINK ASSY RH HINT: Remove the RH side by the same procedures with the LH side. 4. (a) (b) INSPECT REAR STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nut continuously at a rate of 2 − 4 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 0.05 − 1.0 N·m (0.5 − 10 kgf·cm, 0.4 − 8.7 in.·lbf) C66721 5. (a) REMOVE STABILIZER BAR REAR Remove the 8 bolts, 2 No. 1 brackets and 2 bushings. WhereEverybodyKnowsYourName 27−17 REAR SUSPENSION 6. (a) A − STABILIZER BAR REAR INSTALL STABILIZER BAR REAR Install the bushing and bracket with the 4 bolts (LH side). Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf) HINT: B
2 types of bolts (A, B) are used, so make sure the correct bolts are installed.
Install the bushing to the inner side of the bushing stopper on the stabilizer bar. C93541 B53738 7. (a) INSTALL REAR STABILIZER LINK ASSY LH Remove the 2 nuts and stabilizer bar link. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. C91816 8. INSTALL REAR STABILIZER LINK ASSY RH HINT: Install the RH side by the same procedures with the LH side. 9. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 27−18 REAR SUSPENSION − STRUT ROD ASSY REAR STRUT ROD ASSY REAR 2704T−05 REPLACEMENT HINT: COMPONENTS: See page 27−2 1. REMOVE REAR WHEEL 2. (a) REMOVE STRUT ROD ASSY REAR Remove the bolt, nut and disconnect the parking brake cable. (b) Remove the bolt, nut and disconnect the strut rod (front side). B53739 HINT: Keep the nut fixed while loosening and removing the bolt. B53740 (c) Remove the bolt, nut and strut rod from rear axle carrier. HINT: Keep the nut fixed while loosening and removing the bolt. B53741 3. (a) TEMPORARILY TIGHTEN STRUT ROD ASSY REAR Install the strut rod (rear side), bolt nut and temporarily tighten the bolt. HINT:

Insert the bolt from the inner side of the vehicle and temporarily install the bolt. Keep the nut fixed while tightening the bolt. B53741 WhereEverybodyKnowsYourName 27−19 REAR SUSPENSION (b) − STRUT ROD ASSY REAR Connect the strut rod (inner side) with the bolt. Torque: 113 N⋅m (1,150 kgf⋅cm, 83 ft⋅lbf) HINT: Keep the nut fixed while tightening the bolt. B53740 4. (a) STABILIZE SUSPENSION Jack up the rear axle carrier, placing a wood block between them. Apply load to the suspension so that the installed bolt of the suspension arm assy No. 1 (vehicle side) is horizontally aligned with the center of the rear axle hub. 5. (a) FULLY TIGHTEN STRUT ROD ASSY REAR Fully tighten the bolt. Torque: 113 N⋅m (1,152 kgf⋅cm, 83 ft⋅lbf) C91813 HINT: Keep the nut fixed while tightening the bolt. B53741 (b) Install the parking brake cable with the bolt and nut. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) B53739 6. 7. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (See page 27−3) WhereEverybodyKnowsYourName 27−2 REAR SUSPENSION − REAR SUSPENSION REAR SUSPENSION 2704V−08 COMPONENTS Rear Suspension Support No. 1 Cover LH 49 (500, 36) Rear Suspension Member Sub−Assy Collar
39 (400, 29) Suspension Support 100 (1,020, 74) Spring Bumper 38 (387, 28) 55 (561, 41) 100 (1,020, 74) Rear Suspension Arm Assy No. 2 LH Coil Spring 100 (1,020, 74) Rear Suspension Arm Assy No. 1 LH Lower Insulator 100 (1,020, 74) 113 (1,150, 83) 113 (1,150, 83) Strut Rod Assy Rear 19 (195, 14) Bracket Bushing 39 (400, 29) 5.4 (55, 48 in.⋅lbf) Shock Absorber Assy Rear LH 19 (195, 14) Parking Brake Cable Stabilizer Bar Rear Rear Stabilizer Link Assy LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part 255 (2,600, 188) WhereEverybodyKnowsYourName B53746 27−3 REAR SUSPENSION − REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT 2704P−09 ADJUSTMENT 1. INSPECT TIRE (See page 28−1) 2. MEASURE VEHICLE HEIGHT (See page 26−5) NOTICE: Before inspecting wheel alignment, adjust the vehicle height to the specified value. 3. B A D INSPECT TOE−IN Toe−in (total) Front A + B: 0°22’ ± 11’ (0.4° ± 0.2°) C − D: 4 ± 2 mm (0.16 ± 0.08 in.) HINT:

Measure ”A + B” when ”C − D” cannot be measured. If toe−in is not within the specified range, adjust No.2 lower suspension arms. C SA3213 4. (a) ADJUST TOE−IN Measure the lengths of the right and left No.2 lower suspension arms. No.2 lower suspension arm length difference: 1.5 mm (0.06 in.) or less If the left−right difference is larger than 1.5 mm (0.06 in.), adjust it by following the procedures below. C91810 (b) (c) Loosen the 2 lock nuts. Turn the right and left adjusting tubes by an equal amount to adjust toe−in. HINT:

(d) Adjusting Tube C91811 5. Try to adjust toe−in to the center value. One turn of each adjusting tube will adjust toe−in by approximately 1.2 (112’), 10.8 mm (0.425 in.). Torque the 2 lock nuts. Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf) INSPECT CAMBER Camber Right−left error USA, Canada Mexico −1°16’ ± 45’ (−1.27° ± 0.75°) 45’ (0.75°) or less −1°09’ ± 45’ (−1.15° ± 0.75°) 45’ (0.75°) or less HINT: Camber is not adjustable. If the measurement is not within the specification, inspect the suspension parts for damage and/or wear, and replace them if necessary. WhereEverybodyKnowsYourName 27−4 REAR SUSPENSION − SHOCK ABSORBER ASSY REAR LH SHOCK ABSORBER ASSY REAR LH 2705Y−04 REPLACEMENT HINT: COMPONENTS: See page 27−2 1. REMOVE REAR WHEEL 2. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) 3. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 72−32) 4. REMOVE REAR SIDE SEAT BACK ASSY LH HINT: Remove the LH side by the same procedures with the RH side. 5. REMOVE ROOF SIDE GARNISH INNER RH (See page 76−22) 6. REMOVE ROOF SIDE GARNISH INNER LH HINT: Remove the LH side by the same procedures with the RH side. 7. REMOVE CENTER STOP LAMP ASSY (See page 65−22) 8. REMOVE PACKAGE TRAY TRIM PANEL ASSY (a) TMC made: (See page 61−13) (b) TMMK made: (See page 61−16) 9. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER (a) TMC made: (See page 61−13) (b) TMMK made: (See page 61−16) 10. (a) SEPARATE REAR STABILIZER LINK ASSY LH Remove the nut and disconnect the stabilizer bar link from the shock absorber. HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. C66631 11. (a) REMOVE REAR SHOCK ABSORBER WITH COIL SPRING Remove the 2 bolts, disconnect the flexible hose and ABS speed sensor wire harness from shock absorber. F41030 WhereEverybodyKnowsYourName 27−5 REAR SUSPENSION − SHOCK ABSORBER ASSY REAR LH (b) Loosen the 2 nuts on the lower side of the shock absorber. HINT: Do not remove the 2 bolts. (c) Support the rear axle carrier with a jack. (d) Remove the rear suspension support No. 1 cover LH. C66634 (e) Loosen the suspension support center nut. NOTICE: Do not remove the nut. HINT: If not disassembling the rear shock absorber, it is not necessary to loosen the nut. C92182 (f) (g) (h) Remove the 3 nuts of the suspension support. Lower the rear axle carrier and remove the 2 nuts and bolts on the lower side of the shock absorber. Remove the shock absorber with the coil spring. C92184 12. 13. (a) 28mm FIX REAR SHOCK ABSORBER WITH COIL SPRING REMOVE SHOCK ABSORBER ASSY REAR LH Install 2 nuts and a bolt to the bracket at the lower part of the shock absorber, and secure it in a vise. (1.1 in) F40121 (b) Using SST, compress the coil spring. SST 09727−30021 NOTICE: Do not use an impact wrench. It will damage the SST. (c) Remove the nut, collar and suspension support. (d) Remove the coil spring, spring bumper and lower insulator. SST F41028 WhereEverybodyKnowsYourName 27−6 REAR SUSPENSION − SHOCK ABSORBER ASSY REAR LH 14. (a) C83163 INSPECT SHOCK ABSORBER ASSY REAR LH Compress and extend the shock absorber rod, and check that there is no abnormal resistance or unusual operation sound. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing the shock absorber, see DISPOSAL on page 27−9. 15. (a) (b) INSTALL SHOCK ABSORBER ASSY REAR LH Install the spring bumper. Install the lower insulator, as shown in the illustration. F40193 (c) Using SST, compress the coil spring. SST 09727−30021 NOTICE: Do not use an impact wrench. It will damage the SST. (d) Install the coil spring to the shock absorber. HINT:
Fit the lower end of the coil spring into the gap of the lower seat. SST F41029
Check that the 2 flat faces of the piston rod are positioned in parallel with the 2 flat faces of the rear suspension support. (e) Align the suspension support with the shock absorber lower bracket, as shown in the illustration. C93791 Lower Bracket HINT: Set the suspension support so that the ribbed part of the suspension support faces out side. 5 Front 5 Outside Suspension support C93768 WhereEverybodyKnowsYourName 27−7 REAR SUSPENSION (f) (g) (h) − SHOCK ABSORBER ASSY REAR LH Install the collar to the piston rod. Temporarily install a new nut. Remove the SST. SST 09727−30021 HINT: After removing SST, recheck the direction of the suspension support. F02773 16. (a) INSTALL REAR SHOCK ABSORBER WITH COIL SPRING Install the shock absorber with the coil spring and 3 nuts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) C92184 (b) Install the shock absorber with the coil spring, 2 bolts and nuts. Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf) HINT: Keep the bolt fixed while tightening the nut. C66634 (c) Install the flexible hose and ABS speed sensor wire harness with the 2 bolts. Torque: A: Flexible hose: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) B: ABS speed sensor wire harness: 5.5 N⋅m (56 kgf⋅cm, 49 in⋅lbf) (d) Tighten the nut in the center of suspension support. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) A B F41030 HINT: If the shock absorber has not been disassembled, it is necessary to torque the nut. (e) Install the rear suspension support No. 1cover LH. C92182 WhereEverybodyKnowsYourName 27−8 REAR SUSPENSION 17. (a) − SHOCK ABSORBER ASSY REAR LH INSTALL REAR STABILIZER LINK ASSY LH Install the stabilizer bar link to the shock absorber with the nut. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. C66631 18. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER (a) TMC made: (See page 61−13) (b) TMMK made: (See page 61−16) 19. INSTALL REAR SIDE SEAT BACK ASSY RH (See page 72−32) 20. INSTALL REAR SIDE SEAT BACK ASSY LH HINT: Install the LH side by the same procedures with the RH side. 21. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 22. INSPECT REAR WHEEL ALIGNMENT (See page 27−3) WhereEverybodyKnowsYourName 27−9 REAR SUSPENSION − SHOCK ABSORBER ASSY REAR LH 2701L−14 DISPOSAL 1. (a) (b) A DISPOSE OF SHOCK ABSORBER ASSY REAR LH Fully extend the shock absorber rod. Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION:
When drilling, chips may fly out, work carefully.
The gas is colorless, odorless and non−poisonous. B C83384 WhereEverybodyKnowsYourName 82−1 CRUISE CONTROL − CRUISE CONTROL MAIN SWITCH ASSY CRUISE CONTROL MAIN SWITCH ASSY 8205N−01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60−1) 2. REMOVE STEERING WHEEL COVER LOWER NO.2 3. REMOVE STEERING WHEEL COVER LOWER NO.3 4. REMOVE HORN BUTTON ASSY (SEE PAGE 60−25) 5. (a) (b) REMOVE CRUISE CONTROL MAIN SWITCH ASSY Disconnect the connector. Remove the 2 screws. (c) Pull out the cruise control main switch assy in the direction shown by the arrow in the illustration. B84683 B87754 6. 7. 8. 9. INSTALL HORN BUTTON ASSY (SEE PAGE 60−25) INSPECT HORN BUTTON ASSY (SEE PAGE 60−17) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05−1456) WhereEverybodyKnowsYourName 82−2 CRUISE CONTROL − CLUTCH SWITCH ASSY CLUTCH SWITCH ASSY 8201K−03 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71−16) 2. REMOVE COWL SIDE TRIM SUB−ASSY LH (SEE PAGE 71−16) 3. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (SEE PAGE 71−16) 4. REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH (SEE PAGE 71−16) 5. (a) (b) REMOVE CLUTCH SWITCH ASSY Disconnect the connector. Loosen the nut and remove the clutch switch assy. E58575 WhereEverybodyKnowsYourName 71−1 INSTRUMENT PANEL/METER − COMBINATION METER COMBINATION METER 7105L−06 PROBLEM SYMPTOMS TABLE Warning Lights: Symptom Suspected Area 1. Wire Harness or Connector 2. ECM Check engine warning light does not come on. 3. Combination Meter Assy 1. Wire Harness or Connector 2. ECM Discharge warning light does not come on. 3. Combination Meter Assy 1. Wire Harness or Connector 2. Brake Actuator Assy (ABS) Brake warning light does not come on. 3. Combination Meter Assy 1. Wire Harness or Connector 2. Brake Actuator Assy (ABS) See page − 05−5 05−353 05−496 71−29 − 05−5 05−353 05−496 71−29 − 05−870 05−930 71−29 3. ABS & Traction Actuator Assy (VSC) 4. Combination Meter Assy − 05−870 05−930 05−983 71−29 SRS warning light does not come on. 1. Wire Harness or Connector 2. Airbag Sensor Assy Center 3. Combination Meter Assy − 05−1449 71−29 Open door warning light does not come on. 1. 2. 3. 4. − 05−2026 − 71−29 Fuel level warning light does not come on. 1. Wire Harness or Connector 2. Fuel Sender Gauge Assy 3. Combination Meter Assy − − 71−29 Low oil pressure warning light does not come on. 1. Wire Harness or Connector 2. Low Oil Pressure Warning Switch 3. Combination Meter Assy − 71−3 71−29 Window washer level warning does not come on. 1. Wire Harness or Connector 2. Window Washer Level Waring Switch 3. Combination Meter Assy − 71−3 71−29 Seat belt warning lamp for driver’s seat does not come on. 1. Wire Harness or Connector 2. Refer to Troubleshooting 3. Combination Meter Assy ABS warning light does not come on. Wire Harness or Connector Front Door Courtesy Lamp Switch Circuit Body ECU Combination Meter Assy − 05−2021 71−29 Indicator Lights: Symptom Suspected Area 1. Wire Harness or Connector 2. Park/Neutral Position Switch Circuit See page 3. Combination Meter Assy − 05−1111 05−1239 71−29 Turn signal indicator light does not come on. 1. Wire Harness or Connector 2. Turn Signal and Hazard Warning System 3. Combination Meter Assy − 05−1788 71−29 High beam indicator light does not come on. 1. Wire Harness or Connector 2. Headlight Dimmer Switch 3. Combination Meter Assy − 05−1788 71−29 Shift indicator lights do not come on. WhereEverybodyKnowsYourName 71−2 INSTRUMENT PANEL/METER − COMBINATION METER 1. Wire Harness or Connector 2. O/D Main Switch Circuit 4. Combination Meter Assy − 05−1111 05−1239 05−5 05−353 05−496 71−29 TRAC indicator light does not come on. 1. Wire Harness or Connector 2. VSC OFF Indicator, VSC Cut Switch Circuit 3. Combination Meter Assy − 05−983 71−29 SLIP indicator light does not come on. 1. Wire Harness or Connector 2. Slip Indicator Circuit 3. Combination Meter Assy − 05−2206 71−29 HEADLAMP indicator light does not come on. 1. Wire Harness or Connector 2. Combination Meter Assy − 71−29 MAINT REQD indicator light does not come on. 1. Refer to Troubleshooting 2. Combination Meter Assy 71−3 71−29 CRUISE indicator light does not come on. 1. Wire Harness or Connector 2. ABS & Traction Actuator Assy (VSC) 3. Combination Meter Assy − 05−2206 71−29 VSC indicator light does not come on. 1. Wire Harness or Connector 2. ABS & Traction Actuator Assy (VSC) 3. Combination Meter Assy − 05−2206 71−29 O/D OFF indicator light does not come on. 3. ECM Meter Gauges: Symptom Suspected Area See page Tachometer, fuel gauge and water temperature gauge do not operate. 1. Wire Harness or Connector 2. GAUGE Fuse 3. Combination Meter Assy − − 71−29 Fuel gauge does not operate or abnormal operation. 1. Wire Harness or Connector 2. Fuel Receiver Gauge 3. Combination Meter Assy − − 71−29 Buzzer: Symptom Suspected Area See page Key reminder warning buzzer does not sound. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05−2026 − 71−29 Driver’s seat belt warning buzzer does not sound. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05−2026 − 71−29 Front passenger’s seat belt warning buzzer does not sound. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05−2026 − 71−29 Clock: Symptom Suspected Area Seat belt warning lamp for passenger’s seat does not come on. 1. Wire Harness or Connector 2. Refer to Troubleshooting 3. Combination Meter Assy WhereEverybodyKnowsYourName See page − 05−2023 71−29 71−15 INSTRUMENT PANEL/METER − INSTRUMENT PANEL SAFETY PAD SUB−ASSY INSTRUMENT PANEL SAFETY PAD SUB−ASSY 7105H−03 PRECAUTION 1. (a) PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations, read the SRS airbag NOTICE (See page 60−1). WhereEverybodyKnowsYourName 71−16 INSTRUMENT PANEL/METER − INSTRUMENT PANEL SAFETY PAD SUB−ASSY 710P2−01 REPLACEMENT HINT:

COMPONENTS: See page 71−9. Installation is in the reverse order of removal. TABLE OF BOLT, SCREW AND NUT 1. HINT: All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with their alphabet code in the table below. mm (in.) (L = Length) Code Shape Code φ=6 (0.24) L = 20 (0.79) φ=6 (0.24) L = 18 (0.71) φ=6 (0.24) L = 20 (0.79) Shape Code φ=6 (0.24) L = 16 (0.63) φ=6 (0.24) L = 20 (0.79) φ=5 (0.20) L = 14 (0.55) φ=5 (0.20) L = 16 (0.63) φ=5 (0.20) L = 18 (0.71) φ=6 (0.24) φ=6 (0.24) Shape φ=6 (0.24) L = 16 (0.63) φ=8 (0.31) L = 20 (0.79) φ=5 (0.20) L = 16 (0.63) φ=6 (0.24) L = 25 (0.98) B84690 WhereEverybodyKnowsYourName 71−17 INSTRUMENT PANEL/METER 2. 3. 4. 5. 6. INSTRUMENT PANEL SAFETY PAD SUB−ASSY DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60−1) REMOVE STEERING WHEEL COVER LOWER NO.2 REMOVE STEERING WHEEL COVER LOWER NO.3 REMOVE HORN BUTTON ASSY (SEE PAGE 60−25) REMOVE STEERING WHEEL ASSY (SEE PAGE 50−9 or 50−21) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) 7. (a) Clip 8. 9. 10. − REMOVE INSTRUMENT CLUSTER FINISH PANEL Disengage the 4 clips and remove the instrument cluster finish panel. B86164 REMOVE STEERING COLUMN COVER (SEE PAGE 50−9 or 50−21) REMOVE HEADLAMP DIMMER SWITCH ASSY (SEE PAGE 65−23) REMOVE WINDSHIELD WIPER SWITCH ASSY (SEE PAGE 66−10) Clip Claw Clip 11. (a) (b) REMOVE COMBINATION METER ASSY Remove the 2 screws and disengage the 2 clips. Pull out the combination meter assy, then disconnect the connectors. 12. (a) REMOVE FRONT DOOR SCUFF PLATE LH Disengage the 7 claws and 4 clips then remove the front door scuff plate LH. B86165 B56115 WhereEverybodyKnowsYourName 71−18 INSTRUMENT PANEL/METER − INSTRUMENT PANEL SAFETY PAD SUB−ASSY 13. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures for the RH side and LH side. 14. Pin (a) (b) Claw REMOVE INSTRUMENT PANEL UNDER COVER SUB−ASSY NO.1 Disengage the 3 claws and pin. Remove the instrument panel under cover sub−assy No.1. B56119 15. (a) (b) Clip REMOVE COWL SIDE TRIM SUB−ASSY LH Remove the clip. Disengage the 2 clips and remove the cowl side trim sub− assy LH. B56116 16. REMOVE COWL SIDE TRIM SUB−ASSY RH HINT: Use the same procedures for the RH side and LH side. 17. Claw (a) REMOVE INSTRUMENT PANEL COIN BOX SUB−ASSY Disengage the claw and remove the instrument panel coin box sub−assy. B56469 WhereEverybodyKnowsYourName 71−19 INSTRUMENT PANEL/METER 18. (a) (b) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY REMOVE INSTRUMENT PANEL SUB−ASSY UPPER Disconnect the hood lock control cable. Using a screwdriver, open the instrument panel sub−assy upper cover. HINT: Tape the screwdriver tip before use. (c) TMC made: Remove the bolt and 2 screws . (d) TMMK made: Remove the bolt and 2 screws . (e) Disengage the 3 clips. (f) Disconnect the connectors and remove the instrument panel sub−assy upper. Clip B56117 19. (a) (b) (c) Claw REMOVE INSTRUMENT PANEL INSERT LOWER TMC made: Remove the 4 bolts . TMMK made: Remove the 4 bolts . Disengage the 2 claws and remove the instrument panel insert lower. B56456 20. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (AUTO AIR CONDITIONING) (a) Put in a hand from the position indicated in the illustration and push out the clip with fingers. (b) Remove the remaining clips, disengage the claws, and then take off the air conditioner control assembly. NOTICE:
Perform this procedure wearing the protection gloves.
Do not use any tools to avoid damage to the instrument panel safety pad sub−assembly. Claw Clip B62775 21. REMOVE AIR CONDITIONING PANEL SUB−ASSY (MANUAL AIR CONDITIONING) HINT: Use the same procedures for the air conditioner control assembly and air conditioning panel sub−assy. WhereEverybodyKnowsYourName 71−20 INSTRUMENT PANEL/METER 22. (a) (b) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB−ASSY CENTER Remove the 4 bolts. Using a moulding remover, disengage 5 clips, remove the instrument cluster finish panel sub−assy center with radio receiver assy, then disconnect the connectors. Clip B56923 23. (a) REMOVE GLOVE COMPARTMENT DOOR PAD Using a screwdriver, remove the glove compartment door pad. HINT: Tape the screwdriver tip before use. B86424 24. (a) (b) (c) Clip Claw 25. (a) REMOVE INSTRUMENT PANEL SUB−ASSY LOWER TMC made: Remove the bolt and 4 screws . TMMK made: Remove the bolt and 4 screws . Disengage the claw and clip and remove the instrument panel sub−assy lower. B56120 REMOVE SHIFT LEVER KNOB SUB−ASSY (MANUAL TRANSAXLE) Turn the shift lever knob sub−assy counterclockwise and remove the shift lever knob sub−assy. 26. (a) REMOVE CONSOLE PANEL UPPER REAR Foot parking brake: Using a moulding remover, disengage the claw and 8 clips and remove the console panel upper rear. HINT: Set the shift lever in the N position. Claw Clip B56121 WhereEverybodyKnowsYourName 71−21 INSTRUMENT PANEL/METER (b) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY Hand parking brake: Using a moulding remover, disengage the claw and 8 clips and remove the console panel upper rear. HINT: Set the shift lever in the N position (Automatic transaxle). Claw Clip 27. B56458 REMOVE CONSOLE BOX CARPET 28. (a) (b) Claw (c) Claw REMOVE RR CONSOLE BOX TMC made: Remove the 2 bolts and 2 screws . TMMK made: Remove the 2 bolts and 2 screws . Disengage the 2 claws and remove the RR console box. B56122 29. (a) (b) w/ Ash Tray: REMOVE CONSOLE PANEL SUB−ASSY Using a moulding remover, disengage the 4 clips. Disconnect the connectors and remove the console panel sub−assy. HINT: Set the shift lever in the N position (Automatic transaxle). w/o Ash Tray: Clip B84691 WhereEverybodyKnowsYourName 71−22 INSTRUMENT PANEL/METER Claw INSTRUMENT PANEL SAFETY PAD SUB−ASSY 30. (a) (b) REMOVE CONSOLE BOX FRONT Remove the 2 nuts . Disengage the 2 claws and remove the console box front. 31. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER TMC made: Remove the 2 screws . TMMK made: Remove the 2 screws . Disengage the 4 clips and remove the instrument panel finish panel lower center. B86163 (a) (b) (c) Clip B56461 32. (a) : Clip : Claw − REMOVE FRONT PILLAR GARNISH LH (W/O CURTAIN SHIELD AIR BAG) Using a moulding remover, disengage the 2 clips and 2 claws then remove the front pillar garnish LH. B56623 33. REMOVE FRONT PILLAR GARNISH LH (W/ CURTAIN SHIELD AIR BAG) Using a screwdriver, open the cover and remove the bolt. (a) HINT: Tape the screwdriver tip before use. (b) Using a moulding remover, disengage the clip and 2 claws then remove the front pillar garnish LH. : Clip : Claw B56624 34. REMOVE FRONT PILLAR GARNISH RH (W/O CURTAIN SHIELD AIR BAG) HINT: Use the same procedures for the RH side and LH side. WhereEverybodyKnowsYourName 71−23 INSTRUMENT PANEL/METER − INSTRUMENT PANEL SAFETY PAD SUB−ASSY 35. REMOVE FRONT PILLAR GARNISH RH (W/ CURTAIN SHIELD AIR BAG) HINT: Use the same procedures for the RH side and LH side. 36. 12 mm (0.472 in.) REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB−ASSY NO.2 Using a screwdriver, disengage the 2 clips and 2 claws. (a) HINT: Tape the screwdriver tip before use. (b) Remove the instrument panel speaker panel sub−assy No.2. Clip Claw B56467 37. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB−ASSY HINT: Use the same procedures for the instrument panel speaker panel sub−assy and instrument panel speaker panel sub−assy No.2. 38. REMOVE FRONT NO.2 SPEAKER ASSY (SEE PAGE 67−9) 39. DISCONNECT PASSENGER AIRBAG CONNECTOR (SEE PAGE 60−37) 40. (a) REMOVE INSTRUMENT PANEL SAFETY PAD CAP Using a screwdriver, remove the instrument panel safety pad cap. HINT: Tape the screwdriver tip before use. B56462 WhereEverybodyKnowsYourName 71−24 INSTRUMENT PANEL/METER 41. (a) (b) (c) (d) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY REMOVE INSTRUMENT PANEL SAFETY PAD SUB−ASSY W/FRONT PASSENGER AIRBAG ASSY TMC made: Remove the 2 screws , nut and 5 bolts . TMMK made: Remove the 2 screws or , nut and 4 bolts . Disconnect the connectors. Disengage the 5 pins and remove the instrument panel safety pad sub−assy with front passenger airbag assy. TMC Made: Pin Pin B72062 TMMK Made: Pin or Pin B72063 WhereEverybodyKnowsYourName 71−25 INSTRUMENT PANEL/METER 42. (a) (b) 43. (a) (b) 44. (a) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 Disengage the 3 clips and 3 claws. Remove the instrument panel register assy No.2. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 Disengage the 3 clips and 3 claws. Remove the instrument panel register assy No.1. REMOVE GLOVE BOX LAMP ASSY Disengage the 4 claws and remove the glove box lamp assy. 45. (a) REMOVE AUTOMATIC LIGHT CONTROL SENSOR Using a screwdriver, remove the automatic light control sensor. HINT: Tape the screwdriver tip before use. B56371 46. REMOVE COOLER (SOLAR SENSOR) THERMISTOR (AUTO AIR CONDITIONING) (a) Remove the cooler (solar sensor) thermistor. NOTICE: Do not pry the cooler (solar sensor) thermistor off from the upper side. B51293 47. 48. (a) (b) 49. (a) (b) 50. (a) (b) REMOVE SPARE SWITCH HOLE COVER (MANUAL AIR CONDITIONING) REMOVE SIDE DEFROSTER NOZZLE DUCT NO.2 TMC made: Remove the screw and side defroster nozzle duct No.2. TMMK made: Remove the screw or and side defroster nozzle duct No.2. REMOVE SIDE DEFROSTER NOZZLE DUCT NO.1 TMC made: Remove the screw and side defroster nozzle duct No.1. TMMK made: Remove the screw or and side defroster nozzle duct No.1. REMOVE DEFROSTER NOZZLE ASSY TMC made: Remove the 5 screws and defroster nozzle assy. TMMK made: Remove the 5 screws or and defroster nozzle assy. WhereEverybodyKnowsYourName 71−26 INSTRUMENT PANEL/METER 51. (a) (b) 52. (a) (b) 53. (a) (b) 54. (a) 55. (a) (b) 56. 57. 58. (a) (b) (c) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY REMOVE HEATER TO REGISTER DUCT NO.1 TMC made: Remove the 2 screws and heater to register duct No.1. TMMK made: Remove the 2 screws or and heater to register duct No.1. REMOVE HEATER TO REGISTER DUCT NO.3 TMC made: Remove the 2 screws and heater to register duct No.3. TMMK made: Remove the 2 screws or and heater to register duct No.3. REMOVE HEATER TO REGISTER DUCT NO.2 TMC made: Remove the screw and heater to register duct No.2. TMMK made: Remove the screw or and heater to register duct No.2. REMOVE DEFROSTER NOZZLE GARNISH NO.1 Disengage the 5 clips and remove the defroster nozzle garnish No.1. REMOVE INSTRUMENT PANEL PIN NO.1 TMC made: Remove the 2 screws and 2 instrument panel pin No.1. TMMK made: Remove the 2 screws or and 2 instrument panel pin No.1. REMOVE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60−37) INSTALL FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60−37) INSTALL INSTRUMENT PANEL SAFETY PAD SUB−ASSY W/FRONT PASSENGER AIRBAG ASSY Engage the 5 pins. Connect the connectors. TMC made: Install the instrument panel safety pad sub−assy w/ front passenger aibag assy with the 2 screws , nut , and 5 bolts . Torque: Bolt : 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) WhereEverybodyKnowsYourName 71−27 INSTRUMENT PANEL/METER (d) − INSTRUMENT PANEL SAFETY PAD SUB−ASSY TMMK made: Install the instrument panel safety pad sub−assy w/ front passenger airbag assy with the 2 screws or , nut , and 4 bolts . Torque : Bolt : 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) TMC Made: Pin Pin B72062 TMMK Made: Pin or Pin B72063 WhereEverybodyKnowsYourName 71−28 INSTRUMENT PANEL/METER 59. (a) (b) : Clip : Claw − INSTRUMENT PANEL SAFETY PAD SUB−ASSY INSTALL FRONT PILLAR GARNISH LH (W/ CURTAIN SHIELD AIR BAG) Engage the 2 claws and clip. Install the front pillar garnish with the bolt. Torque: 7.5 to 20 N⋅m (77 to 204 kgf⋅cm, 67 in.⋅lbf to 14 ft⋅lbf) B56663 60. INSTALL FRONT PILLAR GARNISH RH (W/ CURTAIN SHIELD AIR BAG) HINT: Use the same procedures for the RH side and LH side. 61. CENTER SPIRAL CABLE (SEE PAGE 60−34) 62. INSTALL STEERING WHEEL ASSY (SEE PAGE 50−9 or 50−21) 63. INSTALL HORN BUTTON ASSY (SEE PAGE 60−25) 64. INSPECT HORN BUTTON ASSY (SEE PAGE 60−17) 65. INSPECT SRS WARNING LIGHT (SEE PAGE 05−1456) WhereEverybodyKnowsYourName 71−29 INSTRUMENT PANEL/METER − COMBINATION METER COMBINATION METER ASSY 7105J−03 OVERHAUL HINT:

1. COMPONENTS: See page 71−9. Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE PAGE 71−16) 2. (a) (b) REMOVE COMBINATION METER ASSY Remove the 2 screws and disengage the 2 clips. Disconnect the connectors and remove the combination meter assy. 3. (a) (b) (c) REMOVE COMBINATION METER GLASS Reverse the combination meter and remove the 2 screws. Remove the tape. Disengage the 7 claws and remove the combination meter glass. Clip B56834 Tape Claw B56758 WhereEverybodyKnowsYourName 71−3 INSTRUMENT PANEL/METER − COMBINATION METER 710P4−02 ON−VEHICLE INSPECTION 1. (a) INSPECT SPEEDOMETER Check the operation. (1) Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. USA (mph): Standard indication Allowable range 20 mph 20 to 23.0 mph 40 mph 40 to 43.5 mph 60 mph 60 to 64.0 mph 80 mph 80 to 84.5 mph 100 mph 100 to 105.0 mph 120 mph 120 to 125.5 mph CANADA (km/h): Standard indication Allowable range 20 km/h 17.5 to 21.5 km/h 40 km/h 38.0 to 42.0 km/h 60 km/h 58.0 to 63.0 km/h 80 km/h 78.0 to 84.0 km/h 100 km/h 98.5 to 104.5 km/h 120 km/h 119.0 to 125.0 km/h 140 km/h 139.0 to 146.0 km/h 160 km/h 159.0 to 167.0 km/h 180 km/h 179.0 to 188.0 km/h 200 km/h 199.0 to 209.0 km/h NOTICE: Tire wear and tire over or under inflation will cause the indication error. (2) Check the deflection range of the speedometer indicator. Reference: Below 0.5 km/h (0.3 mph) 2. (a) C7−36 I31247 INSPECT OUTPUT SIGNAL OF VEHICLE SPEED Check the input signal wave form. (1) Remove the combination meter with connectors still connected. (2) Connect the oscilloscope to terminal C7−36 and body ground. (3) Start the engine. (4) Check the signal wave form. OK: Signal wave form generates. HINT: A wave form as shown on the left appears if the voltage is 12 V under the following conditions: GND I42329 Item Condition Tool setting 5 V/DIV, 20 ms/DIV Vehicle condition Driving at approx. 20 km/h (12 mph) HINT: As vehicle speed increases, the cycle of the signal wave form narrows. WhereEverybodyKnowsYourName 71−4 INSTRUMENT PANEL/METER − COMBINATION METER 3. (a) INSPECT TACHOMETER Check the operation (1) Connect a tune−up test tachometer, and start the engine. NOTICE:
Reversing the connection of the tachometer will damage the transistors and diodes inside.
When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. (2) Compare the result of the test and tachometer indications. DC 13.5 V, 25C at (77F) 2AZ−FE: Allowable range (r/min) Data in ( ) are for reference Standard indication (r/min) 700 630 to 770 1,000 (900 to 1,100) 2,000 (1,850 to 2,150) 3,000 2,800 to 3,200 4,000 (3,800 to 4,200) 5,000 4,800 to 5,200 6,000 (6,750 to 6,250) 7,000 (6,700 to 7,000) 1MZ−FE, 3MZ−FE: Allowable range (r/min) Data in ( ) are for reference Standard indication (r/min) 700 618 to 758 1,000 (883 to 1,083) 2,000 (1,817 to 2,117) 3,000 2,750 to 3,150 4,000 (3,733 to 4,133) 5,000 4,717 to 5,117 6,000 (5,650 to 6,150) 7,000 (6,583 to 7,000) 4. (a) Fuel Sender Gauge: INSPECT FUEL RECEIVER GAUGE Inspect the circuit. (1) Disconnect the connector from the sender gauge. (2) Turn the ignition switch ON, then check the position of the receiver gauge needle. Standard: Needle position is EMPTY and FUEL warning light comes on. I30899 5. (a) INSPECT FUEL LEVEL WARNING Inspect the circuit. (1) Disconnect the connector from the sender gauge. (2) Turn the ignition switch to ON, and check the position of the fuel level needle and the FUEL level warning light. Standard: Needle position is EMPTY and FUEL warning light comes on. WhereEverybodyKnowsYourName 71−5 INSTRUMENT PANEL/METER 6. (a) 7. (a) 8. (a) 9. (a) (b) − COMBINATION METER INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE WARNING LIGHT Inspect the circuit. (1) Disconnect the connector from the sender gauge. (2) Turn the ignition switch to ON, and check the position of the water temperature receiver gauge needle. OK: Needle position: COOL (3) Ground terminal 2 on the wire harness side, then check the position of the water temperature receiver gauge needle. OK: Needle position: HOT INSPECT SEAT BELT WARNING LIGHT (Driver Side) Check the operation. (1) Turn the ignition switch to ON and check that the warning light lights up. (2) Fasten the outer belt to the inner belt and check that the warning light goes off. (3) Disconnect the connector from the buckle switch and ground terminal on the wire harness side connector. (4) Turn the ignition switch to ON and check the warning light. OK: Seat belt warning light: Come on INSPECT LOW OIL PRESSURE WARNING LIGHT Inspect the circuit. (1) Disconnect the connector from the low oil pressure switch. (2) Turn the ignition switch to ON. (3) Connect the terminal of wire harness side connector to ground, then check the warning low oil pressure warning light. OK: Low oil pressure warning light: Come on INSPECT BRAKE WARNING LIGHT Inspect the parking brake warning light. (1) Disconnect the connector from the parking brake switch and ground terminal on the wire harness side connector. (2) Turn the ignition switch to ON and check the warning light. OK: Brake warning light: Come on Inspect the brake fluid level warning light. (1) Disconnect the connector from the brake fluid level warning switch and connect terminals on the wire harness side connector. (2) Turn the ignition switch to ON and check the warning light. OK : Brake fluid level warning light: Come on WhereEverybodyKnowsYourName 71−6 INSTRUMENT PANEL/METER 10. (a) 11. (a) (b) 12. (a) 13. (a) (b) (c) − COMBINATION METER INSPECT BRAKE FLUID LEVEL WARNING SWITCH Inspect the continuity. (1) Remove the reservoir tank cap and strainer. (2) Disconnect the connector. (3) Check that the continuity exists between the terminals. OK: Float up (switch off): No continuity (4) Use a syphon, etc., to take fluid out of the reservoir tank. (5) Check that the continuity exists between the terminals. OK: Float down (switch on): Continuity (6) Pour the fluid back in the reservoir tank. INSPECT SEAT BELT WARNING BUZZER When only driver’s seat is occupied. (1) Turn the ignition switch to ON and check that the driver’s seat belt warning sounds if the driver’s seat belt is not fastened about 1.8 seconds after the ignition switch is turned to ON. (2) Check that the buzzer stops after about 6 seconds. When both driver’s seat and passenger’s seat are occupied (1) When either of the seat belts for the driver seat and front passenger seat is not fastened within 13.8 seconds after the ignition switch is turned to ON, the buzzer sounds for 9.6 seconds. (2) When the seat belt is still not fastened after that, the buzzer is switched to level 2 and sounds for 20 seconds. INSPECT KEY REMINDER WARNING BUZZER Check warning buzzer function. (1) Turn the ignition switch off and check that the key reminder warning sounds if the ignition key is inserted into the key cylinder and the front driver side door is opened. OK : Warning buzzer sounds INSPECT WASHER LEVEL WARNING SWITCH Disconnect the connector from the washer level warning switch. Turn the ignition switch to ON. Ground terminal of the wire harness side connector, then check the washer level warning light. OK: Washer level warning light comes on. WhereEverybodyKnowsYourName 71−7 INSTRUMENT PANEL/METER − COMBINATION METER 14. MAINTENANCE LIQUID RESETTING PROCEDURE Indicator Condition: State (a) (b) (c) (d) HINT:

Condition Specified state Blinking The vehicle runs 4,500
100 miles after the previous setting The indicator blinks for 15 seconds after the ignition switch is turned on (including 3 seconds for a valve check). Continuously Illuminated The vehicle runs 5,000
100 miles after the previous setting The indicator is continuously illuminated after the ignition switch is turned on. Set the display window to ODO. Turn the ignition switch off. While pressing the reset switch, turn the ignition switch to the ON position (keep pressing for at least 5 seconds). Reset procedure is completed. If the ignition switch is turned off during the reset procedure, reset mode is canceled. If the reset switch is turned off during the reset procedure, reset mode is canceled and the display shows the condition prior to the reset procedure. WhereEverybodyKnowsYourName 71−30 INSTRUMENT PANEL/METER − CLOCK ASSY CLOCK ASSY 7105K−03 REPLACEMENT HINT:

1. 2. 3. COMPONENTS: See page 71−9. Installation is in the reverse order of removal. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (AUTO AIR CONDITIONING) (SEE PAGE 71−16) REMOVE AIR CONDITIONING PANEL SUB−ASSY (MANUAL AIR CONDITIONING) (SEE PAGE 71−16) REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB−ASSY CENTER (SEE PAGE 71−16) 4. (a) (b) Claw REMOVE CLOCK ASSY Remove the 2 screws. Disengage the claw and remove the clock assy. B56465 WhereEverybodyKnowsYourName 71−8 INSTRUMENT PANEL/METER − COMBINATION METER 710PD−02 INSPECTION 1. (a) T RV TC Switch Tester connection (Symbol) Condition Turn the knob to maximum 1 (TC) − 4 (T) Below 1 Ω Conditions oher than the above 1 (TC) − 4 (T) 10 kΩ or higher I43773 (b) Resistance 10kΩ 0kΩ E58742 LIGHT CONTROL RHEOSTAT Inspect continuity. (1) Check the continuity between the light control rheostat connector terminals when operating the rheostat volume knob. Standard: Check the resistance between terminal 3 (RV) and terminal 4 (T) when operating the light control rheostat volume knob. Also, check that the resistance changes continuously. Standard: Turn the knob to maximum: Approx. 10 kΩ Turn the knob to minimum: Approx. 0 kΩ Dark Bright Rheostat Volume Knob I32117 WhereEverybodyKnowsYourName 71−9 INSTRUMENT PANEL/METER − INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 710P3−01 COMPONENTS TMC Made: Instrument Panel Sub−assy Lower Cowl Side Trim Sub−assy RH K Instrument Panel Insert Lower K L L K K E Front Door Scuff Plate RH Glove Compartment Door Pad L L Instrument Panel Sub−assy Upper K Instrument Panel Under Cover Sub−assy No.1 K E Combination Meter Assy Instrument Panel Coin Box Sub−assy Cowl Side Trim Sub−assy LH Combination Meter Glass Windshield Wiper Switch Assy Instrument Cluster Finish Panel Headlamp Dimmer Switch Assy Front Door Scuff Plate LH 3 Spoke Steering Wheel: 8.8 (90, 78 in.·lbf) 4 Spoke Steering Wheel: 8.8 (90, 78 in.·lbf) 50 (510, 37) 50 (510, 37) Horn Button Assy Steering Wheel Assy Steering Wheel Cover Lower No.3 N·m (kgf·cm, ft·lbf) Steering Column Cover Steering Wheel Assy Steering Wheel Cover Lower No.2 Steering Wheel Cover Lower No.3 : Specified torque WhereEverybodyKnowsYourName Horn Button Assy Steering Wheel Cover Lower No.2 B88046 71−10 INSTRUMENT PANEL/METER − INSTRUMENT PANEL/METER TMMK Made: Instrument Panel Sub−assy Lower Cowl Side Trim Sub−assy RH H Instrument Panel Insert Lower H A D Front Door Scuff Plate RH Glove Compartment Door Pad A A A H H Instrument Panel Sub−assy Upper H Instrument Panel Under Cover Sub−assy No.1 H D Combination Meter Assy Instrument Panel Coin Box Sub−assy Cowl Side Trim Sub−assy LH Combination Meter Glass Windshield Wiper Switch Assy Instrument Cluster Finish Panel Headlamp Dimmer Switch Assy Front Door Scuff Plate LH 3 Spoke Steering Wheel: 8.8 (90, 78 in.·lbf) 4 Spoke Steering Wheel: 8.8 (90, 78 in.·lbf) 50 (510, 37) 50 (510, 37) Horn Button Assy Steering Wheel Assy Steering Wheel Cover Lower No.3 N·m (kgf·cm, ft·lbf) Steering Column Cover Steering Wheel Assy Steering Wheel Cover Lower No.2 Steering Wheel Cover Lower No.3 Horn Button Assy Steering Wheel Cover Lower No.2 : Specified torque B88046 WhereEverybodyKnowsYourName 71−11 INSTRUMENT PANEL/METER TMC Made: w/o Curtain Shield Air Bag: Front Pillar Garnish LH − INSTRUMENT PANEL/METER w/o Curtain Shield Air Bag: Front Pillar Garnish RH w/ Curtain Shield Air Bag: Front Pillar Garnish LH w/ Curtain Shield Air Bag: Front Pillar Garnish RH 7.5 to 20 (77 to 204, 67 in.·lbf to 14) 7.5 to 20 (77 to 204, 67 in.·lbf to 14) Instrument Panel Speaker Panel Sub−assy No.2 Instrument Panel Speaker Panel Sub−assy No.1 Front No.2 Speaker Assy Instrument Panel Safety Pad Cap G A I Front No.2 Speaker Assy Clock Assy F F Instrument Cluster Finish Panel Sub−assy Center with Radio Receiver Assy A N 20 (204, 15) Instrument Panel Safety Pad Sub−assy A Manual Air Conditioning: Instrument Panel Finish Panel Lower Center K K M M Auto Air Conditioning: Air Conditioning Panel Sub−assy Console Box Front w/o Ash Tray: Air Conditioner Control Assembly w/ Ash Tray: Console Panel Sub−assy Console Panel Sub−assy Manual Transaxle: Shift Lever Knob Sub−assy Console Box Carpet Foot Parking Brake: I I I B B I B B Console Panel Upper Rear Instrument Panel Upper Rear RR Console Box N·m (kgf·cm, ft·lbf) RR Console Box : Specified torque WhereEverybodyKnowsYourName B86384 71−12 INSTRUMENT PANEL/METER − INSTRUMENT PANEL/METER TMMK Made: w/o Curtain Shield w/ Curtain Shield Air Bag: Air Bag: Front Pillar Front Pillar Garnish RH w/o Curtain Shield Garnish LH Air Bag: Front Pillar Garnish LH 7.5 to 20 (77 to 204, 67 in.·lbf to 14) w/ Curtain Shield Air Bag: Front Pillar Garnish RH 7.5 to 20 (77 to 204, 67 in.·lbf to 14) Instrument Panel Speaker Panel Sub−assy No.2 Front No.2 Speaker Assy Instrument Panel Speaker Panel Sub−assy No.1 H or J G A Front No.2 Speaker Assy Instrument Panel Safety Pad Cap Clock Assy F F Instrument Cluster Finish Panel Sub−assy Center with Radio Receiver Assy A M 20 (204, 15) Instrument Panel Safety Pad Sub−assy Manual Air Conditioning: Instrument Panel Finish Panel Lower Center H H M M Auto Air Conditioning: Air Conditioning Panel Sub−assy Console Box Front w/o Ash Tray: w/ Ash Tray: Console Panel Sub−assy Air Conditioner Control Assembly Console Panel Sub−assy Console Box Carpet Foot Parking Brake: H H C C Instrument Panel Upper Rear H H C C Console Panel Upper Rear RR Console Box RR Console Box N·m (kgf·cm, ft·lbf) : Specified torque WhereEverybodyKnowsYourName B86167 71−13 INSTRUMENT PANEL/METER − INSTRUMENT PANEL/METER TMC Made: Instrument Panel Pin No.1 I Side Defroster Nozzle Duct No.2 Instrument Panel Pin No.1 I I Defroster Nozzle Assy I I Side Defroster Nozzle Duct No.1 I Heater to Register Duct No.3 I I I I Heater to Register Duct No.2 I I Heater to Register Duct No.1 Front Passenger Airbag Assy I I Defroster Nozzle Garnish No.1 Automatic Light Control Sensor Cooler Solar (Solar Sensor) Thermistor Instrument Panel Safety Pad Sub−assy Instrument Panel Register Assy No.1 Glove Box Lamp Assy Instrument Panel Register Assy No.3 B86386 WhereEverybodyKnowsYourName 71−14 INSTRUMENT PANEL/METER − INSTRUMENT PANEL/METER TMMK Made: Instrument Panel Pin No.1 H or J Side Defroster Nozzle Duct No.2 Instrument Panel Pin No.1 H or J H or J Defroster Nozzle Assy H or J H or J Side Defroster Nozzle Duct No.1 H or J Heater to Register Duct No.3 H or J H or J H or J H or J Heater to Register Duct No.2 H or J H or J Heater to Register Duct No.1 Front Passenger Airbag Assy H or J H or J Defroster Nozzle Garnish No.1 Automatic Light Control Sensor Auto Air Conditioning: Cooler Solar (Solar Sensor) Thermistor Manual Air Conditioning: Spare Switch Hole Cover Instrument Panel Safety Pad Sub−assy Instrument Panel Register Assy No.1 Glove Box Lamp Assy Instrument Panel Register Assy No.3 B86145 WhereEverybodyKnowsYourName DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 30−1 DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 300M2−04 PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The causes of problem are listed in order of probability in the ”Suspected Area” column. Check each part in order. If necessary, replace these parts. Symptom Suspected Area 1. Wheel alignment Wander 2. Steering linkage (Loosen or worn) 3. Hub bearing (Worn) 4. Stabilizer bar 1. Wheel balance 2. Shock absorber 26−5 27−3 − 30−2 26−20 27−16 3. Ball joint (Worn) 4. Hub bearing (Worn) 28−1 26−11 27−4 26−19 30−2 Inboard joint or outboard joint (Worn) 30−8 Front wheel shimmy Noise See page WhereEverybodyKnowsYourName 30−2 DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 300M1−01 ON−VEHICLE INSPECTION 1. 2. 3. REMOVE FRONT WHEEL DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30−8) REMOVE FRONT DISC 4. (a) INSPECT FRONT AXLE HUB BEARING BACKLASH Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. NOTICE: Ensure that the dial indicator is set at a right angle to the measurement surface. F40163 5. (a) INSPECT FRONT AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the axle hub. NOTICE: Ensure that the dial indicator is set at a right angle to the measurement surface. F40164 6. 7. 8. 9. 10. 11. 12. INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30−8) INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) REMOVE REAR WHEEL DISCONNECT REAR DISC BRAKE CALIPER ASSY LH(DISC REAR BRAKE TYPE) (SEE PAGE 30−29) REMOVE REAR DISC(DISC REAR BRAKE TYPE) REMOVE REAR BRAKE DRUM SUB−ASSY(DRUM REAR BRAKE TYPE) 13. (a) C83015 INSPECT REAR AXLE HUB BEARING BACKLASH Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub assembly. NOTICE: Ensure that the dial indicator is set at a right angle to the measurement surface. WhereEverybodyKnowsYourName DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 14. (a) C83016 15. 16. 17. 18. 30−3 INSPECT REAR AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0027 in.) If the deviation exceeds the maximum, replace the axle hub assembly. NOTICE: Ensure that the dial indicator is set at a right angle to the measurement surface. INSTALL REAR DISC(DISC REAR BRAKE TYPE) INSTALL REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) (SEE PAGE 30−29) INSTALL REAR BRAKE DRUM SUB−ASSY(DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 30−23 DRIVE SHAFT / PROPELLER SHAFT − FRONT AXLE HUB SUB−ASSY LH (From July, 2003) FRONT AXLE HUB SUB−ASSY LH (From July, 2003) 300M4−03 REPLACEMENT HINT:


1. 2. 3. COMPONENTS: SEE PAGE 30−4 Use the same procedures for the RH side and LH side. The Procedures listed below are for the LH side. REMOVE FRONT WHEEL REMOVE FRONT AXLE HUB LH NUT (SEE PAGE 30−8) SST 09930−00010 DISCONNECT SPEED SENSOR FRONT LH (W/ ABS) (SEE PAGE 30−8) 4. (a) SEPARATE FRONT DISC BRAKE CALIPER ASSY LH Remove the 2 bolts and separate the front disc brake caliper assy LH from the steering knuckle LH. NOTICE: Use a string or other device to keep the brake caliper from hanging down by the flexible hose. C67088 5. 6. 7. REMOVE FRONT DISC SEPARATE TIE ROD ASSY LH (SEE PAGE 30−8) SST 09628−62011 SEPARATE FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (SEE PAGE 30−8) 8. (a) REMOVE FRONT AXLE ASSY LH Using a plastic hammer, separate the front drive shaft assy LH from the front axle hub sub−assy LH. NOTICE: Be careful not to damage the boot and speed sensor rotor. (w/ABS) D27403 (b) Remove the 2 bolts, nuts and steering knuckle LH with the front axle hub sub−assy LH. C83023 WhereEverybodyKnowsYourName 30−24 DRIVE SHAFT / PROPELLER SHAFT SST − FRONT AXLE HUB SUB−ASSY LH (From July, 2003) 9. (a) (b) REMOVE LOWER BALL JOINT ASSY FRONT LH Remove the cotter pin and nut. Using SST, remove the lower ball joint assy front LH. SST 09628−62011 10. REMOVE FRONT WHEEL BEARING DUST DEFLECTOR NO.1 LH Using a screwdriver, remove the bearing dust deflector No.1 LH. F40153 (a) F40154 C83852 11. (a) REMOVE FRONT AXLE HUB LH HOLE SNAP RING Using snap ring pliers, remove the front axle hub LH hole snap ring. 12. (a) REMOVE FRONT AXLE HUB SUB−ASSY LH Using SST, remove the front axle hub sub−assy LH. SST 09520−00031 (b) Using SST and a press, remove the bearing inner race (outside) from the front axle hub sub−assy LH. SST 09950−00020, 09950−60010 (09951−00410), 09950−70010 (09951−07100) F45465 SST F40156 SST F02261 WhereEverybodyKnowsYourName 30−25 DRIVE SHAFT / PROPELLER SHAFT 13. (a) − FRONT AXLE HUB SUB−ASSY LH (From July, 2003) REMOVE DISC BRAKE DUST COVER FRONT LH Using a torx wrench (T30), remove the 4 bolts and disc brake dust cover front LH. 14. (a) SST (b) REMOVE FRONT AXLE HUB LH BEARING Place the bearing inner race (outside) on the front axle hub LH bearing. Using SST and a press, press the front axle hub LH bearing until it contacts the SST. SST 09527−17011, 09950−60010 (09951−00600), 09950−70010 (09951−07100) SST F40230 (c) Using a spanner to make the steering knuckle LH horizontal, fix it to the V block, as shown in the illustration. NOTICE: Be sure the steering knuckle is horizontally positioned. (d) Using SST and a press, remove the front axle hub LH bearing. SST 09527−17011, 09950−60010 (09951−00600), 09950−70010 (09951−07100) SST Spanner V Block F11547 15. (a) SST INSTALL FRONT AXLE HUB LH BEARING Using SST and a press, install a new front axle hub LH bearing to the steering knuckle LH. SST 09950−60020 (09951−00790), 09950−70010 (09951−07100) F40231 16. (a) INSTALL DISC BRAKE DUST COVER FRONT LH Place the disc brake dust cover front LH and using a torx wrench (T30), torque the 4 bolts. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) 17. (a) SST INSTALL FRONT AXLE HUB SUB−ASSY LH Using SST and a press, install the front axle hub sub− assy LH. SST 09608−32010, 09950−60020 (09951−00790), 09950−70010 (09951−07100) SST F40157 WhereEverybodyKnowsYourName 30−26 DRIVE SHAFT / PROPELLER SHAFT C83852 FRONT AXLE HUB SUB−ASSY LH (From July, 2003) 18. (a) INSTALL FRONT AXLE HUB LH HOLE SNAP RING Using snap ring pliers, install a new front axle hub LH hole snap ring. 19. FRONT WHEEL BEARING DUST DEFLECTOR NO.1 LH Using SST and a hammer, install the bearing dust deflector No.1 LH. SST 09316−60011 (09316−00011, 09316−00031), 09608−32010 F45465 (a) SST C97690 − F45054 HINT: Align the hole for the speed sensor in the bearing dust deflector No.1 LH with the steering knuckle. 20. (a) INSTALL LOWER BALL JOINT ASSY FRONT LH Install the lower ball joint assy front LH and tighten the nut. Torque: 123 N⋅m (1,254 kgf⋅cm, 91 ft⋅lbf) (b) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, further tighten the nut up to 60. 21. (a) 22. 23. 24. INSTALL FRONT AXLE ASSY LH Install front axle assy LH with the 2 bolts and nuts to the shock absorber assy front LH. Torque: 210 N⋅m (2,141 kgf⋅cm, 155 ft⋅lbf) NOTICE:
Only when reusing the bolts and nuts, apply the small amount of engine oil to the screw part of the nuts.
Do not excessively push out the front axle assy LH.
Be careful not to damage the outboard joint boot. C83023
Be careful not to damage the speed sensor rotor. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH (SEE PAGE 30−8) INSTALL TIE ROD ASSY LH (SEE PAGE 30−8) INSTALL FRONT DISC WhereEverybodyKnowsYourName 30−27 DRIVE SHAFT / PROPELLER SHAFT 25. (a) − FRONT AXLE HUB SUB−ASSY LH (From July, 2003) INSTALL FRONT DISC BRAKE CALIPER ASSY LH Install the front disc brake caliper assy LH with the 2 bolts to the steering knuckle LH. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) C67088 26. (a) INSTALL FRONT AXLE HUB LH NUT Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 294 N⋅m (2,998 kgf⋅cm, 217 ft⋅lbf) 27. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (a) Remove the 2 bolts and separate the front disc brake caliper assy LH from the steering knuckle LH. NOTICE: Use a string or other device to keep the brake caliper from hanging down. 28. REMOVE FRONT DISC 29. INSPECT BEARING BACKLASH (SEE PAGE 30−2) 30. INSPECT AXLE HUB DEVIATION (SEE PAGE 30−2) 31. INSTALL FRONT DISC 32. INSTALL FRONT DISC BRAKE CALIPER ASSY LH (a) Install the front disc brake caliper assy LH with the 2 bolts to the steering knuckle LH. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) 33. INSTALL SPEED SENSOR FRONT LH (W/ ABS) (SEE PAGE 30−8) 34. (a) (b) INSTALL FRONT AXLE HUB LH NUT Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 294 N⋅m (2,998 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the axle hub LH nut. C68609 35. 36. 37. (a) (b) (c) INSTALL FRONT WHEEL INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26−5) CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) ABS WITH EBD SYSTEM (BOSCH MADE) (SEE PAGE 05−873) ABS WITH EBD SYSTEM (DENSO MADE) (SEE PAGE 05−933) ABS WITH EBD & BA & TRAC & VSC SYSTEM (SEE PAGE 05−990) WhereEverybodyKnowsYourName 30−28 DRIVE SHAFT / PROPELLER SHAFT − FRONT AXLE LH HUB BOLT FRONT AXLE LH HUB BOLT 30020−08 REPLACEMENT HINT:

1. 2. 3. COMPONENTS: SEE PAGE 30−4 Replace the RH side by the same procedures with LH side. REMOVE FRONT WHEEL DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH(SEE PAGE 30−8) REMOVE FRONT DISC 4. (a) REMOVE FRONT AXLE LH HUB BOLT Using SST and a screwdriver or an equivalent to hold, remove the front axle LH hub bolt. SST 09628−10011 5. (a) INSTALL FRONT AXLE LH HUB BOLT Install a washer and nut to a new front axle LH hub bolt as shown in the illustration. Using a screwdriver to hold, install the hub bolt by torquing the nut. SST F40170 (b) F40171 6. 7. 8. INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH(SEE PAGE 30−8) INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 30−29 DRIVE SHAFT / PROPELLER SHAFT − REAR AXLE HUB & BEARING ASSY LH REAR AXLE HUB & BEARING ASSY LH 3006I−05 REPLACEMENT HINT:

1. COMPONENTS: SEE PAGE 30−4 Replace the RH side by the same procedures with the LH side. REMOVE REAR WHEEL 2. (a) DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) Remove the bolt and disconnect the rear flexible hose. (b) (c) Remove the 2 bolts and rear disc brake caliper assy LH. Support the brake caliper assy LH securely. C83014 C83008 3. 4. 5. REMOVE REAR DISC (DISC REAR BRAKE TYPE) REMOVE REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) DISCONNECT SKID CONTROL SENSOR WIRE (W/ ABS) 6. (a) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and rear axle hub LH & bearing assy LH. C83035 WhereEverybodyKnowsYourName 30−30 DRIVE SHAFT / PROPELLER SHAFT 7. 8. − REAR AXLE HUB & BEARING ASSY LH REMOVE SKID CONTROL SENSOR (W/ ABS)(SEE PAGE 32−68) INSTALL SKID CONTROL SENSOR (W/ ABS)(SEE PAGE 32−68) 9. (a) INSTALL REAR AXLE HUB & BEARING ASSY LH Install the rear axle hub LH & bearing assy LH with the 4 bolts. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) C83035 10. INSTALL SKID CONTROL SENSOR WIRE (W/ ABS) 11. (a) INSPECT BEARING BACKLASH Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub assembly. C83015 12. (a) INSPECT AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the backlash exceeds the maximum, replace the axle hub assembly. C83016 13. INSTALL REAR DISC (DISC REAR BRAKE TYPE) WhereEverybodyKnowsYourName 30−31 DRIVE SHAFT / PROPELLER SHAFT 14. (a) − REAR AXLE HUB & BEARING ASSY LH INSTALL REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 62 N⋅m (630 kgf⋅cm, 46 ft⋅lbf) C83008 (b) Install the rear flexible hose with the bolt. Torque: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) C83014 15. 16. 17. 18. (a) (b) (c) INSTALL REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST REAR WHEEL ALIGNMENT(SEE PAGE 27−3) CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) ABS WITH EBD SYSTEM (BOSCH MADE) (SEE PAGE 05−873) ABS WITH EBD SYSTEM (DENSO MADE) (SEE PAGE 05−933) ABS WITH EBD & BA & TRAC & VSC SYSTEM (SEE PAGE 05−990) WhereEverybodyKnowsYourName 30−32 DRIVE SHAFT / PROPELLER SHAFT − REAR AXLE LH HUB BOLT REAR AXLE LH HUB BOLT 30024−06 REPLACEMENT HINT:

1. 2. 3. 4. COMPONENTS: SEE PAGE 30−4 Replace the RH side by the same procedures with the LH side. REMOVE REAR WHEEL REMOVE REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) (SEE PAGE 30−29) REMOVE REAR DISC (DISC REAR BRAKE TYPE) REMOVE REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) SST 5. (a) REMOVE REAR AXLE LH HUB BOLT Using SST and a screwdriver or an equivalent to hold, remove the rear axle LH hub bolt. SST 09628−10011 6. (a) INSTALL REAR AXLE LH HUB BOLT Install a washer and nut to a new rear axle LH hub bolt as shown in the illustration. Using a screwdriver to hold, install the rear axle LH hub bolt by torquing the nut. C83020 (b) C83021 7. 8. 9. 10. INSTALL REAR DISC (DISC REAR BRAKE TYPE) INSTALL REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) (SEE PAGE 30−29) INSTALL REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) WhereEverybodyKnowsYourName 30−33 DRIVE SHAFT / PROPELLER SHAFT − REAR AXLE CARRIER SUB−ASSY LH REAR AXLE CARRIER SUB−ASSY LH 3006J−07 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. (a) 8. COMPONENTS: SEE PAGE 30−4 Replace the RH side by the same procedures with the LH side. REMOVE REAR WHEEL REMOVE STRUT ROD ASSY REAR(SEE PAGE 27−18) DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) (SEE PAGE 30−29) REMOVE REAR DISC (DISC REAR BRAKE TYPE) REMOVE REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) DISCONNECT SKID CONTROL SENSOR WIRE (W/ ABS) DISCONNECT REAR BRAKE TUBE NO.4 (DRUM REAR BRAKE TYPE) Using SST, disconnect the rear brake tube No.4 from the LH front or upper rear wheel brake cylinder assy. SST 09023−00101 REMOVE REAR AXLE HUB & BEARING ASSY LH(SEE PAGE 30−29) 9. (a) DISCONNECT REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt, nut and rear suspension arm assy No.2 LH from the rear axle carrier sub−assy LH. HINT: While fixing the nut, turn and remove the bolt. C83017 10. (a) DISCONNECT REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt, nut and rear suspension arm assy No.1 LH from the rear axle carrier sub−assy LH. HINT: While fixing the nut, turn and remove the bolt. C83018 11. (a) REMOVE REAR AXLE CARRIER SUB−ASSY LH Remove the 2 bolts, nuts and rear axle carrier sub−assy LH from the shock absorber assy rear LH. NOTICE: When removing bolt, stop the bolt from rotating and loosen the nut. C83019 WhereEverybodyKnowsYourName 30−34 DRIVE SHAFT / PROPELLER SHAFT − REAR AXLE CARRIER SUB−ASSY LH 12. (a) C83019 INSTALL REAR AXLE CARRIER SUB−ASSY LH Install the rear axle carrier sub−assy LH with the 2 bolts and nuts. Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf) NOTICE: When installing bolt, stop the bolt from rotating and torque the nut. HINT: Insert the bolt from the rear side of the vehicle and install the nut. 13. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Install the rear suspension arm No.1 to the rear axle carrier sub−assy LH with the bolt and nut, temporarily tighten the bolt. HINT: Insert the bolt from the front side of the vehicle and while fixing the nut, turn and install the bolt. C83018 14. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Install the rear suspension arm No.2 to the rear axle carrier sub−assy LH with the bolt and nut, temporarily tighten the bolt. HINT: Insert the bolt from the rear side of the vehicle and while fixing the nut, turn and install the bolt. C83017 15. 16. (a) 17. 18. 19. 20. 21. 22. 23. 24. 25. INSTALL REAR AXLE HUB & BEARING ASSY LH(SEE PAGE 30−29) INSTALL REAR BRAKE TUBE NO.4 (DRUM REAR BRAKE TYPE) Using SST, install the rear brake tube No.4 to the LH front or upper rear wheel brake cylinder assy. Torque: 15 N⋅m (155 kgf⋅cm,11 ft⋅lbf) SST 09023−00101 INSTALL SKID CONTROL SENSOR WIRE (W/ ABS) INSTALL REAR DISC (DISC REAR BRAKE TYPE) INSTALL REAR DISC BRAKE CALIPER ASSY LH (DISC REAR BRAKE TYPE) (SEE PAGE 30−29) INSTALL REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE) TEMPORARILY TIGHTEN STRUT ROD ASSY REAR(SEE PAGE 27−18) STABILIZE SUSPENSION(SEE PAGE 27−18) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH(SEE PAGE 27−10) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH(SEE PAGE 27−14) FULLY TIGHTEN STRUT ROD ASSY REAR(SEE PAGE 27−18) WhereEverybodyKnowsYourName 30−35 DRIVE SHAFT / PROPELLER SHAFT 26. 27. 28. 29. 30. 31. 32. 33. (a) (b) (c) − REAR AXLE CARRIER SUB−ASSY LH FILL RESERVOIR WITH BRAKE FLUID (DRUM REAR BRAKE TYPE) BLEED MASTER CYLINDER (DRUM REAR BRAKE TYPE)(SEE PAGE 32−4) SST 09023−00101 BLEED BRAKE LINE (DRUM REAR BRAKE TYPE) CHECK FLUID LEVEL IN RESERVOIR (DRUM REAR BRAKE TYPE) CHECK BRAKE FLUID LEAKAGE (DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST REAR WHEEL ALIGNMENT(SEE PAGE 27−3) CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) ABS WITH EBD SYSTEM (BOSCH MADE) (SEE PAGE 05−873) ABS WITH EBD SYSTEM (DENSO MADE) (SEE PAGE 05−933) ABS WITH EBD & BA & TRAC & VSC SYSTEM (SEE PAGE 05−990) WhereEverybodyKnowsYourName 30−4 DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 300M0−01 COMPONENTS Front Drive Shaft Assy RH Drive Shaft Bearing Bracket Hole Snap Ring Front Drive Shaft Assy LH
32 (330, 24) Tie Rod Assy LH w/ ABS: Speed Sensor Front LH Front Stabilizer Link Assy LH 19 (192, 13) 8.0 (82, 71 in.⋅lbf) 74 (755, 55) Front Flexible Hose No. 1 Front Axle Assy LH
Front Suspension Arm Sub−assy Lower No.1 LH 294 (2,998, 217) 49 (500, 36)
Cotter Pin N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part 75 (765, 55) WhereEverybodyKnowsYourName C91583 DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 30−5 w/o ABS: Front Drive Outboard Joint Shaft Assy RH
Front Wheel Bearing Dust Deflector RH No.2
Front Axle Outboard Joint Boot RH No.2 Clamp
Front Axle Outboard Joint Boot RH Clamp
Outboard Joint Boot LH Side: Except MT RH Side: Except 1MZ−FE
Front Drive Shaft Damper RH Front Drive Inboard Joint Assy RH
Front Drive Inner Shaft Inner RH Shaft Snap Ring LH:
Front Drive Shaft Damper RH Clamp
Front Axle Inboard Joint Boot
Front Axle Inboard Joint Boot RH No.2 Clamp
Front Axle Inboard Joint Boot RH Clamp
Front Drive Shaft Bearing
Front Drive Shaft Hole Snap Ring RH
Front Drive Shaft Dust Cover LH
Front Drive Shaft Dust Cover
Front Drive Shaft Dust Cover RH Front Drive Inboard Joint Assy LH
Non−reusable part
Front Drive Shaft LH Hole Snap Ring F46966 WhereEverybodyKnowsYourName 30−6 DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) Shock Absorber Assy Front LH Tie Rod Assy LH 210 (2,141, 155) w/ ABS: Speed Sensor Front LH Front Drive Shaft Assy LH 107 (1,090, 79) 8.0 (82, 71 in.⋅lbf) Front Axle Assy LH Front Disc Front Suspension Arm Sub−assy Lower No.1 LH 75 (765, 55) 49 (500, 36)
Front Axle LH Hub Bolt
Cotter Pin
Front Axle Hub LH Hole Snap Ring
Front Wheel Bearing Dust Deflector No.1 LH
294 (2,998, 217) Steering Knuckle LH
Front Axle Hub LH Bearing Disc Brake Dust Cover Front LH
Cotter Pin 123 (1,254, 91) 8.3 (85, 73 in.⋅lbf) Lower Ball Joint Assy LH 8.3 (85, 73 in.⋅lbf) Front Axle Hub Sub−assy LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part G29148 WhereEverybodyKnowsYourName DRIVE SHAFT / PROPELLER SHAFT − DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July, 2003) 30−7 Shock Absorber Assy Rear LH Rear Suspension Arm Assy No.2 LH 255 (2,600, 188) 100 (1,020, 74) Rear Suspension Arm Assy No.1 LH 62 (630, 46) Rear Axle Carrier Sub−assy LH Rear Disc Brake Caliper Assy LH 19 (192, 14) 100 (1,020, 74) 62 (630, 46) REAR DRUM BRAKE: 113 (1,152, 83) 113 (1,152, 83) Parking Brake Assy Strut Rod Assy Rear 80 (816, 59) 5.4 (55, 48 in.⋅lbf) Rear Disc Rear Axle Hub & Bearing Assy LH 5.4 (55, 48 in.⋅lbf) X5 REAR DRUM BRAKE: 80 (816, 59)
Rear Axle LH Hub Bolt Rear Brake Drum Sub−assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName C91593 30−8 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) FRONT DRIVE SHAFT (From July, 2003) 300M3−02 OVERHAUL HINT:


1. 2. 3. COMPONENTS: SEE PAGE 30−4 Use the same procedures for the RH side and LH side. The Procedures listed below are for the LH side. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (SEE PAGE 40−37) DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (SEE PAGE 41−3) REMOVE FRONT WHEEL 4. (a) SST F40146 REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, unstake the staked part of the axle hub LH nut. SST 09930−00010 NOTICE: Loosen the staked part of the lock nut completely, otherwise the screw of the drive shaft may be damaged. (b) While applying the brakes, remove the front axle hub LH nut. 5. DISCONNECT FRONT STABILIZER LINK ASSY LH (a) Remove the nut, and separate the stabilizer link assy LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40136 6. (a) DISCONNECT SPEED SENSOR FRONT LH (W/ ABS) Remove the bolt and clip, and separate the sensor wire and hose from the shock absorber. NOTICE: Be careful not to damage the speed sensor. C83022 WhereEverybodyKnowsYourName 30−9 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) (b) Remove the bolt, and separate the speed sensor front LH from the steering knuckle. NOTICE: Prevent foreign matter from adhering to the speed sensor. F40147 SST 7. (a) (b) DISCONNECT TIE ROD ASSY LH Remove the cotter pin and nut. Using SST, separate the tie rod end from the steering knuckle. SST 09628−62011 8. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and disconnect the front suspension arm sub−assy lower No.1 LH from the lower ball joint. C92142 (a) F40142 9. (a) DISCONNECT FRONT AXLE ASSY LH Using a plastic hammer, separate the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and speed sensor rotor. (w/ABS) D27403 10. (a) REMOVE FRONT DRIVE SHAFT ASSY LH Using SST, remove the front drive shaft assy LH. SST 09520−01010, 09520−24010 (09520−32040) NOTICE:
Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
Be careful not to drop the drive shaft assy. SST C83850 WhereEverybodyKnowsYourName 30−10 DRIVE SHAFT / PROPELLER SHAFT 11. (a) (b) − FRONT DRIVE SHAFT (From July, 2003) REMOVE FRONT DRIVE SHAFT ASSY RH Using pliers, remove the drive shaft bearing bracket hole snap ring. Remove the bolt and front drive shaft assy RH from the drive shaft bearing bracket. C66549 12. FIX FRONT AXLE ASSY LH SST 09608−16042 (09608−02021, 09608−02041) NOTICE: The hub bearing could be damaged if it is subjected to the vehicle’s full weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST. SST C92143 13. (a) (b) (c) (d) INSPECT FRONT DRIVE SHAFT ASSY LH Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. C91598 14. Omega Type: (a) REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP Using pliers, remove the inboard joint boot LH No.2 clamp, as shown in the illustration. Claw Engagement Type: C86265 F07391 F45953 WhereEverybodyKnowsYourName 30−11 DRIVE SHAFT / PROPELLER SHAFT 15. (a) − FRONT DRIVE SHAFT (From July, 2003) REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP Remove the inboard joint boot LH clamp using the same procedures as for the inboard joint boot LH clamp. C98688 16. (a) DISCONNECT FR AXLE INBOARD JOINT BOOT Separate the inboard joint boot from the inboard joint assy. 17. (a) REMOVE FRONT DRIVE INBOARD JOINT ASSY LH Put matchmarks on the inboard joint assy and outboard joint shaft. NOTICE: Do not use a punch for the marks. (b) Remove the inboard joint assy from the outboard joint shaft. Matchmarks C91600 (c) Using a snap ring expander, remove the front drive inner shaft inner RH shaft snap ring. F45046 C67414 (d) Matchmarks N00194 Put matchmarks on the outboard joint shaft and tripod joint. NOTICE: Do not use a punch for the marks. (e) Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft. NOTICE: Do not tap the roller. HINT: This procedure is unnecessary for a manual transaxle vehicle because it does not have a drive shaft damper. WhereEverybodyKnowsYourName 30−12 DRIVE SHAFT / PROPELLER SHAFT 18. (a) (b) 19. (a) F44759 (b) 20. (a) − FRONT DRIVE SHAFT (From July, 2003) REMOVE FRONT DRIVE SHAFT DAMPER LH (EXCEPT MANUAL TRANSAXLE) Using pliers, remove the drive shaft damper clamp, as shown in the illustration. Remove the drive shaft damper. REMOVE FRONT DRIVE SHAFT DAMPER RH (EXCEPT 1MZ−FE ENGINE TYPE) Using pliers, remove the drive shaft damper clamp, as shown in the illustration. Remove the drive shaft damper. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP Using pliers, remove the outboard joint boot LH No.2 clamp, as shown in the illustration. C81167 21. (a) REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP Remove the outboard joint boot LH clamp using the same procedures as for the outboard joint boot LH No.2 clamp. C98688 22. (a) (b) REMOVE OUTBOARD JOINT BOOT Remove the outboard joint boot from the outboard joint shaft. Remove the old grease from the outboard joint. 23. (a) (b) REMOVE FRONT WHEEL BEARING DUST DEFLECTOR LH NO.2 (W/O ABS) Mount the front drive outboard joint shaft assy LH in a soft jaw vise. Using a screwdriver and a hammer, remove the front wheel bearing dust deflector LH No.2. C91603 WhereEverybodyKnowsYourName 30−13 DRIVE SHAFT / PROPELLER SHAFT 24. (a) − FRONT DRIVE SHAFT (From July, 2003) REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING Using a screwdriver, remove the hole snap ring. C57543 25. (a) REMOVE FRONT DRIVE SHAFT DUST COVER LH Using SST and a press, remove the front drive shaft dust cover LH. SST 09950−00020 NOTICE: Be careful not to drop the inboard joint assy. SST F40647 26. (a) REMOVE FRONT DRIVE SHAFT DUST COVER RH Using a press, remove the front drive shaft dust cover RH. 27. (a) REMOVE FRONT DRIVE SHAFT DUST COVER Using SST and a press, remove the front drive shaft dust cover. SST 09950−00020 28. (a) REMOVE FRONT DRIVE SHAFT BEARING Using snap ring pliers, remove the front drive shaft hole snap ring RH. C67101 SST F40648 C53236 F40209 WhereEverybodyKnowsYourName 30−14 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) (b) Using SST and a press, remove the bearing. SST 09527−10011 NOTICE: Be careful not to drop the inboard joint assy. C68339 SST F40210 29. (a) Steel Plate SST C66790 INSTALL FRONT DRIVE SHAFT BEARING Using SST and a steel plate, install a new front drive shaft bearing. SST 09527−30010, 09527−10011 NOTICE: Bearing should be completely installed. C92032 (b) C66605 Using a snap ring expander, install a new front drive shaft hole snap ring RH. C92033 30. (a) INSTALL FRONT DRIVE SHAFT DUST COVER Using SST and a press, install a new drive shaft dust cover. SST 09726−40010 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. SST C91253 F46405 WhereEverybodyKnowsYourName 30−15 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) 31. (a) SST (A) C92422 INSTALL FRONT DRIVE SHAFT DUST COVER RH Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration. SST 09527−10011 Distance (A): 1MZ−FE, 3MZ−FE: 110.5
0.5 mm (4.3
0.02 in.) 2AZ−FE: 91.5
0.5 mm (3.6
0.02 in.) NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. 32. (a) INSTALL FRONT DRIVE SHAFT DUST COVER LH Using SST and a press, install a new front drive shaft dust cover LH. SST 09527−10011 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. SST F41033 33. (a) INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING Install a new front drive shaft LH hole snap ring. 34. SST (a) C91588 INSTALL FRONT WHEEL BEARING DUST DEFLECTOR LH NO.2 (W/O ABS) Using SST and a press, install a new front wheel bearing dust deflector LH No.2 until the distance from the tip of front drive outboard joint shaft assy LH to the front wheel bearing dust deflector LH No.2 reaches the specification, as shown in the illustration. SST 09387−00020 Distance: 13.5 − 13.8 mm (0.531 − 0.543 in.) WhereEverybodyKnowsYourName 30−16 DRIVE SHAFT / PROPELLER SHAFT Vinyl Tape W01994 FRONT DRIVE SHAFT (From July, 2003) 35. INSTALL OUTBOARD JOINT BOOT HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged. (a) Hold the drive shaft lightly in a soft vise. (b) Temporarily install a new outboard joint boot with 2 clamps to the drive shaft. (c) Pack the outboard joint shaft and boot with grease. Grease capacity: Drive type Grease capacity 2AZ−FE (AT) 100 to 120 g (3.5 to 4.2 oz.) 2AZ−FE (MT) 105 to 125 g (3.7 to 4.4 oz.) 1MZ−FE 3MZ−FE 195 to 225 g (6.9 to 7.9 oz.) 36. Hold SST Turn − R10425 INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP (a) Install the 2 outboard joint boot clamps onto the boot. (b) Place SST onto the outboard joint boot LH No.2 clamp. SST 09521−24010 (c) Tighten the SST so that the outboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. (d) SST R10426 Using SST, measure the clearance of the outboard joint boot LH No.2 clamp. SST 09240−00020 Clearance: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTICE: When the measured value is greater than the specified value, retighten the clamp. 37. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP (a) The procedure for the outboard joint boot LH clamp is the same as above. SST 09521−24010, 09240−00020 Clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.) 38. (a) (b) (c) 207.0
2.0 mm (8.15
0.079 in.) F40646 INSTALL FRONT DRIVE SHAFT DAMPER LH (EXCEPT MANUAL TRANSAXLE) Install the drive shaft damper LH to the drive shaft. Make sure that the damper is on the shaft groove. Set the distance, as described below. Distance: 207
2.0 mm (8.15
0.079 in.) HINT: This procedure is unnecessary for a manual transaxle vehicle because it does not have a drive shaft damper. WhereEverybodyKnowsYourName 30−17 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) (d) Hold Place SST onto the front drive shaft damper LH clamp. SST 09521−24010 (e) Tighten the SST so that the front drive shaft damper LH clamp is pinched. NOTICE: Do not overtighten the SST. Turn SST C91604 (f) Using SST, measure the clearance of the drive shaft damper clamp. SST 09240−00020 Clearance: 0.5 to 1.2 mm (0.020 to 0.047 in.) NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST C86268 39. (a) (b) (c) INSTALL FRONT DRIVE SHAFT DAMPER RH (EXCEPT 1MZ−FE ENGINE TYPE) Install the drive shaft damper RH to the drive shaft. Make sure that the damper is on the shaft groove. Set the distance, as described below. Distance: 207
2.0 mm (8.15
0.079 in.) 207.0
2.0 mm (8.15
0.079 in.) F40646 (d) Hold Place SST onto the front drive shaft damper RH clamp. SST 09521−24010 (e) Tighten the SST so that the front drive shaft damper RH clamp is pinched. NOTICE: Do not overtighten the SST. Turn SST C91604 (f) Using SST, measure the clearance of the outboard joint boot RH No.2 clamp. SST 09240−00020 Clearance: 0.5 to 1.2 mm (0.020 to 0.047 in.) NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST R10426 WhereEverybodyKnowsYourName 30−18 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) 40. (a) Matchmarks C67417 INSTALL FRONT DRIVE INBOARD JOINT ASSY LH Temporarily install a new inboard joint boot with 2 clamps to the drive shaft. (b) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft. (c) Align the matchmarks. (d) Using a brass bar and a hammer, tap in the tripod joint to the outboard joint shaft. NOTICE:
Do not tap the roller.
Be sure to install the tripod joint assy in the correct direction. (e) (f) C67414 Using a snap ring expander, install a new shaft snap ring. Pack the outboard joint shaft and boot with grease. Grease capacity: 2AZ−FE 170 to 190 g (6.0 to 6.7 oz.) 1MZ−FE 3MZ−FE 155 to 175 g (5.5 to 6.2 oz.) F45046 (g) Matchmarks Align the matchmarks and install the inboard joint assy to the outboard joint shaft assy. F40222 41. (a) INSTALL FR AXLE INBOARD JOINT BOOT Install the inboard joint boot to the inboard joint assy. 42. (a) INSTALL FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP Claw Engagement (1) Using pliers, install the inboard joint boot LH No.2 clamp, as shown in the illustration. F07391 WhereEverybodyKnowsYourName 30−19 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) (b) SST C86269 Omega Clamp Type: Install new inboard joint boot clamps. (1) Hold the drive shaft lightly in a soft vise. (2) Install 2 new inboard joint boot clamps to the boot. (3) Place SST onto the inboard joint boot LH No.2 clamp. SST 09521−24010 (4) Tighten the SST so that the inboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. (5) Using SST, measure the clearance of the inboard joint boot LH No.2 clamp. SST 09240−00020 Clearance: 1.9 mm (0.075 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST C86270 Hold Turn C99983 G28614 43. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP (a) Install new inboard joint boot clamps. (1) Hold the drive shaft lightly in a soft vise. (2) Install 2 new inboard joint boot clamps to the boot. (3) Place SST onto the inboard joint boot LH clamp. SST 09521−24010, 09240−00020 (4) Tighten the SST so that the inboard joint boot LH clamp is pinched. NOTICE: Do not overtighten the SST. (5) Using SST, measure the clearance of the inboard joint boot LH clamp. SST 09240−00020 Clearance: 1.9 mm (0.075 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST G21598 F46443 WhereEverybodyKnowsYourName 30−20 DRIVE SHAFT / PROPELLER SHAFT 44. (a) (b) (c) (d) − FRONT DRIVE SHAFT (From July, 2003) INSPECT FRONT DRIVE SHAFT Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. C91598 (e) (f) Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: mm (in.) 1MZ−FE, 3MZ−FE: Standard Length LH 580.76
2.0 (22.864
0.079) RH 898.0
2.0 (35.354
0.079) 2AZ−FE: R00764 LH 591.2
2.0 (23.276
0.079) RH 890
2.0 (35.039
0.079) 45. (a) (b) C83851 INSTALL FRONT DRIVE SHAFT ASSY LH Coat the spline of the inboard joint shaft assy with ATF. Align the shaft splines and install the drive shaft assy with a brass bar and a hammer. NOTICE:
Set the snap ring with the opening side facing downward.
Be careful not to damage the oil seal boot and dust cover.
Move the drive shaft assy while keeping it level. 46. (a) INSTALL FRONT DRIVE SHAFT ASSY RH Using a screwdriver, install a new bearing bracket hole snap ring. NOTICE: Do not damage the oil seal and boot. (b) Install the bolt. Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf) C66548 WhereEverybodyKnowsYourName 30−21 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) 47. INSTALL FRONT AXLE ASSY LH (a) Install the front drive shaft assy LH to the front axle assy LH. NOTICE:
Be careful not to damage the outboard joint boot.
w/ ABS: Be careful not to damage the speed sensor rotor. 48. (a) INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER NO.1 LH Install the lower ball joint to the front suspension arm sub− assy lower with the bolt and nuts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) F40142 49. (a) INSTALL TIE ROD ASSY LH Install the tie rod end to the steering knuckle with the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, further tighten the nut up to 60. 50. (a) C83022 INSTALL SPEED SENSOR FRONT LH (W/ ABS) Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on knuckle. Torque: 19 N⋅m (192 kgf⋅cm, 13 ft⋅lbf) NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor.
Do not twist the sensor wire when installing the speed sensor. WhereEverybodyKnowsYourName 30−22 DRIVE SHAFT / PROPELLER SHAFT − FRONT DRIVE SHAFT (From July, 2003) (b) Install the speed sensor to the steering knuckle with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Prevent foreign matter from adhering to the speed sensor. F40147 51. (a) INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. Hold Turn F40136 52. (a) (b) INSTALL FRONT AXLE HUB LH NUT Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 294 N⋅m (2,998 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the front axle hub LH nut. F40152 53. 54. 55. 56. 57. 58. 59. (a) (b) (c) INSTALL FRONT WHEEL ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) INSPECT AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (SEE PAGE 40−2) ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (SEE PAGE 41−3) INSPECT MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (SEE PAGE 41−2) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26−5) CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) ABS WITH EBD SYSTEM (BOSCH MADE) (SEE PAGE 05−873) ABS WITH EBD SYSTEM (DENSO MADE) (SEE PAGE 05−933) ABS WITH EBD & BA & TRAC & VSC SYSTEM (SEE PAGE 05−990) WhereEverybodyKnowsYourName 75−1 ENGINE HOOD/DOOR − HOOD HOOD 75094−02 ADJUSTMENT HINT: Since the centering bolt is used as a hood hinge and as a hood lock set bolt, the hood and hood lock can not be adjusted with it on. Substitute a bolt with washer for the centering bolt. Centering Bolt Standard Bolt B57104 1. (a) INSPECT HOOD SUB−ASSY Check that the clearance is within the standard value. Standard 4 (0.16)
1.5 (0.059) 4.9 (0.193)
1.5 (0.059) 0
1.5 (0.059) 8 (0.31)
1.5 (0.059) mm (in.) 2. (a) (b) (c) B56577 ADJUST HOOD SUB−ASSY Loosen the hood side hinge bolts. Adjust the clearance so that it will be in the standard value, by moving the hood. Tighten the hood side hinge bolts after adjustment. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B57103 WhereEverybodyKnowsYourName 75−2 ENGINE HOOD/DOOR (d) − HOOD Adjust the height of the hood front end by the cushion gum. HINT: The cushion gum goes up and down by turning it. B55933 (e) Clip Using a screwdriver, remove the hood lock release lever cover. HINT: Tape the screwdriver tip before use. NOTICE: Removing the protector damages the clips inside the protector, and therefore the use of a new protector is necessary on installation. Clip B55991 (f) (g) Adjust the hood lock position so that the striker will come in, by moving the striker. Tighten the hood side hinge bolts after adjustment. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 ft⋅lbf) B55938 WhereEverybodyKnowsYourName 75−13 ENGINE HOOD/DOOR − REAR DOOR REAR DOOR 7509A−03 COMPONENTS Rear Door Quarter Window Glass Rear Door Glass Sub−assy Rear Door Quarter Window Weatherstrip Rear Door Outside Handle Assy Rear Door Outside Handle Cover Rear Door Glass Run Rear Door Outside Handle Frame Sub−assy 5.5 (56, 49 in.⋅lbf) Rear Door w/ Motor Lock Assy Rear Door Weatherstrip
Rear Door Window Division Bar Sub−assy 5.0 (51, 44 in.⋅lbf)  Rear Door Window Regulator Sub−assy Rear Door Belt Moulding Assy 5.4 (55, 48 in.⋅lbf) Rear Door Lower Frame Plate Rear Door Glass Weatherstrip Inner Adhesive 8.0 (82, 71 in.⋅lbf) Power Window Regulator Motor Assy  Rear Door Service Hole Cover Power Window Regulator Switch Assy Rear Door Inside Handle Bezel Plug Rear Door Inside Handle N⋅m (kgf⋅cm ft⋅lbf) : Specified torque  Non−reusable part
Precoated part WhereEverybodyKnowsYourName Rear Door Trim Board Sub−assy B56616 75−14 ENGINE HOOD/DOOR − REAR DOOR 7509B−02 ADJUSTMENT HINT:
The installation is in the reverse orderof the removal. However, when there is a special point concerning the installation, it is indicated. On the LH side, use the same procedures as on the RH side.
HINT: Since the centering bolt is used as a door hinge set bolt, the door can not be adjusted with it on. Substitute a bolt with washer for the centering bolt. Centering Bolt Standard Bolt B50717 1. (a) INSPECT REAR DOOR PANEL SUB−ASSY LH Check that the clearance is within the standard value. Standerd 5.6 (0.220)
1.5 (0.059) 5.1 (0.201)
1.5 (0.059) 0
1.5 (0.059) 4.6 (0.181)
1.5 (0.059) 0
1.5 (0.059) mm (in.) 2. 3. 4. 5. 6. REMOVE FRONT DOOR SCUFF PLATE LH(See page 76−22) REMOVE REAR DOOR SCUFF PLATE LH(See page 76−22) REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH(See page 76−22) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH(See page 76−22) REMOVE CENTER PILLAR GARNISH LOWER LH(See page 76−22) WhereEverybodyKnowsYourName B56579 75−15 ENGINE HOOD/DOOR 7. (a) (b) − REAR DOOR ADJUST REAR DOOR PANEL SUB−ASSY LH Adjust the door by loosening the body side hinge nuts and bolts. Forward / rearward and vertically. Tighten the bolts after adjustment. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B51156 (c) (d) Adjust the door by loosening the door side hinge bolts. Horizontally and vertically. Tighten the bolts after adjustment. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B30609 (e) (f) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer. Tighten the striker mounting screws after adjustment. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) B55940 WhereEverybodyKnowsYourName 75−16 ENGINE HOOD/DOOR − REAR DOOR 7509C−04 OVERHAUL HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the LH side, use the same procedures as on the RH side. 1. Clip (a) (b) (c) REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR Remove the armrest base cover lower. Remove the screw. Using a screwdriver, remove the regulator switch then disconnect the connector. HINT: Tape the screwdriver tip before use. Clip B56617 2. Clip REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH Using a screwdriver, remove the inside handle bezel plug. (a) HINT: Tape the screwdriver tip before use. B56609 Clip 3. REMOVE REAR DOOR TRIM BOARD SUB−ASSY LH (a) Remove the 4 screws. (b) Using a screwdriver, remove the clip. (c) Using a screwdriver, remove the trim board. HINT: Tape the screwdriver tip before use. (d) Remove the inside handle then disconnect the 2 cables from the rear door lock assembly. B56618 4. REMOVE REAR DOOR LOWER FRAME PLATE SUB−ASSY LH (a) Remove the 3 screws and lower frame plate. 5. REMOVE REAR DOOR SERVICE HOLE COVER LH (a) Disconnect each connector and remove the service hole cover. NOTICE: Remove the remaining tape on the body side. 6. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH 7. REMOVE REAR DOOR GLASS RUN LH WhereEverybodyKnowsYourName 75−17 ENGINE HOOD/DOOR − REAR DOOR 8. REMOVE REAR DOOR WEATHERSTRIP LH (a) Using a screwdriver, remove the door weatherstrip. HINT: Tape the screwdriver tip before use. 9. REMOVE REAR DOOR BELT MOULDING ASSY LH(See page 76−13) 10. REMOVE REAR DOOR WINDOW FRAME SUB−ASSY REAR LOWER LH (a) Remove the screws. (b) Remove the 2 bolts and window frame rear lower. 11. REMOVE REAR DOOR QUARTER WINDOW GLASS LH (a) Remove the quarter window glass. 12. REMOVE REAR DOOR GLASS SUB−ASSY LH HINT: Insert a shop rag inside the door panel to prevent scratching the glass. (a) Open the door glass. (b) Tilt the door glass and disconnect the roller of the regulator from the channel to remove the door glass. NOTICE: Do not damage the door glass. HINT: Pull the glass upward to remove it. 13. REMOVE REAR DOOR WINDOW REGULATOR SUB−ASSY LH (a) Disconnect the connector. (b) Loosen the temporarily installed bolt. NOTICE: When the temporarily installed bolt is removed, the rear door window regulator might drop and be deformed. (c) Remove the 3 bolts and window regulator. 14. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH (a) Using a torx wrench (T25), remove the 3 screws and the motor. 15. REMOVE REAR DOOR W/MOTOR LOCK ASSY LH (a) Disconnect the connector. (b) Using a torx wrench (T30), remove the 3 screws and the door lock. 16. REMOVE REAR DOOR OUTSIDE HANDLE COVER RH (a) Using a torx wrench (T30), loosen the screw and remove the outside handle cover. 17. (a) REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH Pull and hold the release plate of the outside handle frame, as shown in the illustration. B57652 WhereEverybodyKnowsYourName 75−18 ENGINE HOOD/DOOR − REAR DOOR (b) Pushing the outside handle in the arrow mark direction in the illustration, remove the outside handle. NOTICE: If the release plate is not pulled and held when removing the outside handle assembly, then the release pate will interfere with the outside handle and it will damage the release plate. B56613 18. (a) 19. (a) REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB−ASSY LH Using a torx wrench (T30), loosen the screw and remove the outside handle frame. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB−ASSY LH Using a torx wrench (T30), install the outside handle frame with the screw. Torque: 4.0 N⋅m (41 kgf⋅cm, 37 in.⋅lbf) 20. INSTALL REAR DOOR OUTSIDE HANDLE COVER RH (a) Using a torx wrench (T30), install the outside handle cover with the screw. Torque: 4.0 N⋅m (41 kgf⋅cm, 37 in.⋅lbf) 21. INSTALL REAR DOOR W/MOTOR LOCK ASSY LH (a) Install a new door lock wire harness packing. NOTICE:
If reusing the removed lock with rear door lock, the packing in the connecting part should be replaced with a new one.
Be careful that grease and dirt will not stick to the packing surface in the connecting part.
Reusing the removed packing or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock. (b) Engage the door lock with rear door motor with the release plate of the outside handle, and then set it to the door panel. NOTICE: Make sure that the release plate of the outside handle frame is securely engaged with the lock assembly. (c) Apply adhesive to the threads of the 3 screws. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent (d) Using a torx wrench (T30), install the door lock with the 3 screws and bolt. Torque: 5.0 N⋅m (51kgf⋅cm, 44 in.⋅lbf) 22. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH (a) Using a torx wrench (T25), install the power window regulator motor with the 3 screws. 23. INSTALL REAR DOOR WINDOW REGULATOR SUB−ASSY LH (a) Install the temporarily installed bolt securely. (b) Install the temporarily installed bolt to the window regulator to the rear door panel, and install the window regulator temporarily. (c) Tighten the 3 bolts and the temporarily installed bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Connect the connector. WhereEverybodyKnowsYourName 75−19 ENGINE HOOD/DOOR Tape B56619 − REAR DOOR 24. INSTALL REAR DOOR SERVICE HOLE COVER LH (a) Install a new service hole cover to the door panel. HINT:
When installing the service hole cover, pull out the links and connectors through the service hole cover.
There should be no wrinkles or folds on the service hole cover after attaching it.
After attaching the service hole cover, sealing condition should be confirmed. WhereEverybodyKnowsYourName 75−20 ENGINE HOOD/DOOR − LUGGAGE COMPARTMENT DOOR LUGGAGE COMPARTMENT DOOR 7509D−03 ADJUSTMENT 1. (a) INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB−ASSY Check that the clearance is within the standard value. 0
1.5 (0.059) 4 (0.16)
1.5 (0.059) 5 (0.20)
1.5 (0.059) 8 (0.31)
1.5 (0.059) mm (in.) B56606 2. 3. 4. 5. 6. 7. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE LUGGAGE COMPARTMENT DOOR COVER(See page 76−9) LUGGAGE COMPARTMENT FLOOR MAT(See page 76−8) SPARE WHEEL COVER ASSY(See page 76−8) LUGGAGE COMPARTMENT SIDE COVER SUB−ASSY RH(See page 76−8) LUGGAGE COMPARTMENT TRIM HOOK NO.1(See page 76−8) REAR FLOOR FINISH PLATE(See page 76−8) 8. (a) (b) (c) B30599 (d) (e) ADJUST LUGGAGE COMPARTMENT DOOR PANEL SUB−ASSY For forward/rearward and right/left adjustments, loosen the bolts. For a vertical adjustment of the door front end, increase or decrease the number of the washers between the hinge and door. Tighten the bolts after adjustment. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 ft⋅lbf) Using a hammer and a brass bar, tap the striker to adjust it. Tighten the bolts after adjustment. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 ft⋅lbf) B50796 WhereEverybodyKnowsYourName 75−21 ENGINE HOOD/DOOR − LUGGAGE DOOR HINGE TORSION BAR LUGGAGE DOOR HINGE TORSION BAR 7509E−02 REPLACEMENT HINT: On the LH side, use the same procedures as on the RH side. NOTICE: Hold the door when opening / closing it in order to prevent the door from closing without any resistance after removing the torsion bar. 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 2. REMOVE SPARE WHEEL COVER ASSY 3. REMOVE REAR FLOOR FINISH PLATE(See page 76−7) 4. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER RH(See page 76−7) 5. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH(See page 76−7) 6. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH (a) Remove the torsion bar RH from the clip placed in the center of the upper back panel. (b) Remove the tip of the torsion bar by hand from the roof side inner panel. B55944 (c) (d) 7. Take out the hinge arm from the torsion bar in the rear direction. Pull the torsion bar to your side in order to remove the ”U”−shaped part from the hinge support. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH B55945 8. (a) Installation Hole INSTALL LUGGAGE DOOR HINGE TORSION BAR LH Check the paint mark of the torsion bar. (When installing a new one) HINT:

Installation Hole (For Adjustment) B56621 (b) Green paint for a vehicle without rear spoiler Yellow paint for a vehicle with rear spoiler Set the tip of the torsion bar in the installation hole placed in the center part. Holes placed in the upper and lower parts are used for adjustment. WhereEverybodyKnowsYourName 75−22 ENGINE HOOD/DOOR − LUGGAGE DOOR HINGE TORSION BAR HINT: If the return force becomes less because the torsion bar has been damaged, adjustment should be done in the upper hole.
If the return force is little, adjust one of the torsion bars.
If the return force is still little, adjust both of the torsion bars. 9. INSTALL LUGGAGE DOOR HINGE TORSION BAR RH (a) Check the paint mark of the torsion bar. (When installing a new one) HINT:
White paint for a vehicle without rear spoiler
Red paint for a vehicle with rear spoiler WhereEverybodyKnowsYourName 75−3 ENGINE HOOD/DOOR − HOOD SUPPORT ROD HOOD SUPPORT ROD 75095−02 REPLACEMENT 1. (a) REMOVE HOOD SUPPORT ROD Using a screwdriver to hold the left spring, disengage the upper and lower parts of the support rod, and then remove the hood support rod. NOTICE: Removal should be done while the hood is being held up. B51135 2. INSTALL HOOD SUPPORT ROD NOTICE:
Install a metal socket onto the hood except a resinous one onto the body.
After the installation, make sure that the socket is securely attached. WhereEverybodyKnowsYourName 75−4 ENGINE HOOD/DOOR − HOOD SUPPORT ROD 75096−02 DISPOSAL 1. (a) 100 mm A (4 in.) B B51104 DISPOSE OF HOOD SUPPORT ROD Fix the hood stay assembly, with the piston−rod pulled out, on a vise. (b) With protection glasses on, cut a part between A and B as shown in the illustration with a metal saw to release the gas. NOTICE: Although the gas inside the hood stay assembly is colorless, odorless and harmless, there is a possibility that cutting tips of the metal saw would jump around, therefore cover it with clothes or something. WhereEverybodyKnowsYourName 75−5 ENGINE HOOD/DOOR − FRONT DOOR FRONT DOOR 75098−03 COMPONENTS Front Door Glass Run Front Door Frame Sub−assy Rear Lower Front Door Glass Sub−assy Front Door Handle Assy Outside Front Door Outside Handle Cover Door Outside Handle Sub−assy 7.0 (71, 62 in.⋅lbf) Front Door Belt Moulding Assy Front Door Frame Sub−assy Front Lower Front Door Weatherstrip  7.0 (71, 62 in.⋅lbf) 5.0 (51, 44 in.⋅lbf) 5.5 (56, 49 in.⋅lbf) Front Door w/ Motor Lock Assy Outer Rear View Mirror Assy 5.5 (56, 49 in.⋅lbf) Front Door Lower Frame Bracket Garnish 8.0 (82, 71 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) Power Window Regulator Motor Assy  Butyl Tape Front Door Window Regulator Sub−assy Power Window Regulator Master Switch Assy 8 (82, 71 in.⋅lbf)  Front Door Service Hole Cover Front Door Inside Handle Bezel Plug Front No.1 Speaker Assy Front Door Inside Handle Front Door Trim Board Sub−assy N·m (kgf·cm, ft·lbf) : Specified torque  Non−reusable part  Precoated part WhereEverybodyKnowsYourName cmc0281 75−6 ENGINE HOOD/DOOR − FRONT DOOR 75097−02 ADJUSTMENT HINT: On the RH side, use in the same procedure as on the LH side. HINT: Since the centering bolt is used as a door hinge set bolt, the door can not be adjusted with it on. Substitute a bolt with washer for the centering bolt. Centering Bolt Standard Bolt B50717 1. (a) INSPECT FRONT DOOR PANEL SUB−ASSY LH Check that the clearance is within the standard value. Standerd 5.6 (0.220)
1.5 (0.059) 5.1 (0.201)
1.5 (0.059) 4.5 (0.177)
1.5 (0.059) 0
1.5 (0.059) 0
1.5 (0.059) mm (in.) B56580 2. (a) (b) SST ADJUST FRONT DOOR PANEL SUB−ASSY LH Using SST, adjust the door by loosening the body side hinge bolts. Forward / rearward and vertically. Tighten the bolts after adjustment. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B55941 WhereEverybodyKnowsYourName 75−7 ENGINE HOOD/DOOR (c) (d) − FRONT DOOR Adjust the door by loosening the door side hinge bolts. Horizontally and vertically. Tighten the bolts after adjustment. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B55942 (e) (f) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer. Tighten the striker mounting screws after adjustment. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) B55939 WhereEverybodyKnowsYourName 75−8 ENGINE HOOD/DOOR − FRONT DOOR 75099−04 OVERHAUL HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the RH side, use in the same procedure as on the LH side. 1. Clip (a) (b) (c) REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY Remove the armrest base cover lower. Remove the screw. Using a screwdriver, remove the master switch then disconnect the connector. HINT: Tape the screwdriver tip before use. Clip B56607 2. Clip (a) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH Using a screwdriver, remove the lower frame bracket garnish. HINT: Tape the screwdriver tip before use. Clip B56608 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH Using a screwdriver, remove the inside handle bezel plug. (a) HINT: Tape the screwdriver tip before use. Clip B56609 Clip B56610 4. REMOVE FRONT DOOR TRIM BOARD SUB−ASSY LH (a) Remove the hole plug. (b) Remove the 5 screws. (c) Remove the clip. (d) Using a screwdriver, remove the trim board. HINT: Tape the screwdriver tip before use. (e) Remove the inside handle then disconnect the 2 cables from the door lock. WhereEverybodyKnowsYourName 75−9 ENGINE HOOD/DOOR − FRONT DOOR 5. REMOVE FRONT DOOR SERVICE HOLE COVER LH (a) Disconnect each connector and remove the service hole cover. NOTICE: Remove the remaining tape on the body side. 6. REMOVE FRONT NO.1 SPEAKER ASSY (a) Disconnect the connector. (b) Remove the 4 bolts and front No.1 speaker. 7. REMOVE FRONT DOOR GLASS SUB−ASSY LH HINT: Insert a shop rag inside the door panel to prevent scratching the glass. (a) Open the door glass until the bolts appear in the service hole. (b) Remove the 2 bolts and door glass. NOTICE: Do not damage the door glass. B56611 HINT: Pull the glass upward to remove it. 8. REMOVE FRONT DOOR WINDOW REGULATOR SUB−ASSY LH (a) Disconnect the connector. (b) Loosen the temporarily installed bolt. NOTICE: When the temporarily installed bolt is removed, the window regulator might drop and be deformed. (c) Remove the 5 bolts and window regulator. 9. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH (a) Using a torx wrench (T25), remove the 3 screws and the motor assembly. 10. REMOVE FRONT DOOR GLASS RUN LH 11. REMOVE FRONT DOOR FRAME SUB−ASSY FRONT LOWER LH (a) Remove the 2 screws and frame front lower. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) 12. REMOVE FRONT DOOR FRAME SUB−ASSY REAR LOWER LH (a) Remove the screw and frame rear lower. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) 13. (a) (b) REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH Remove the hole plug Using a torx wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed. B56612 WhereEverybodyKnowsYourName 75−10 ENGINE HOOD/DOOR 14. (a) (b) − FRONT DOOR REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH Disconnect the connector. Using a torx wrench (T30), remove the 3 screws and the door motor. 15. (a) REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH Pushing the outside handle in the arrow mark direction in the illustration, remove the outside handle. B56613 16. (a) (b) REMOVE DOOR OUTSIDE HANDLE SUB−ASSY LH Using a torx wrench (T30), loosen the screw. Using pliers, disengage the clips and remove the outside handle, as shown in the illustration. NOTICE: Be sure to remove the outside handle together with the clips, because the clips will be damaged if the clips remain attached to the door panel. B57102 17. REMOVE FRONT DOOR WEATHERSTRIP LH (a) Using a screwdriver, remove the door weatherstrip. HINT: Tape the screwdriver tip before use. 18. REMOVE OUTER REAR VIEW MIRROR ASSY LH (a) Remove the 3 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) (b) Disconnect the connector then remove the mirror. 19. REMOVE FRONT DOOR BELT MOULDING ASSY LH(See page 76−12) 20. INSTALL DOOR OUTSIDE HANDLE SUB−ASSY LH (a) Using a torx wrench (T30), install the handle. Torque: 4.0 N⋅m (41 kgf⋅cm, 37 in.⋅lbf) 21. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH (a) Install a new door lock wire harness packing. NOTICE:
If reusing the removed lock with rear door motor, the packing in the connecting part should be replaced with a new one.
Be careful that grease and dirt will not stick to the packing surface in the connecting part.
Reusing the removed packing or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock. (b) Insert the outside handle link into the door lock with front door motor, and then set it to the door panel. NOTICE: Make sure that the outside handle link is securely engaged with the lock assembly. WhereEverybodyKnowsYourName 75−11 ENGINE HOOD/DOOR (c) (d) − FRONT DOOR Apply adhesive to the threads of the 3 screws. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Using a torx wrench (T30), install the door lock with the 3 screws. Torque: 5.0 N⋅m (51kgf⋅cm, 44 in.⋅lbf) 22. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (a) Using a torx wrench (T30), install the outside handle cover with the screw. B56614 23. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH (W/ JAM PROTECTION) (a) Apply MP grease to the sliding and rotating parts of the window regulator. (b) If the jam protection dose not function properly, perform the following procedure. HINT: It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed. (1) Install the power window motor with the 3 screws. Torque: 5.4 N⋅m (55kgf⋅cm, 48 in.⋅lbf) HINT: Place the matchmarks on the power window motor and window regulator gear. (2) Connect the power window motor and power window switch to the wire harness of the vehicle. (3) Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more). (4) Assemble the power window motor and regulator. HINT:
Install the motor when the regulator arm is below the middle point.
Align the matchmarks on the power window motor and window regulator gear when installing the power window motor. (5) Assemble the power window regulator and door glass. HINT: Never rotate the motor to the down direction until the installation of the window glass is completed. 24. INSTALL FRONT DOOR WINDOW REGULATOR SUB−ASSY LH (a) Install the temporarily installed bolt securely. (b) Install the temporarily installed bolt to the window regulator to the door panel, and install the front door window regulator temporarily. (c) Tighten the 5 bolts and the temporarily installed bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Connect the connector. 25. INSTALL FRONT DOOR GLASS SUB−ASSY LH (a) Install the front door glass with the 2 bolts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) HINT: When the installation point of the glass does not match, adjust the regulator position by manual operation. (1) Connect the power window switch to the wire harness and turn the ignition switch ON. WhereEverybodyKnowsYourName 75−12 ENGINE HOOD/DOOR (2) (3) − FRONT DOOR Repeat UP and DOWN operation several times manually. Check if AUTO UP → AUTO DOWN operates in the automatic operation. HINT:

26. Note that the jam protection function does not operate just after resetting. Reset the regulator again when performing the reverse operating after closing the window fully by AUTO UP operation. INSPECT POWER WINDOW FUNCTION Tape B56615 27. INSTALL FRONT DOOR SERVICE HOLE COVER LH (a) Install a new service hole cover to the door panel. HINT:
When installing the service hole cover, pull out the links and connectors through the service hole cover.
There should be no wrinkles or folds on the service hole cover after attaching it.
After attaching the service hole cover, sealing condition should be confirmed. WhereEverybodyKnowsYourName 60−1 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 600Y2−01 PRECAUTION CAUTION:
The vehicle is equipped with SRS, which consists of a driver airbag, front passenger airbag, side airbag and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures indicated in the repair manual.
Wait at least 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery before starting the operation. (The SRS is equipped with a back−up power source, so that if work is started within 90 seconds after disconnecting the negative (−) terminal cable of the battery, the SRS may be deployed.)
Do not expose the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag sensor front, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor directly to hot air or flames.
Be sure to perform the initialization of the occupant classification ECU under the conditions listed below (See page 05−1452). If the initialization is not performed, the SRS may not operate properly.
The occupant classification ECU is replaced.
Accessories (seatback tray or seat cover, etc.) are installed to the vehicle.
The passenger seat is removed from the vehicle.
Both the SRS warning light and passenger airbag ON/OFF indicator light (”OFF”) come on.
The vehicle is brought to the workshop for repair purpose due to an accident or collision. NOTICE:
Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect DTCs before disconnecting the battery.
Even in the case of a minor collision when the SRS does not deploy, the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag sensor front, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear and seat position airbag sensor should be inspected (see page 60−17).
Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation.
Never use SRS parts from another vehicle. When replacing the parts, replace them with new ones.
Never disassemble or repair the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag sensor front, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor in order to reuse it.
If the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag sensor front, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. WhereEverybodyKnowsYourName 60−2 SUPPLEMENTAL RESTRAINT SYSTEM



− SUPPLEMENTAL RESTRAINT SYSTEM Information labels are attached to the periphery of the SRS components. Follow the instructions in the caution. After work on the SRS is completed, perform the SRS warning light check (See page 05−1456). When the negative (−) terminal cable is disconnected from the battery, the memory will be cleared. Because of this, be sure to make a record of the contents memorized in each system before starting work. When work is finished, adjust each system as it was before. Never use a back−up power supply from outside the vehicle to avoid erasing the memory in any system. If the vehicle is equipped with a mobile communication system, see page 01−5. WhereEverybodyKnowsYourName 60−3 SUPPLEMENTAL RESTRAINT SYSTEM 1. (a) − SUPPLEMENTAL RESTRAINT SYSTEM DEPLOYMENT CONDITION When the vehicle collides and the shock is greater than the specified value, the SRS is activated automatically. The airbag sensor assy center includes the safing sensor and deceleration sensor. The safing sensor was designed to be turned on at a smaller deceleration rate than the deceleration sensor. The deceleration sensor determines whether or not ignition is necessary based on signals from the airbag sensor front. Current flows to the squibs to deploy the SRS when the conditions shown in the illustrations below are met. Safing Sensor ON Horn Button Assy AND Airbag Sensor Front Front Passenger Airbag Assy Deceleration Sensor ON H44896 Safing Sensor ON Front Seat Airbag Assy AND Side Airbag Sensor Assy H44900 Front Seat Airbag Assy Deployment Safing Sensor ON OR AND Curtain Shield Airbag Assy Airbag Sensor Rear H44901 WhereEverybodyKnowsYourName 60−4 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM 2. SRS CONNECTORS HINT: SRS connectors are located as shown in the following illustration. TMC Made: 11 17 *1 Occupant Classification ECU 18 *1 12 Airbag Sensor Rear RH 33 Curtain Shield Airbag 9 Assy RH (Squib) 10 31 Side Airbag Sensor Assy RH RH Sensor Front Seat Outer Belt Assy RH (Squib) 7 8 Airbag Front 34 32 29 Front Seat Airbag Assy RH (Squib) 5 6 27 30 Front Passenger 21 Airbag Assy (Squib) 22 3 28 4 Airbag Sensor Assy Center 1 15 2 16 23 3 4 Airbag Sensor Front LH Spiral Cable Sub−assy 24 25 Assy (Squib) 29 Front Seat Airbag Assy LH (Squib) 31 Sensor Assy LH Front Seat Outer Belt Assy LH (Squib) 33 Rear LH 30 7 8 Airbag Sensor 26 5 6 Side Airbag Horn Button 32 Curtain Shield Airbag 9 13 Assy LH (Squib) 34 10 Seat Position 19 Airbag Sensor 20 *1 w/ Power Seat 14 H43730 No. Connector Type Application (1) Terminal Twin−Lock Mechanism Connectors 2, 4, 6, 8, 10, 14, 15, 16, 18, 20, 21, 22, 23, 29, 30 (2) Activation Prevention Mechanism Connectors 2, 4, 16, 22, 24, 26, 28, 30, 32, 34 (3) Half Connection Prevention Mechanism Connectors 6, 8, 10, 16, 21, 23, 29 (4) Connector Lock Mechanism (1) Connectors 25, 27, 31, 33 (5) Connector Lock Mechanism (2) Connectors 2, 4 (6) Improper Connection Prevention Lock Mechanism Connectors 1, 3 WhereEverybodyKnowsYourName 60−5 SUPPLEMENTAL RESTRAINT SYSTEM TMMK Made: − SUPPLEMENTAL RESTRAINT SYSTEM 11 17 *1 Occupant Classification ECU 18 *1 12 Airbag Sensor Rear RH 33 Curtain Shield Airbag 9 Assy RH (Squib) 10 31 Side Airbag Sensor Assy RH RH Sensor Front Seat Outer Belt Assy RH (Squib) 7 8 Airbag Front 34 32 29 Front Seat Airbag Assy RH (Squib) 5 6 27 30 Front Passenger 21 Airbag Assy (Squib) 22 3 28 4 Airbag Sensor Assy Center 1 15 2 16 23 3 4 Airbag Sensor Front LH Spiral Cable Sub−assy 24 25 Assy (Squib) 29 Front Seat Airbag Assy LH (Squib) 31 Sensor Assy LH Front Seat Outer Belt Assy LH (Squib) 33 Rear LH 30 7 8 Airbag Sensor 26 5 6 Side Airbag Horn Button 32 Curtain Shield Airbag 9 13 Assy LH (Squib) 34 10 Seat Position 19 Airbag Sensor 20 *1 w/ Power Seat 14 H43730 No. Connector Type Application (1) Terminal Twin−Lock Mechanism Connectors 2, 4, 6, 8, 10, 14, 15, 16, 18, 20, 21, 22, 23 29, 30 33, 34 (2) Activation Prevention Mechanism Connectors 2, 4, 16, 22, 24, 26, 28, 30, 32, 33, 34 (3) Half Connection Prevention Mechanism Connectors 6, 8, 10, 16, 21, 23, 29, 33 (4) Connector Lock Mechanism (1) Connectors 25, 27, 31 (5) Connector Lock Mechanism (2) Connectors 2, 4 (6) Improper Connection Prevention Lock Mechanism Connectors 1, 3 WhereEverybodyKnowsYourName 60−6 SUPPLEMENTAL RESTRAINT SYSTEM (a) Housing (2) Female Male Z05953 When Connector is Connected SUPPLEMENTAL RESTRAINT SYSTEM All connectors in the SRS are colored yellow to distinguish them from other connectors, except seat position airbag sensor connector and occupant classification ECU connector. Some connectors have special functions, and are specially designed for the SRS. These connectors use durable gold−plated terminals, and are placed in the locations shown on the previous page to ensure high reliability. (1) Spacer − Terminal twin−lock mechanism: Each connector has a two−piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. Activation prevention mechanism: Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects the positive (+) terminal and the negative (−) terminal of the squib. When Connector is Disconnected Short Spring Plate Short Spring Plate Contacting Male Terminal Housing Housing Short Spring Plate ON Terminal Squib Connectors Short Spring Plate Squib Closed Circuit WhereEverybodyKnowsYourName R10587 60−7 SUPPLEMENTAL RESTRAINT SYSTEM − (3) Half connection prevention mechanism: If the connector is not completely connected, the connector is disconnected due to the spring operation so that no continuity exists. Spring Slider Stopper Locking Part SUPPLEMENTAL RESTRAINT SYSTEM Stopper Locking Arm Rebounded by Slider (Spring) H44955 (4) Connector lock mechanism (1): Locking the connector lock button connects the connector securely. 1.75 Lock Button Claw Groove H40181 WhereEverybodyKnowsYourName 60−8 SUPPLEMENTAL RESTRAINT SYSTEM (5) − SUPPLEMENTAL RESTRAINT SYSTEM Connector lock mechanism (2): Both the primary lock with holder lances and the secondary lock with retainer prevent the connectors from becoming disconnected. Holder Lance Retainer Retainer H43918 (6) Improper connection prevention lock mechanism: When connecting the holder, the lever is pushed into the end by rotating around the A axis to lock the holder securely. A A Lever H43245 WhereEverybodyKnowsYourName 60−9 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) − SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTORS FOR CURTAIN SHIELD AIRBAG ASSY (TMC MADE), HORN BUTTON ASSY AND FRONT PASSENGER AIRBAG ASSY Release the lock button (yellow part) of the connector using a screwdriver. Insert the screwdriver tip between the connector and the base, and then raise the connector. Lock Button (Yellow Part) (a) Lock Button (Yellow Part) (b) Mark H42906 4. (a) (b) CONNECTION OF CONNECTORS FOR CURTAIN SHIELD AIRBAG ASSY (TMC MADE), HORN BUTTON ASSY AND FRONT PASSENGER AIRBAG ASSY Connect the connector. Push down securely on the lock button (yellow part) of the connector. (When locking, a click sound can be heard.) Lock Button (Yellow Part) H43151 WhereEverybodyKnowsYourName 60−10 SUPPLEMENTAL RESTRAINT SYSTEM 5. (a) − SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider Slider Disconnection is completed H01584 6. (a) CONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H43169 WhereEverybodyKnowsYourName 60−11 SUPPLEMENTAL RESTRAINT SYSTEM 7. (a) − SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FOR CURTAIN SHIELD AIRBAG ASSY (TMMK MADE) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider Slider Disconnection is completed H01586 8. (a) CONNECTION OF CONNECTOR FOR CURTAIN SHIELD AIRBAG ASSY (TMMK MADE) Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H43731 WhereEverybodyKnowsYourName 60−12 SUPPLEMENTAL RESTRAINT SYSTEM 9. (a) − SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FOR AIRBAG SENSOR ASSY CENTER Pull the lever by pushing part A as shown in the illustration and disconnect the holder (with connectors). A Holder (with connectors) Disconnection is completed H45112 HINT: Perform the following procedures when replacing the holder. (b) Remove the holder. (1) Using a screwdriver, unlock the retainer. Retainer H43188 WhereEverybodyKnowsYourName 60−13 SUPPLEMENTAL RESTRAINT SYSTEM (2) − SUPPLEMENTAL RESTRAINT SYSTEM Release the lances and remove the holder. Lances H43189 (c) Install the holder. (1) Install the connectors to the holder. (When locking, a click sound can be heard.) HINT: The retainer is locked when the holder is connected. H43190 WhereEverybodyKnowsYourName 60−14 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM 10. CONNECTION OF CONNECTOR FOR AIRBAG SENSOR ASSY CENTER (a) Firmly insert the holder (with connectors) until it can not be pushed any further. (b) Push the lever to connect the holder (with connectors). (When locking, a click sound can be heard.) HINT: The holder slides when connecting. Be sure not to hold the holder while connecting, as it may result in an insecure fit. Holder (with connectors) Lever Connection is completed H45113 WhereEverybodyKnowsYourName 60−15 SUPPLEMENTAL RESTRAINT SYSTEM 11. Outer (a) (b) H02763 − SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR While holding both outer flank sides, slide the outer in the direction shown by the arrow. When the connector lock is released, the connectors are disconnected. HINT: Be sure to hold both outer flank sides. Holding the top and bottom will make disconnection difficult. Connector lock is released Disconnection is completed H02764 12. (a) CONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR Connect the connector as shown in the illustration. (When locking, make sure that the outer returns to its original position and a click sound can be heard.) HINT: When connecting the outer slides. Be sure not to hold the outer while connecting, as it may result in an insecure fit. Outer Outer Connection is completed H02768 WhereEverybodyKnowsYourName 60−16 SUPPLEMENTAL RESTRAINT SYSTEM 13. (a) − SUPPLEMENTAL RESTRAINT SYSTEM NOTICE REGARDING AIRBAG SENSOR INSTALLATION BOLT As the tightening torque is different depending on the property class of the airbag sensor installation bolt, choose a bolt referring to the following illustration and tighten it with the specified tightening torque written in the repair manual. PROPERTY CLASS 6T 8T Deep Recess Bolt C92133 H41649 WhereEverybodyKnowsYourName 60−17 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM 600OM−02 ON−VEHICLE INSPECTION CAUTION: Be sure to perform the initialization of the occupant classification ECU under the conditions listed below (See page 05−1452). If the initialization is not performed, the SRS may not operate properly.
The occupant classification ECU is replaced.
Accessories (seatback tray or seat cover, etc.) are installed to the vehicle.
The passenger seat is removed from the vehicle.
Both the SRS warning light and passenger airbag ON/OFF indicator light (”OFF”) come on.
The vehicle is brought to the workshop for repair purpose due to an accident or collision. 1. H45548 HINT: There are two types of horn button assy: One is used with 3−spoke steering wheel assy and the other is used with 4−spoke steering wheel assy. (a) Perform a diagnostic system check (see page 05−1464). (b) With the horn button assy installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the horn button assy with a new one: Cuts, minute cracks or marked discoloration on the horn button assy top surface or in the grooved portion. 2. (a) (b) H41102 HORN BUTTON ASSY (VEHICLE NOT INVOLVED IN COLLISION) HORN BUTTON ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05−1464). With the horn button assy removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the horn button assy or steering wheel assy with a new one:
Cuts, minute cracks or marked discoloration on the horn button assy top surface or in the grooved portion.
Cracks or other damage to the connector.
Deformation of the steering wheel assy.
Horn Button Contact Plate Deformation of the horn button contact plate of the horn button assy. H43982 WhereEverybodyKnowsYourName 60−18 SUPPLEMENTAL RESTRAINT SYSTEM
H45549 SUPPLEMENTAL RESTRAINT SYSTEM There should be no interference between the horn button assy and steering wheel assy, and the clearance should be uniform all the way around when the new horn button assy is installed on the steering wheel assy. CAUTION: For removal and installation procedures of the horn button assy, see page 60−25, and be sure to follow the correct procedure. 3. (a) (b) H41398 4. (a) (b) H43172 − FRONT PASSENGER AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05−1464). With the front passenger airbag assy installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the instrument panel with a new one: Cuts, minute cracks or marked discoloration on the instrument panel around the doorless instrument panel passenger airbag assy. FRONT PASSENGER AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05−1464). With the front passenger airbag assy removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front passenger airbag assy, instrument panel or instrument panel reinforcement with a new one:
Cuts, minute cracks or marked discoloration on the front passenger airbag assy.
Cracks or other damage to the connectors.
Deformation or cracks on the instrument panel or instrument panel reinforcement. CAUTION: For removal and installation procedures of the front passenger airbag assy, see page 60−37, and be sure to follow the correct procedure. H45514 WhereEverybodyKnowsYourName 60−19 SUPPLEMENTAL RESTRAINT SYSTEM 5. (a) (b) H43796 − SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05−1464). With the front seat airbag assy installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seatback assy with a new one: Cuts, minute cracks or marked discoloration on the front seatback assy around the front seat airbag assy. 6. H41401 FRONT SEAT AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). (b) With the front seat airbag assy removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat airbag assy with a new one:
Cuts, minute cracks or marked discoloration on the front seat airbag assy.
Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation procedures of the front seat airbag assy, see page 72−23 (power seat type) or see page 72−15 (manual seat type), and be sure to follow the correct procedure. 7. (a) (b) C92094 CURTAIN SHIELD AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05−1464). With the curtain shield airbag assy installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front pillar garnish or roof headlining assy with a new one: Cuts, minute cracks or marked discoloration on the front pillar garnish or roof headlining assy around the curtain shield airbag assy. WhereEverybodyKnowsYourName 60−20 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM 8. CURTAIN SHIELD AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). (b) With the curtain shield airbag assy removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag assy with a new one:
Cuts, minute cracks or marked discoloration on the H41402 curtain shield airbag assy.
Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the curtain shield airbag assy, see page 60−46, and be sure to follow the correct procedure. 9. AIRBAG SENSOR ASSY CENTER (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 10. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). 11. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the airbag sensor assy center (see page 60−59). CAUTION: For removal and installation procedures of the airbag sensor assy center, see page 60−59, and be sure to follow the correct procedure. HINT: The airbag sensor assy center should be replaced after any of the airbags has deployed, as it has been subjected to the impact. 12. AIRBAG FRONT SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 13. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). (b) When the front bumper of the vehicle or its periphery is damaged, check if there is any damage to the airbag sensor front. If any of the airbag sensor front have defects as mentioned below, replace it with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the airbag sensor front, see page 60−63, and be sure to follow the correct procedure. WhereEverybodyKnowsYourName 60−21 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM 14. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the airbag front sensor (see page 60−61). CAUTION: For removal and installation procedures of the airbag sensor front, see page 60−63, and be sure to follow the correct procedure. HINT: The airbag sensor front on the impacted side should be replaced after the horn button assy or front passenger airbag assy has deployed. 15. SIDE AIRBAG SENSOR ASSY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 16. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). (b) When the center pillar of the vehicle or its periphery is damaged, check if there is any damage to the side airbag sensor assy. If there are any defects as mentioned below, replace the side airbag sensor assy with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor assy, see page 60−65, and be sure to follow the correct procedure. 17. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor assy (see page 60−65). CAUTION: For removal and installation procedures of the side airbag sensor assy, see page 60−65, and be sure to follow the correct procedure. HINT: The side airbag sensor assy on the impacted side should be replaced after the front seat airbag assy and curtain shield airbag assy have deployed. 18. AIRBAG SENSOR REAR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 19. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05−1464). (b) When the quarter panel of the vehicle or its periphery is damaged, check if there is any damage to the airbag sensor rear. If there are any defects as mentioned below, replace the airbag sensor rear with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the airbag sensor rear, see page 60−67, and be sure to follow the correct procedure. 20. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the airbag sensor rear (see page 60−67). CAUTION: For removal and installation procedures of the airbag sensor rear, see page 60−67, and be sure to follow the correct procedure. WhereEverybodyKnowsYourName 60−22 SUPPLEMENTAL RESTRAINT SYSTEM − SUPPLEMENTAL RESTRAINT SYSTEM HINT: The airbag sensor rear on the impacted side should be replaced after the curtain shield airbag assy has deployed. 21. SEAT POSITION AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 22. SEAT POSITION AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). (b) Even if the airbag was not deployed, perform a visual check for damage to the seat position airbag sensor including the following:
Cracks, dents or chips in the case.
Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the seat position airbag sensor, see page 60−69, and be sure to follow the correct procedure. 23. OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 24. OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). (b) Even if the airbag was not deployed, perform a visual check for damage to the occupant classification ECU including the following:
Cracks, dents or chips in the case.
Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the occupant classification ECU, see page 60−72, and be sure to follow the correct procedure. 25. WIRE HARNESS AND CONNECTOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). 26. WIRE HARNESS AND CONNECTOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05−1464). (b) Check for breaks in all wires of the SRS wire harness and exposed conductors. (c) Check to see if the SRS wire harness connectors are cracked or chipped. HINT: The SRS wire harness is integrated with the engine room main wire, instrument panel wire, instrument panel wire No.2, floor wire, floor wire No.2, front seat LH wire (TMC made) and front seat RH wire. WhereEverybodyKnowsYourName 60−23 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY HORN BUTTON ASSY 600Y3−01 COMPONENTS 4−spoke Steering Wheel Assy: Torx Screw 8.8 (90, 78 in.⋅lbf) w/ VSC: Steering Sensor Steering Wheel Assy Spiral Cable Sub−assy Steering Wheel Cover Lower No.2 Steering Wheel Cover Lower No.3 Torx Screw 8.8 (90, 78 in.⋅lbf) Horn Button Assy Steering Column Cover (Lower) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName H45529 60−24 SUPPLEMENTAL RESTRAINT SYSTEM − 3−spoke Steering Wheel Assy: HORN BUTTON ASSY Torx Screw 8.8 (90, 78 in.⋅lbf) w/ VSC: Steering Sensor Steering Wheel Assy Spiral Cable Sub−Assy Steering Wheel Cover Lower No.2 Steering Wheel Cover Lower No.3 Torx Screw 8.8 (90, 78 in.⋅lbf) Horn Button Assy Steering Column Cover (Lower) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName H45530 60−25 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY 600Y4−01 REPLACEMENT HINT:

Installation is in the reverse order of removal. There are two types of horn button assy: One is used with 3−spoke steering wheel assy and the other is used with 4−spoke steering wheel assy. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. Screw Case Steering Wheel Cover Lower No.3 Torx Screw Steering Wheel Cover Lower No.2 H45552 H45532 3. (a) REMOVE STEERING WHEEL COVER LOWER NO.2 Using a screwdriver, remove the steering wheel cover lower No.2. HINT: Tape up the screwdriver tip before use. 4. REMOVE STEERING WHEEL COVER LOWER NO.3 (a) Using a screwdriver, remove the steering wheel cover lower No.3. HINT: Tape up the screwdriver tip before use. 5. REMOVE HORN BUTTON ASSY (a) Place the front wheels facing straight ahead. (b) Using a torx socket wrench (T30), loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. (c) Pull out the horn button assy from the steering wheel assy and support the horn button assy with one hand as shown in the illustration. NOTICE: When removing the horn button assy, do not pull the airbag wire harness. (d) Disconnect the horn connector. (e) Disconnect the connector from the horn button assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (f) Remove the horn button assy. 6. (a) INSTALL HORN BUTTON ASSY Support the horn button assy with one hand as shown in the illustration. (b) Connect the connector to the horn button assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Connect the horn connector. H45532 WhereEverybodyKnowsYourName 60−26 SUPPLEMENTAL RESTRAINT SYSTEM (d) (e) 7. HORN BUTTON ASSY Confirm that the circumference groove of the torx screw fits in the screw case, and place the horn button assy onto the steering wheel assy. Using a torx socket wrench (T30), tighten the 2 torx screws. Torque: 8.8 N⋅m (90 kgf⋅cm, 78 in.⋅lbf) CONNECT BATTERY NEGATIVE TERMINAL 8. (a) 9. − INSPECT HORN BUTTON ASSY With the horn button assy installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the horn button assy with a new one: Cuts, minute cracks or marked discoloration on the horn button assy top surface or in the grooved portion. Make sure that the horn sounds. (b) HINT: If the horn does not sound, inspect the horn system H45549 (see page 69−3). INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−27 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY 600Y5−01 DISPOSAL HINT:


There are two types of horn button assy: One is used with 3−spoke steering wheel assy and the other is used with 4−spoke steering wheel assy. The procedures listed below are for the 4−spoke steering wheel assy. When scrapping a vehicle equipped with the SRS or disposing of the horn button assy, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a horn button assy which has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying an airbag, perform the operation at least 10 m (33 ft) away from the horn button assy. The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assy with a deployed airbag. Do not apply water, etc. to a horn button assy with the deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF HORN BUTTON ASSY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check function of the SST. SST 09082−00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST H40004 WhereEverybodyKnowsYourName 60−28 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (−) terminal. (2) Check function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. Battery SST H40005 SST H40006 CAUTION:
Do not connect the SST connector (yellow colored one) to the airbag.
If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace the SST with a new one. (3) Disconnect the SST from the battery. (b) Precaution (see page 60−1). (c) Disconnect the battery negative terminal. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (d) Remove the steering column cover (lower). (1) While turning the steering wheel assy to the right and left, remove the 2 screws and steering column cover (lower). H45550 SST H45551 (e) Install the SST. CAUTION: Check that there is no looseness in the steering wheel assy and horn button assy. (1) Disconnect the airbag connector (yellow colored one) from the spiral cable sub−assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the SST connector to the airbag connector of the spiral cable sub−assy. SST 09082−00700, 09082−00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. WhereEverybodyKnowsYourName 60−29 SUPPLEMENTAL RESTRAINT SYSTEM − (3) (4) Battery SST 10 m (33 ft) or more H40007 SST H40004 HORN BUTTON ASSY Move the SST at least 10 m (33 ft) away from the vehicle front side window. Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (−) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
When deploying the airbag, make sure that no one is near the vehicle.
The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a horn button assy with a deployed airbag.
Do not apply water, etc. to a horn button assy with a deployed airbag.
Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2. DISPOSE OF HORN BUTTON ASSY (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the horn button assy, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (see step 1−(a)). (b) Remove the horn button assy (See page 60−25). CAUTION:
When removing the horn button assy, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery.
When storing the horn button assy, keep the airbag deployment side facing upward. WhereEverybodyKnowsYourName 60−30 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY (c) Wire Harness Diameter Stripped Wire Harness Section H40008 Using a service−purpose wire harness for the vehicle, tie down the horn button assy to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the horn button assy, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) L M H45533 Install the 2 bolts with washers into the 2 bolt holes on the horn button assy. Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until they become difficult to turn.
Do not tighten the bolts excessively. (2) After connecting the SST below to each other, connect them to the horn button assy. SST 09082−00802 (09082−10801, 09082−30801) H45535 WhereEverybodyKnowsYourName 60−31 SUPPLEMENTAL RESTRAINT SYSTEM − (3) HORN BUTTON ASSY Using 3 wire harnesses, wind wire harness at least 2 times each around the bolts installed on the left and right sides of the horn button assy. CAUTION:
Tightly wind the wire harness around the bolts so that there is no slack.
Make sure that the wire harness is tight. If there is slack in wire harness, the horn button assy may become loose due to the shock when the airbag is deployed. 2 Times or more H45534 (4) H45536 Face the airbag deployment side of the horn button assy upward. Separately tie the left and right sides of the horn button assy to the disc wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole in the disc wheel. CAUTION:
Make sure that the wire harness is tight. If there is slack in wire harness, the horn button assy may become loose due to the shock when the airbag is deployed.
Always tie down the horn button assy with the airbag deployment side facing upward. NOTICE: The disc wheel will be marked by the airbag deployment, so use an extra disc wheel. (d) SST H45537 Install the SST. SST 09082−00700 CAUTION: Place the disc wheel on level ground. (1) Connect the connector of the SST. NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. WhereEverybodyKnowsYourName 60−32 SUPPLEMENTAL RESTRAINT SYSTEM (2) Battery − HORN BUTTON ASSY Move the SST to at least 10 m (33 ft) away from the horn button assy tied down to the disc wheel. SST 10 m (33 ft) or more H05075 (e) Y Y X Weight H40176 Cover the horn button assy with a cardboard box or tires. (1) Covering method using a cardboard box: Cover the horn button assy with the cardboard box and place weights on the cardboard box in 4 places totalling at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTICE:
When the dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the horn button assy is tied to, X should be the following size. X = 460 mm (18.11 in.) + width of tire
If a cardboard box which is smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. (2) Inner Diameter Width Tires (3 or more) H45114 Covering method using tires: Place at least 3 tires without disc wheels on the tire with disc wheel which the horn button assy is tied to. Place the tire with disc wheel on them. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels except on the top and bottom. NOTICE:
The tires may be marked by the airbag deployment, so use an extra tire.
Do not place the SST connector under the tire because it could be damaged. WhereEverybodyKnowsYourName 60−33 SUPPLEMENTAL RESTRAINT SYSTEM − HORN BUTTON ASSY (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. H45115 (f) Horn Button Assy Battery SST 10 m (33 ft) or more H45116 H42635 Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (−) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the disc wheel which the horn button assy is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (g) Dispose of the horn button assy. CAUTION:
The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a horn button assy with a deployed airbag.
Do not apply water, etc. to a horn button assy with a deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the horn button assy from the disc wheel. (2) Place the horn button assy in a plastic bag, tie it tightly and dispose of it as other general part disposal. WhereEverybodyKnowsYourName 60−34 SUPPLEMENTAL RESTRAINT SYSTEM − SPIRAL CABLE SUB−ASSY SPIRAL CABLE SUB−ASSY 600DZ−02 REPLACEMENT HINT:

COMPONENTS: See page 60−23 Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO.2 (See page 60−25) 5. REMOVE STEERING WHEEL COVER LOWER NO.3 (See page 60−25) 6. REMOVE HORN BUTTON ASSY (See page 60−25) 7. REMOVE STEERING WHEEL ASSY (See page 50−9) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) 8. REMOVE STEERING COLUMN COVER (LOWER) (See page 50−9) 9. (a) (b) Claw Steering Column Cover (Upper) Claw H45517 REMOVE SPIRAL CABLE SUB−ASSY Raise the steering column cover (upper). Disconnect the connectors from the spiral cable sub− assy. CAUTION: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Disengage the 3 claws and remove the spiral cable sub− assy. 10. 11. (a) REMOVE STEERING SENSOR (W/ VSC) (See page 32−72) INSPECT SPIRAL CABLE SUB−ASSY If any of the following conditions occur, replace the spiral cable sub−assy with a new one. Condition: Scratches or cracks on the connector Cracks, dents or chipping of the spiral cable sub−assy 12. INSTALL STEERING SENSOR (W/ VSC) (See page 32−72) 13. INSTALL SPIRAL CABLE SUB−ASSY (a) Check that the front wheels are facing straight ahead. (b) Set the turn signal switch to the neutral position. NOTICE: Make sure that the turn signal switch is in the neutral position, or the pin of the turn signal switch may be snapped. (c) Install the spiral cable sub−assy. NOTICE: When replacing the spiral cable sub−assy with a new one, remove the lock pin before installing the steering wheel assy. (d) Connect the connector to the spiral cable sub−assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. WhereEverybodyKnowsYourName 60−35 SUPPLEMENTAL RESTRAINT SYSTEM 14. − SPIRAL CABLE SUB−ASSY INSTALL STEERING COLUMN COVER (LOWER) (See page 50−9) 15. (a) (b) ADJUST SPIRAL CABLE SUB−ASSY Check that the ignition switch is off. Check that the battery negative (−) terminal is disconnected. NOTICE: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Rotate the spiral cable sub−assy counterclockwise slowly by hand until it feels firm. NOTICE: Do not turn the spiral cable sub−assy by the airbag wire harness. H41415 (d) Rotate the spiral cable sub−assy clockwise approximately 2.5 turns to align the marks. NOTICE: Do not turn the spiral cable sub−assy by the airbag wire harness. HINT: The spiral cable sub−assy will rotate approximately 2.5 turns to both the left and right from the center. Marks H41416 16. 17. 18. 19. 20. 21. INSTALL STEERING WHEEL ASSY (See page 50−9) INSPECT STEERING WHEEL CENTER POINT INSTALL HORN BUTTON ASSY (See page 60−25) CONNECT BATTERY NEGATIVE TERMINAL INSPECT HORN BUTTON ASSY (See page 69−3) INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−36 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) FRONT PASSENGER AIRBAG ASSY (From July, 2003) 600ON−01 COMPONENTS 1. Instrument Panel Pin No.1 Side Defroster Nozzle Duct No.2 Instrument Panel Pin No.1 Defroster Nozzle Assy Side Defroster Nozzle Duct No.1 Heater to Register Duct No.3 Heater to Register Duct No.2 Front Passenger Airbag Assy Heater to Register Duct No.1 Instrument Panel Wire No.2 20 (204, 15) Instrument Panel Safety Pad Sub−assy Instrument Panel Register Assy No.2 Instrument Panel Register Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName H43174 60−37 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) 600OO−02 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO.2 5. REMOVE STEERING WHEEL COVER LOWER NO.2 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) 6. REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) 7. REMOVE CONNECTOR COVER (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) 8. REMOVE HORN BUTTON ASSY (See page 60−25) 9. REMOVE STEERING WHEEL ASSY (See page 50−9) SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021) 10. REMOVE STEERING COLUMN COVER (See page 50−9) 11. DISCONNECT FRONT PASSENGER AIRBAG ASSY CONNECTOR (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H43177 12. 13. 14. 15. 16. 17. 18. 19. 20. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−16) INSTRUMENT PANEL REGISTER ASSY NO.2 (See page 71−16) INSTRUMENT PANEL REGISTER ASSY NO.1 (See page 71−16) SIDE DEFROSTER NOZZLE DUCT NO.2 (See page 71−16) SIDE DEFROSTER NOZZLE DUCT NO.1 (See page 71−16) DEFROSTER NOZZLE ASSY (See page 71−16) HEATER TO REGISTER DUCT NO.1 (See page 71−16) HEATER TO REGISTER DUCT NO.3 (See page 71−16) HEATER TO REGISTER DUCT NO.2 (See page 71−16) 21. (a) (b) DISCONNECT INSTRUMENT PANEL WIRE NO.2 Remove the clip. Disconnect the connectors from the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H43799 WhereEverybodyKnowsYourName 60−38 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) 22. (a) REMOVE FRONT PASSENGER AIRBAG ASSY Remove the 2 screws. (b) Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the front passenger airbag assy forward. Release the front side wall of the airbag door from the other hook and remove the front passenger airbag assy. H43175 Hook Hook (c) Front Airbag Door 23. 24. H43176 INSTALL FRONT PASSENGER AIRBAG ASSY INSPECT FRONT PASSENGER AIRBAG ASSY (See page 60−17) 25. (a) CONNECT INSTRUMENT PANEL WIRE NO.2 Connect the connectors to the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Install the clip. H43799 26. INSTALL INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−16) 27. CONNECT FRONT PASSENGER AIRBAG ASSY CONNECTOR (a) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H43251 WhereEverybodyKnowsYourName 60−39 SUPPLEMENTAL RESTRAINT SYSTEM 28. 29. 30. 31. 32. 33. 34. − FRONT PASSENGER AIRBAG ASSY (From July, 2003) INSTALL SPIRAL CABLE SUB−ASSY (See page 60−34) ADJUST SPIRAL CABLE SUB−ASSY (See page 60−34) INSTALL STEERING WHEEL ASSY (See page 50−9) INSPECT STEERING WHEEL CENTER POINT INSTALL HORN BUTTON ASSY (See page 60−25) INSPECT HORN BUTTON ASSY (See page 60−25) INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−40 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) 600OP−02 DISPOSAL HINT: When scrapping a vehicle equipped with SRS or disposing of the front passenger airbag assy, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of the front passenger airbag assy that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. SST H40004 When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assy. The front passenger airbag assy is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling the front passenger airbag assy with the deployed airbag. Do not apply water, etc. to the front passenger airbag assy with the deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF FRONT PASSENGER AIRBAG ASSY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See step 1−(a) on page 60−27). (b) Precaution (See page 60−1). (c) Disconnect the battery negative terminal. (d) Remove the front scuff plate (See page 76−22). (e) Remove the cowl side trim sub−assy (See page 76−22). (f) Remove the instrument panel under cover sub−assy No.1 (See page 71−16). (g) Remove the glove compartment door pad (See page 71−16). (h) Remove the instrument panel sub−assy lower (See page 71−16). WhereEverybodyKnowsYourName 60−41 SUPPLEMENTAL RESTRAINT SYSTEM 1. − FRONT PASSENGER AIRBAG ASSY (From July, 2003) (i) SST H43178 Install the SST. (1) Disconnect the connectors from the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the connector of the SST to the front passenger airbag assy. SST 09082−00700, 09082−00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) (4) Battery SST 10 m (33 ft) or more H40007 Move the SST at least 10 m (33 ft) away from the vehicle front side window. Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (−) terminal. (j) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the activation switch of the SST and deploy the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. CAUTION:
The front passenger airbag assy is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the front passenger airbag assy with the deployed airbag.
Do not apply water, etc. to the front passenger airbag assy with the deployed airbag.
Always wash your hands with water after completing the operation. WhereEverybodyKnowsYourName 60−42 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) 2. SST H40004 DISPOSE OF FRONT PASSENGER AIRBAG ASSY (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the front passenger airbag assy, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See step 1−(a) on page 60−27). (b) Remove the front passenger airbag assy. CAUTION:
When removing the front passenger airbag assy, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery.
When storing the front passenger airbag assy, keep the upper surface of the airbag deployment side facing upward. (c) Wire Harness Diameter Stripped Wire Harness Section H40008 Using a service−purpose wire harness for the vehicle, tie down the front passenger airbag assy to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If a wire harness which is too thin or an alternative object is used to tie down the front passenger airbag assy, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which has a section of at least 1.25 mm2 (0.0019 in.2). HINT:
To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4
Position the front passenger airbag assy inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the front passenger airbag assy coming free due to the shock from the airbag deployment. WhereEverybodyKnowsYourName 60−43 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003)
Always tie down the front passenger airbag assy with the airbag deployment side facing inside the tire. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. Inner Diameter Width Tire H43179 (d) SST Install the SST. After connecting the SST below to each other, connect them to the front passenger airbag assy. SST 09082−00802 (09082−10801, 09082−30801) H43180 (e) Tires (5 or more) H43181 Place the tires. (1) Place at least 2 tires under the tire to which the front passenger airbag assy is tied. (2) Place at least 2 tires over the tire to which the front passenger airbag assy is tied. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because the SST connector could be damaged. WhereEverybodyKnowsYourName 60−44 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSY (From July, 2003) (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the tires coming free due to the shock from the airbag deployment. H42763 (f) Front Passenger Airbag Assy Battery SST 10 m (33 ft) or more H43723 H41436 Install the SST. Connect the connector of the SST. SST 09082−00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (−) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire to which the front passenger airbag assy is tied. (3) Press the activation switch of the SST and deploy the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (h) Dispose of the front passenger airbag assy. CAUTION:
The front passenger airbag assy is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the front passenger airbag assy with the deployed airbag.
Do not apply water, etc. to the front passenger airbag assy with the deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the front passenger airbag assy from the tire. (2) Place the front passenger airbag assy in a plastic bag, tie it tightly and dispose of it in the same way as for other general parts disposal. WhereEverybodyKnowsYourName 60−45 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH CURTAIN SHIELD AIR BAG ASSY LH 60095−05 COMPONENTS Curtain Shield Airbag Assy LH 14 (143, 10 ft⋅lbf) 14 (143, 10 ft⋅lbf) 14 (143, 10 ft⋅lbf) 14 (143, 10 ft⋅lbf) 14 (143, 10 ft⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H41535 WhereEverybodyKnowsYourName 60−46 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH 60096−08 REPLACEMENT HINT:

Replacement procedure of the RH side is the same as that for the LH side. Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE ROOF HEADLINING ASSY (See page 76−22) 4. REMOVE CURTAIN SHIELD AIR BAG ASSY LH (a) Disconnect the connector from the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 9 bolts and curtain shield airbag assy LH. HINT: Remove the bolts from front side of the vehicle in order. Connector C92093 5. (a) H41533 INSTALL CURTAIN SHIELD AIR BAG ASSY LH Install the curtain shield airbag assy LH with the 9 bolts. Torque: 14 N⋅m (143 kgf⋅cm, 10 ft⋅lbf) HINT: Install the bolts from rear side of the vehicle in order. (b) Connect the connector to the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 6. INSPECT CURTAIN SHIELD AIR BAG ASSY LH (See page 60−17) 7. INSTALL ROOF HEADLINING ASSY (See page 76−22) 8. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−47 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH 600OQ−02 DISPOSAL HINT:

Disposal procedure of the RH side is the same as that for the LH side. When scrapping a vehicle equipped with SRS or disposing of the curtain shield airbag assy LH, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of the curtain shield airbag assy LH that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the curtain shield airbag assy LH. The curtain shield airbag assy LH is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling the curtain shield airbag assy LH with the deployed airbag. Do not apply water, etc. to the curtain shield airbag assy LH with the deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF CURTAIN SHIELD AIR BAG ASSY LH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) (b) (c) (d) (e) SST H40004 (f) (g) (h) Check the function of the SST (See step 1−(a) on page 60−27). Precaution (See page 60−1). Disconnect the battery negative terminal. Remove the rear door scuff plate LH (See page 76−22). Remove the rear door opening trim weatherstrip LH (See page 76−22). Remove the rear seat cushion assy (See page 72−32). Remove the rear side seat back LH (See page 72−32). Remove the roof side inner garnish LH (See page 76−22). WhereEverybodyKnowsYourName 60−48 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH (i) SST (TMC Made) SST (TMMK Made) H41534 Install the SST. (1) Disconnect the connector from the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) TMC Made: After connecting the SST below to each other, connect them to the curtain shield airbag assy LH. SST 09082−00700, 09082−00802 (09082−10801, 09082−20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) TMMK Made: Connect the connector of the SST to the curtain shield airbag assy LH (TMMK Made). SST 09082−00700, 09082−00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (4) (5) Battery SST 10 m (33 ft) or more H41078 Move the SST at least 10 m (33 ft) away from the vehicle rear side window. Maintaining enough clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (−) terminal. (j) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the activation switch of the SST and deploy the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. CAUTION:
The curtain shield airbag assy LH is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the curtain shield airbag assy LH with the deployed airbag. WhereEverybodyKnowsYourName 60−49 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH
Do not apply water, etc. to the curtain shield airbag assy LH with the deployed airbag.
Always wash your hands with water after completing the operation. 2. DISPOSE OF CURTAIN SHIELD AIR BAG ASSY LH (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the curtain shield airbag assy LH, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See step 1−(a) on page 60−27). SST (b) H40004 Remove the curtain shield airbag assy LH (See page 60−46). CAUTION: When removing the curtain shield airbag assy LH, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery. (c) Cut off the deployment section of the curtain shield airbag assy LH. H41417 WhereEverybodyKnowsYourName 60−50 SUPPLEMENTAL RESTRAINT SYSTEM − CURTAIN SHIELD AIR BAG ASSY LH (d) Wire Harness Diameter Stripped Wire Harness Section H40008 Width Inner Diameter H41548 (e) SST (TMMK Made) SST (TMC Made) Using a service−purpose wire harness for the vehicle, tie down the curtain shield airbag assy LH to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If a wire harness which is too thin or an alternative object is used to tie down the curtain shield airbag assy LH, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use which has a section of at least 1.25 mm2 (0.0019 in.2). HINT:
To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4
Place the curtain shield airbag assy LH inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the curtain shield airbag assy LH coming free due to the shock from the airbag deployment. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. H43725 Install the SST. (1) TMC Made: After connecting the SST below to each other, connect them to the curtain shield airbag assy LH. SST 09082−00802 (09082−10801, 09082−20801) (2) TMMK Made: Connect the connector of the SST to the curtain shield airbag assy LH. SST 09082−00760 WhereEverybodyKnowsYourName 60−51 SUPPLEMENTAL RESTRAINT SYSTEM Tires (5 or more) H43729 − CURTAIN SHIELD AIR BAG ASSY LH (f) Place the tires. CAUTION: Do not place the deployment direction of the curtain shield airbag assy LH facing toward the ground. (1) Place at least 2 tires under the tire to which the curtain shield airbag assy LH is tied. (2) Place at least 2 tires over the tire to which the curtain shield airbag assy LH is tied. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because the SST connector could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the tires coming free due to the shock from the airbag deployment. H42763 (g) Curtain Shield Airbag Assy LH Battery SST 10 m (33 ft) or more H41421 Install the SST. Connect the connector of the SST. SST 09082−00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (−) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire to which the curtain shield airbag assy LH is tied. (3) Press the activation switch of the SST and deploy the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. WhereEverybodyKnowsYourName 60−52 SUPPLEMENTAL RESTRAINT SYSTEM H41422 − CURTAIN SHIELD AIR BAG ASSY LH (i) Dispose of the curtain shield airbag assy LH. CAUTION:
The curtain shield airbag assy LH is extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the curtain shield airbag assy LH with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to the curtain shield airbag assy LH with the deployed airbag. (1) Remove the curtain shield airbag assy LH from the tire. (2) Place the curtain shield airbag assy LH in a plastic bag, tie it tightly and dispose of it in the same way as for other general parts disposal. WhereEverybodyKnowsYourName 60−53 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT SEAT AIRBAG ASSY RH FRONT SEAT AIRBAG ASSY RH 6007P−06 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the front seat airbag assy always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat airbag assy with an airbag deployed in a collision, follow the same procedure given in step 1−(e) in ”DISPOSAL”. CAUTION:
Never dispose of a front seat airbag assy which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out of doors and where it will not create a nuisance to nearby residents.

SST
H40004


1. Battery When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool), perform the operation in a place away from electrical noise. When deploying an airbag, perform the operation at least 10 m (33 ft) away from the airbag assy. The front seat airbag assy is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling front seat airbag assy with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat airbag assy with the deployed airbag. DISPOSE OF FRONT SEAT AIRBAG ASSY RH (WHEN SCRAPPING VEHICLE DEPLOYMENT METHOD) HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST (See page 60−27). SST H40005 WhereEverybodyKnowsYourName 60−54 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT SEAT AIRBAG ASSY RH (b) Remove the front seat assy (See page 72−23 (power seat) or 72−15 (manual seat)). (c) Disconnect the front seat airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H41647 (d) Install the SST. (1) Connect the connectors of the 2 SST connector to the front seat airbag connector. SST 09082−00700, 09082−00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Battery SST H41648 (2) 10 m (33 ft) or more H40007 Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (−) terminal. (e) Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the activation switch of the SST and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (f) Dispose of the front seat airbag assy. CAUTION:
The front seat airbag assy is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat airbag assy with the deployed airbag.
When moving a vehicle for scrapping which has a front seat airbag assy with the deployed airbag, use gloves and safety glasses.
Do not apply water, etc. to a front seat airbag assy with the deployed airbag.
Always wash your hands with water after completing the operation. WhereEverybodyKnowsYourName 60−55 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT SEAT AIRBAG ASSY RH HINT: When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front seat airbag assy still installed. 2. DISPOSE OF FRONT SEAT AIRBAG ASSY RH (WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD) NOTICE:
When disposing of the front seat airbag assy only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the front seat airbag assy. (1) Remove the front seat assy (See page 72−23 (power seat) or 72−15 (manual seat)). (2) Remove the 2 nuts and front seat airbag assy from the seatback assembly. CAUTION: Store the front seat airbag assy with the airbag deployment side facing upward. (b) Wire Harness Diameter Stripped Wire Harness Section H40008 Using a service−purpose wire harness, tie down the front seat airbag assy. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2 or more) HINT: To calculate the square of the stripped wire harness section : Square = 3.14 x (Diameter)2 divided by 4 CAUTION: If a wire harness which is too thin or some other thing is used to tie down the front seat airbag assy, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2). (1) Install the 2 nuts in the front seat airbag assy. H41437 WhereEverybodyKnowsYourName 60−56 SUPPLEMENTAL RESTRAINT SYSTEM (2) − FRONT SEAT AIRBAG ASSY RH Wind the wire harness around the stud bolts of the front seat airbag assy as shown in the illustration. H41438 (3) H40526 Battery Position the front seat airbag assy inside the tire with the airbag deployment direction facing inside. Tire size : Must exceed the following dimensions:− Width 185 mm (7.28 in.) Inner diameter 360 mm (14.17 in.) CAUTION:
Make sure the wire harness is tight. It is very dangerous if looseness in the wire harness results in the front seat airbag assy coming free due to the shock from the airbag deploying.
Always tie down the front seat airbag assy with the airbag door facing inside. NOTICE: The tire will be marked by the airbag deployment, so use the redundant tire. (c) Check functioning of the SST (See step 1−(a) on page 60−27). SST 09082−00700 SST H40005 (d) Tires (5 or More) Place the tires. (1) Place at least 2 tires under the tire to which the front seat airbag assy is tied. (2) Place at least 2 tires over the tire to which the front seat airbag assy is tied. The top tire should have the wheel installed. H01336 WhereEverybodyKnowsYourName 60−57 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT SEAT AIRBAG ASSY RH (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Secure at least 1 m (3 ft) of slack for the wire harness. H40016 (e) Front Seat Airbag Assy Battery SST 10 m (33ft) or more H01337 H00544 Install the SST. Connect the connectors of the 2 SST to the front seat airbag assy connector. SST 09082−00700, 09082−00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (f) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (−) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the front seat airbag assy is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (g) Dispose of the front seat airbag assy. CAUTION:
The front seat airbag assy is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat airbag assy with the deployed airbag.
Do not apply water etc. to a front seat airbag assy with the deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the front seat airbag assy from the tire. (2) Place the front seat airbag assy in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. WhereEverybodyKnowsYourName 60−58 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR ASSY CENTER AIR BAG SENSOR ASSY CENTER 60099−07 COMPONENTS Console Box Front w/ Ash Tray: Console Panel Upper w/ Ash Tray: Console Panel Upper Manual Transaxle: Shift Lever Knob Sub−assy Console Box Carpet Foot Parking Brake: Instrument Panel Upper Rear Instrument Panel Upper Rear Rr Console Box Rr Console Box Air Duct Rear No.2 Auto A/C Model: Console Box Duct No.1 Air Duct Rear No.1 17.5 (178, 13) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Airbag Sensor Assy Center WhereEverybodyKnowsYourName H45547 60−59 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR ASSY CENTER 6009A−08 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. SEPARATE BATTERY NEGATIVE TERMINAL CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. 3. REMOVE SHIFT LEVER KNOB SUB−ASSY (MANUAL TRANSAXLE) (See page 71−16) 4. REMOVE CONSOLE PANEL UPPER REAR (See page 71−16) 5. REMOVE CONSOLE BOX CARPET (See page 71−16) 6. REMOVE RR CONSOLE BOX (See page 71−16) 7. REMOVE CONSOLE PANEL SUB−ASSY (See page 71−16) 8. REMOVE CONSOLE BOX FRONT (See page 71−16) 9. REMOVE AIR DUCT REAR NO.1 (See page 55−34) 10. REMOVE AIR DUCT REAR NO.2 (See page 55−34) 11. REMOVE CONSOLE BOX DUCT NO.1 (A/T TRANSAXLE) (See page 55−34) 12. (a) (b) REMOVE AIR BAG SENSOR ASSY CENTER Disconnect the holder (with connectors) from the airbag sensor assy center. Remove the 3 bolts and the airbag sensor assy center. H45524 13. INSPECT AIR BAG SENSOR ASSY CENTER (See page 60−17) 14. INSTALL AIR BAG SENSOR ASSY CENTER (a) Check that the ignition switch is off. (b) Check that the battery negative (−) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Temporarily install the airbag sensor assy center with the 3 bolts. NOTICE:
If the airbag sensor assy center has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the airbag sensor assy center with a new one.
When installing the airbag sensor assy center, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. (d) Tighten the 3 bolts to the specified torque. Torque: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) (e) Connect the holder (with connectors) to the airbag sensor assy center. (f) Check that there is no looseness in the installation parts of the airbag sensor assy center. (g) Check that the water−proof sheet is properly set. 15. CONNECT BATTERY NEGATIVE TERMINAL 16. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−60 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG FRONT RH SENSOR AIR BAG FRONT RH SENSOR 6007S−03 COMPONENTS 17.5 (178, 13) Airbag Front RH Sensor Engine Under Cover RH Airbag Sensor Front LH 17.5 (178, 13) Engine Under Cover LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H41544 WhereEverybodyKnowsYourName 60−61 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG FRONT RH SENSOR 6007T−02 REPLACEMENT HINT: COMPONENTS: See page 60−60 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE ENGINE UNDER COVER RH (See page 14−29) 4. (a) REMOVE AIR BAG FRONT RH SENSOR Remove the bolt and front airbag sensor RH. (b) Disconnect the connector from the front airbag sensor RH. C93765 HINT: Insert a screw driver in any of the three opening sections of the sensor and slide the sensor to disconnect it from the connector. C84229 5. INSPECT AIR BAG FRONT RH SENSOR (See page 60−17) 6. INSTALL AIR BAG FRONT RH SENSOR (a) Check that the ignition switch trun OFF. (b) Check that the battery negative (−) terminal is disconnected. NOTICE: Do not start the operation for 90 seconds after removing the terminal. (c) Install the front airbag sensor RH with the bolt. Torque: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) (d) Connect the connector to the front airbag sensor RH. (e) Check that no play is identified. 7. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−62 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR FRONT LH AIR BAG SENSOR FRONT LH 6007U−03 COMPONENTS (See page 60−60) WhereEverybodyKnowsYourName 60−63 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR FRONT LH 6007V−03 REPLACEMENT HINT: COMPONENTS: See page 60−60 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE ENGINE UNDER COVER LH (See page 72−32) 4. (a) REMOVE AIR BAG SENSOR FRONT LH Remove the bolt and front airbag sensor LH. (b) Disconnect the connector from the front airbag sensor LH. C93764 HINT: Insert a screw driver in any of the three opening sections of the sensor and slide the sensor to disconnect it from the connector. C84229 5. INSPECT AIR BAG SENSOR FRONT LH (See page 60−17) 6. INSTALL AIR BAG SENSOR FRONT LH (a) Check that the ignition switch is off. (b) Check that the battery negative (−) terminal is disconnected. NOTICE: Do not start the operation for 90 seconds after removing the terminal. (c) Install the front airbag sensor LH with the bolt. Torque: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) (d) Connect the connector to the front airbag sensor LH. (e) Check that no play is identified. 7. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−64 SUPPLEMENTAL RESTRAINT SYSTEM − SIDE AIR BAG SENSOR ASSY RH SIDE AIR BAG SENSOR ASSY RH 600OR−01 COMPONENTS Side Airbag Sensor Assy RH 20 (204, 15) 7.5 (76, 66 in.⋅lbf) Center Pillar Garnish Lower RH 20 (204, 15) Front Seat Outer Belt Assy RH 42 (420, 31) Front Door Opening Trim Weatherstrip RH Rear Door Opening Trim Weatherstrip RH Rear Door Scuff Plate RH Front Door Scuff Plate RH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H41545 WhereEverybodyKnowsYourName 60−65 SUPPLEMENTAL RESTRAINT SYSTEM − SIDE AIR BAG SENSOR ASSY RH 6009G−09 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. Replacement procedure of the LH side is the same as that for the RH side. Installation is in the reverse order of removal. PRECAUTION (See page 60−1) DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE FRONT DOOR SCUFF PLATE RH (See page 76−22) REMOVE REAR DOOR SCUFF PLATE RH (See page 76−22) REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 61−5) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 61−5) REMOVE CENTER PILLAR GARNISH LOWER RH (See page 61−5) REMOVE FRONT SEAT OUTER BELT ASSY RH (See page 61−5) 9. (a) (b) REMOVE SIDE AIR BAG SENSOR ASSY RH Disconnect the connector from the side airbag sensor assy RH. Remove the 3 bolts and the side airbag sensor assy RH. H41550 10. INSTALL SIDE AIR BAG SENSOR ASSY RH (a) Check that the ignition switch is off. (b) Check that the battery negative (−) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the side airbag sensor assy RH with the 3 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) NOTICE:
If the side airbag sensor assy RH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the side airbag sensor assy RH with a new one.
When installing the side airbag sensor assy RH, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. (d) Connect the connector to the side airbag sensor assy RH. (e) Check that there is no looseness in the installation parts of the side airbag sensor assy RH. 11. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−66 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR REAR LH AIR BAG SENSOR REAR LH 6007Y−02 COMPONENTS Property Class 8T 20 (200, 14) Property Class 6T Airbag Sensor Rear LH 17.5 (178, 13) Rear Side Seat Back Assy LH 18 (184, 13) Rear Seat Cushion Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H41546 WhereEverybodyKnowsYourName 60−67 SUPPLEMENTAL RESTRAINT SYSTEM − AIR BAG SENSOR REAR LH 6007Z−03 REPLACEMENT HINT: Replacement procedure of the RH side is the same as that for the LH side. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE REAR SEAT CUSHION ASSY (See page 72−32) 4. REMOVE REAR SIDE SEAT BACK ASSY LH (See page 72−32) 5. (a) (b) REMOVE AIR BAG SENSOR REAR LH Disconnect the connector from the airbag sensor rear LH. Remove the 2 bolts and the airbag sensor rear LH. C92096 6. INSTALL AIR BAG SENSOR REAR LH (a) Check that the ignition switch is off. (b) Check that the battery negative (−) terminal is disconnected. NOTICE: After removing the terminal wait for at least 90 seconds before starting the operation. (c) Install the airbag sensor rear LH with the 2 bolts. Torque: Property class 6T: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) Property class 8T: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf) HINT: Select a suitable bolt (See page 03−2). NOTICE:
If the airbag sensor rear LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the airbag sensor rear LH with a new one.
When installing the airbag sensor rear LH, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. (d) Connect the connector to the airbag sensor rear LH. (e) Check that there is no looseness in the installation parts of the airbag sensor rear LH. 7. INSPECT AIR BAG SENSOR REAR LH (See page 60−17) 8. INSTALL REAR SIDE SEAT BACK ASSY LH (See page 72−32) 9. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 60−68 SUPPLEMENTAL RESTRAINT SYSTEM − SEAT POSITION AIR BAG SENSOR (From July, 2003) SEAT POSITION AIR BAG SENSOR (From July, 2003) 6009J−07 COMPONENTS Front LH Seat Assy Power Seat: Slide & Vertical Power Seat Switch Knob Reclining Power Seat Switch Knob Front Seat Cushion Shield LH 37 (375, 27) Front Seat Cushion Shield Inner No.1 LH Slide Position Sensor Protector 37 (375, 27) Torx Screw 8.0 (82, 71 in.⋅lbf) Seat Position Airbag Sensor Reclining Adjuster Release Handle LH 37 (375, 27) Vertical Seat Adjuster Knob Vertical Seat Adjuster Knob Cap Manual Seat: Front Seat Cushion Shield LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H43183 WhereEverybodyKnowsYourName 60−69 SUPPLEMENTAL RESTRAINT SYSTEM − SEAT POSITION AIR BAG SENSOR (From July, 2003) 600OS−02 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE FRONT SEAT ASSY LH (See page 72−23 (POWER SEAT) OR 72−15 (MANUAL SEAT)) 4. REMOVE RECLINING POWER SEAT SWITCH KNOB (POWER SEAT) (See page 72−23) 5. REMOVE SLIDE & VERTICAL POWER SEAT SWITCH KNOB (POWER SEAT) (See page 72−23) 6. REMOVE FRONT SEAT CUSHION SHIELD INNER NO.1 LH (POWER SEAT) (See page 72−23) 7. REMOVE FRONT SEAT CUSHION SHIELD LH (POWER SEAT) (See page 72−23) 8. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH (MANUAL SEAT) (See page 72−15) 9. REMOVE VERTICAL SEAT ADJUSTER KNOB CAP (MANUAL SEAT) (See page 72−15) 10. REMOVE VERTICAL SEAT ADJUSTER KNOB (MANUAL SEAT) (See page 72−15) 11. REMOVE FRONT SEAT CUSHION SHIELD LH (MANUAL SEAT) (See page 72−15) 12. (a) 13. (a) (b) REMOVE SEAT SLIDE POSITION SENSOR PROTECTOR Remove the seat slide position sensor protector from the seat position airbag sensor. REMOVE SEAT POSITION AIR BAG SENSOR Disconnect the connector from the seat position airbag sensor. Using a torx socket wrench (T30), remove the torx screw and the seat position airbag sensor. Seat Slide Position Sensor Protector Seat Position Airbag Sensor Torx Screw H43184 WhereEverybodyKnowsYourName 60−70 SUPPLEMENTAL RESTRAINT SYSTEM − SEAT POSITION AIR BAG SENSOR (From July, 2003) 14. (a) (b) INSTALL SEAT POSITION AIR BAG SENSOR Check that the ignition switch is off. Check that the battery negative (−) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. Using a feeler gauge 1 mm (0.039 in.), install the seat position airbag sensor. Feeler Gauge NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the 1 mm case, bracket or connector, replace the seat position airbag sensor with a new one.
When installing the seat position airbag sensor, be Seat Rail careful that the SRS wiring does not interfere with H43794 other parts and is not pinched between other parts. HINT: Be sure to maintain a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (d) Using a torx socket wrench, tighten the torx screw to install the seat position airbag sensor. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (e) Make sure that a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (f) Connect the connector to the seat position airbag sensor. (g) Check that there is no looseness in the installation parts of the seat position airbag sensor. 15. INSTALL FRONT SEAT ASSY LH (See page 72−23 (POWER SEAT) OR 72−15 (MANUAL SEAT)) 16. INSPECT SRS WARNING LIGHT (See page 05−1456) Seat Position Airbag Sensor (c) WhereEverybodyKnowsYourName 60−71 SUPPLEMENTAL RESTRAINT SYSTEM − OCCUPANT CLASSIFICATION ECU (From July, 2003) OCCUPANT CLASSIFICATION ECU (From July, 2003) 600KX−03 COMPONENTS Front RH Seat Assy 37 (375, 27) 37 (375, 27) Occupant Classification ECU N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName H43185 60−72 SUPPLEMENTAL RESTRAINT SYSTEM − OCCUPANT CLASSIFICATION ECU (From July, 2003) 600KY−02 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (See page 60−1) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. REMOVE FRONT RH SEAT ASSY (See page 72−15) 4. (a) (b) REMOVE OCCUPANT CLASSIFICATION ECU Disconnect the connectors from the occupant classification ECU. Using a screwdriver, remove the occupant classification ECU. H43186 5. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is off. (b) Check that the battery negative (−) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the occupant classification ECU. (d) Connect the connectors to the occupant classification ECU. NOTICE:
If the occupant classification ECU has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the occupant classification ECU with a new one.
When installing the occupant classification ECU, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. 6. INSTALL FRONT RH SEAT ASSY (See page 72−15) 7. OCCUPANT CLASSIFICATION ECU INITIALIZATION (See page 05−1452) 8. INSPECT SRS WARNING LIGHT (See page 05−1456) WhereEverybodyKnowsYourName 11−1 FUEL − FUEL SYSTEM (2AZ−FE)(From July, 2003) FUEL SYSTEM (2AZ−FE)(From July, 2003) 110XE−02 PRECAUTION 1. (a) (b) (c) PRECAUTION Before working on the fuel system, disconnect the negative (−) terminal cable from the battery. Do not smoke or be near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. 2. DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. (a) (b) Engine Room J/B C/OPN Relay A62391 Remove the C/OPN relay from the engine room J/B. Start the engine. After the engine has stopped, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system to lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and let the air out of the fuel tank. (e) Disconnect the negative (−) terminal cable from the battery. (f) Reinstall the C/OPN relay. 3. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Try to prevent gasoline from spilling out. (2) Disconnect the fuel pump tube (see page 11−14). (3) Drain the fuel remained inside the fuel pump tube. (4) (5) To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag. Put a container under the connection. B00679 WhereEverybodyKnowsYourName 11−2 FUEL New O−ring CORRECT − FUEL SYSTEM (2AZ−FE)(From July, 2003) (b) Observe these precautions when removing and installing the injector. (1) Never reuse the O−rings. (2) When placing a new O−ring on the injector, take care not to damage it in any way. (3) Coat a new O−rings with grease or gasoline before installing. Never use engine, gear or brake oil. (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe touches the O−ring of the injector. (d) Observe these precautions when disconnecting the fuel delivery pipe. Grommet Delivery Pipe Injector INCORRECT A91307 Delivery Pipe O−ring Grommet B09613 O−ring Retainer Pipe HINT: The structure of the metallic connector is shown as left. (1) Remove the fuel pipe clamp No.2. Nylon Tube Housing A50709 (2) Find the metallic connector of the fuel tube assembly, pull vehicle’s and hold it as it is. (3) Assemble SST to the connection as shown. SST 09268−21010 SST A60818 (4) (5) Retainer (at 4 places) Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly. B09615 WhereEverybodyKnowsYourName 11−3 FUEL (e) Fuel Pipe Clamp No.1 − FUEL SYSTEM (2AZ−FE)(From July, 2003) Observe these following precautions when disconnecting the fuel tube connector (quick type). (1) Remove the fuel pipe clamp No.1. (2) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if nesessary. A60083 (3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. (4) If the connector and the pipe are stuck. pinch the fuel pipe, push and pull the connector to disconnect and pull it out. Do no use any tools. Inspect for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. A A B12941 (5) B12944 (6) Vinyl Bag To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag. A52581 4. (a) CHECK FUEL LEAK Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page 11−4). WhereEverybodyKnowsYourName 11−10 FUEL − FUEL INJECTOR ASSY (2AZ−FE)(From July, 2003) 11021−09 REPLACEMENT 1. 2. 3. 4. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11−1) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 10−7) REMOVE ENGINE COVER SUB−ASSY NO.1 (See page 10−7) DISCONNECT FUEL TUBE SUB−ASSY (See page 11−1) A52073 6. (a) 5. REMOVE FUEL DELIVERY PIPE W/INJECTOR NOTICE: Be careful not to drop the injectors when removing the delivery pipe. (a) Remove the ventilation hose No. 2. (b) Disconnect the 4 injector connecters from the injector. (c) Remove the 2 clamps and wire harnesses from the delivery pipe. (d) Remove the 2 bolts and the delivery pipe together with the 4 injectors. (e) Remove the 2 spacers from the cylinder head. REMOVE FUEL INJECTOR ASSY Pull out the 4 injectors from the delivery pipe. 7. (a) (b) Insulator O−Ring INSTALL FUEL INJECTOR ASSY Install a new insulator to each injector. Apply a light coat of grease or gasoline to a new O−ring and install to each injector. A50145 (c) Push Turn Connector B09635 Apply a light coat of grease or gasoline on the place where a delivery pipe touches the O−ring. (d) To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth. (e) Install the 4 injectors. NOTICE:
Be careful not to twist the O−ring.
After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O−ring. (f) Position the injector connector downward. WhereEverybodyKnowsYourName 11−11 FUEL 8. (a) (b) Spacer − FUEL INJECTOR ASSY (2AZ−FE)(From July, 2003) INSTALL FUEL DELIVERY PIPE W/INJECTOR Place the 2 spacers in position on the cylinder head. Place the delivery pipe together with the 4 injectors in position on the cylinder head. B09636 (c) A52073 9. 10. 11. 12. Temporarily install the 2 bolts holding the delivery pipe to the cylinder. NOTICE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O−ring. (d) Position the injector connector outward. (e) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) CONNECT FUEL TUBE SUB−ASSY (See page 11−1) INSPECT FOR FUEL LEAKS (See page 11−4) INSTALL ENGINE COVER SUB−ASSY NO.1 (See page 10−7) INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 10−7) WhereEverybodyKnowsYourName 11−12 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) FUEL PUMP ASSY (2AZ−FE)(From July, 2003) 1109M−04 COMPONENTS Rear Seat Cushion Assembly Rear Floor Service Hole Cover Fuel Pump Connector Vapor Pressure Sensor Connector x8 Fuel Pump Tube Sub−assy 5.9 (60, 52 in.⋅lbf) Fuel Tank Bent Tube Set Plate Tube Joint Clip Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Set Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A79485 11−13 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) Vapor Pressure Sensor Assy Fuel Suction Plate Sub−assy Tube Joint Clip Fuel Pump Harness Fuel Sender Gage Assy Fuel Tank Fuel Filter
O−ring Fuel Pressure Regulator Assy Fuel Pump Assy Fuel Pump Filter
Fuel Pump Filter Clip Fuel Pump Cushion Rubber Fuel Suction Support No. 2
Non−reusable part A79486 WhereEverybodyKnowsYourName 11−14 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) 110XJ−03 REPLACEMENT 1. 2. DISCHARGE FUEL SYSTEM PRESSURE (See page 11−1) REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72−32) (c) 3. (a) (b) (c) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear floor service hole cover. Disconnect the vapor pressure sensor connector. Disconnect the fuel pump connector. 4. (a) SEPARATE FUEL PUMP TUBE SUB−ASSY Remove the tube joint clip, and pull out the fuel pump tube. (b) A79487 Tube Joint Clip A79488 Fuel Tube Joint O−ring Nylon Tube Tube Joint Clip Fuel Suction Plate A60575 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tool in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and the connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. 5. (a) REMOVE FUEL TANK VENT TUBE SET PLATE Remove the 8 bolts and the set plate. A79489 WhereEverybodyKnowsYourName 11−15 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) 6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Remove the fuel suction tube from the fuel tank. NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gage. (b) Remove the gasket from the fuel suction tube. A79490 Cover 7. (a) (b) Tube Joint Clip REMOVE VAPOR PRESSURE SENSOR ASSY Remove the cover. Remove the tube joint clip, and pull out the vapor pressure sensor. A79491 8. (a) REMOVE FUEL SUCTION SUPPORT NO.2 Using a screwdriver with its tip wrapped in tape, detach the 5 snap claws from the claw holes, and remove the fuel suction support. NOTICE: Do not damage the fuel suction support. Tape A77832 9. REMOVE FUEL PUMP CUSHION RUBBER 10. (a) (b) REMOVE FUEL SENDER GAGE ASSY Disconnect the fuel sender gage connector. Using a screwdriver with its tip wrapped in tape, unfasten the clamp to release the fuel sender gage. Slide the fuel sender gage to remove it from the fuel pump. A79492 (a) Tape Slide A79494 WhereEverybodyKnowsYourName 11−16 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) 11. (a) (b) REMOVE FUEL SUCTION PLATE SUB−ASSY Disconnect the fuel pump connector. Using a screwdriver with its tip wrapped in tape, detach the 4 snap claws from the claw holes, and pull out the fuel suction plate. NOTICE: Do not damage the fuel suction support. Tape (a) A79493 (b) 12. (a) (b) REMOVE FUEL PUMP HARNESS Disconnect the connector. Using a small screwdriver, pry out the fuel pump harness. 13. (a) REMOVE FUEL PUMP Pull out the fuel pump from the fuel tank fuel filter. 14. (a) (b) REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Pull out the fuel pump filter from the fuel pump. 15. (a) REMOVE FUEL PRESSURE REGULATOR ASSY Pull out the fuel pressure regulator from the fuel tank fuel filter. Remove the O−ring from the fuel pressure regulator. (a) (b) A79495 A79496 A79497 (b) A65037 WhereEverybodyKnowsYourName 11−17 FUEL − FUEL PUMP ASSY (2AZ−FE)(From July, 2003) 16. INSTALL FUEL PRESSURE REGULATOR ASSY (a) Apply a light coat of gasoline or grease to a new O−ring, and install it to the fuel pressure regulator. (b) Push in the fuel pressure regulator to the fuel tank fuel filter. 17. INSTALL FUEL PUMP FILTER (a) Install the fuel pump filter with a new clip. 18. INSTALL FUEL PUMP (a) Apply a light coat of gasoline or grease to the O−ring of the fuel pump. (b) Push in the fuel pump to the fuel tank fuel filter. 19. INSTALL FUEL PUMP HARNESS 20. INSTALL FUEL SUCTION PLATE SUB−ASSY 21. INSTALL FUEL SENDER GAGE ASSY 22. INSTALL FUEL PUMP CUSHION RUBBER 23. INSTALL FUEL SUCTION SUPPORT NO.2 24. INSTALL VAPOR PRESSURE SENSOR ASSY 25. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Install a new gasket to the fuel suction tube. (b) Install the fuel suction tube. NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gage. 26. INSTALL FUEL TANK VENT TUBE SET PLATE (a) Align the mark of the set plate with the fuel suction tube. (b) Install the set plate with the 8 bolts. Torque: 5.9 N⋅m (60 kgf⋅cm, 52 in.⋅lbf) Mark A79489 Collar Tube Joint Clip A81595 27. CONNECT FUEL PUMP TUBE SUB−ASSY (a) Install the fuel pump tube with the tube joint clip. NOTICE:
Check that there are no scratches or foreign objects on the connecting part.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint has not been pulled off. 28. CHECK FOR FUEL LEAKS (See page 11−4) 29. INSTALL REAR FLOOR SERVICE HOLE COVER 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page 72−32) WhereEverybodyKnowsYourName 11−18 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) FUEL TANK ASSY (2AZ−FE)(From July, 2003) 1109O−05 COMPONENTS Rear Seat Cushion Assembly Rear Floor Service Hole Cover Fuel Pump Connector Vapor Pressure Sensor Connector x8 Fuel Pump Tube Sub−assy 5.9 (60, 52 in.⋅lbf) Fuel Tank Bent Tube Set Plate Tube Joint Clip Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Set Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A79485 11−19 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) Fuel Tube No. 1 Hose Clamp Fuel Tank To Filler Pipe Hose Fuel Tank Assy Fuel Tank Protector Lower Center 5.4 (55, 48 in.⋅lbf) x4 39 (400, 29) Fuel Tank Band Sub−assy No. 1 RH Pin 39 (400, 29) Fuel Tank Band Sub−assy No. 1 LH Pin 5.4 (55, 48 in.⋅lbf)
Exhaust Pipe Gasket Parking Brake Cable Assy No. 2 5.4 (55, 48 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) Parking Brake Cable Assy No. 3 5.4 (55, 48 in.⋅lbf)
56 (571, 41) Exhaust Pipe Assy Center
Exhaust Pipe Gasket Floor Panel Brace Rear 20 (204, 14) 56 (571, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A91351 WhereEverybodyKnowsYourName 11−20 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) Fuel Pump Tube Sub−assy
Fuel Tank Cushion No. 2 x7 Fuel tank Vent Hose Fuel Tank Assy Clip Nut x4 5.4 (55, 48 in.⋅lbf) Fuel Main Tube Support N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A79483 WhereEverybodyKnowsYourName 11−21 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) 110XM−03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. (a) DISCHARGE FUEL SYSTEM PRESSURE (See page 11−1) REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72−32) REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11−14) SEPARATE FUEL PUMP TUBE SUB−ASSY (See page 11−14) REMOVE FUEL TANK VENT TUBE SET PLATE (See page 11−14) REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11−14) DRAIN FUEL REMOVE FLOOR PANEL BRACE REAR (See page 15−3) REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts, 4 nuts, exhaust pipe and 2 gaskets. 10. (a) DISCONNECT PARKING BRAKE CABLE ASSY NO.2 Remove the set bolt and the set nut of the parking brake cable. 11. (a) DISCONNECT PARKING BRAKE CABLE ASSY NO.3 Remove the set bolt and the set nut of the parking brake cable. 12. (a) REMOVE FUEL TANK PROTECTOR LOWER CENTER Remove the 4 bolts and fuel tank protector. A79472 A79473 A79476 WhereEverybodyKnowsYourName 11−22 FUEL 13. (a) Pinch − FUEL TANK ASSY (2AZ−FE)(From July, 2003) REMOVE FUEL TANK ASSY Disconnect the fuel pump tube. (1) Pinch the tab of the retainer to remove the lock claws and pull down it as shown in the illustration. (2) Pull out the fuel tank main tube. Retainer Pinch A79474 Fuel Tube Connector Retainer Pipe O−ring A81596 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (b) Pinch Disconnect the fuel tube No. 1. (1) Pinch the tube connector and then pull out the fuel tube No. 1. Pinch A92181 Nylon Tube Tube Connector O−ring Pipe A75650 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. WhereEverybodyKnowsYourName 11−23 FUEL (c) (d) (e) (f) Pinch (f) (g) − FUEL TANK ASSY (2AZ−FE)(From July, 2003) Set up a transmission jack underneath the fuel tank. Remove the 2 set bolts of the fuel tank bands. Remove the hose clamp and disconnect the fuel tank to filler pipe hose. Disconnect the fuel tank vent hose from the charcoal canister. (1) Push the connector deep into the charcoal canister to release the locking pin. (2) Pinch portion A. (3) Pull out the connector. Remove the fuel tank. Push Pinch A (e) A A91352 (h) Remove the 2 pins and 2 fuel tank bands as shown in the illustration. (i) Remove the 4 clip nuts. 14. (a) REMOVE FUEL TANK VENT HOSE Push the connector deep into the charcoal canister to release the locking pin. Pinch portion A. Pull out the connector. A79478 A79482 Push A (b) (c) A Pinch Pinch A79479 WhereEverybodyKnowsYourName 11−24 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) 15. (a) REMOVE FUEL PUMP TUBE SUB−ASSY Remove the fuel pump tube from the fuel main tube support. 16. (a) REMOVE FUEL MAIN TUBE SUPPORT Remove the bolt and tube support. A79480 A79481 17. 18. (a) 19. A79484 Fuel Tube Connector Pipe A91572 REMOVE FUEL TANK CUSHION NO.2 INSTALL FUEL TANK CUSHION NO.2 Install 7 new fuel tank cushions to the fuel tank. INSTALL FUEL MAIN TUBE SUPPORT Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 20. INSTALL FUEL PUMP TUBE SUB−ASSY 21. INSTALL FUEL TANK VENT HOSE 22. INSTALL FUEL TANK ASSY (a) Install the 4 clip nuts. (b) Install the 2 fuel tank bands with the 2 pins. (c) Connect the fuel tank vent hose. (d) Connect the fuel tank inlet pipe with the fuel filler pipe clamp. (e) Tighten the set 2 bolts of the fuel tank bands. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (f) Connect the fuel tube No. 1. (1) Push the fuel tube connector into the pipe until fuel tube connector makes ”click” sound. NOTICE:
Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart. WhereEverybodyKnowsYourName 11−25 FUEL − FUEL TANK ASSY (2AZ−FE)(From July, 2003) (g) Retainer A81598 23. 24. 25. 26. (a) 27. 28. 29. 30. 31. 32. 33. 34. 35. Connect the fuel pump tube. (1) Push in the fuel tube connector to the pipe until, and push up retainer to the claws lock. NOTICE:
Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart. INSTALL FUEL TANK PROTECTOR LOWER CENTER Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL PARKING BRAKE CABLE ASSY NO.3 Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL EXHAUST PIPE ASSY CENTER Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11−14) INSTALL FUEL TANK VENT TUBE SET PLATE (See page 11−14) CONNECT FUEL PUMP TUBE SUB−ASSY (See page 11−14) ADD FUEL CHECK FOR FUEL LEAKS (See page 11−4) CHECK FOR EXHAUST GAS LEAKS INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11−14) INSTALL REAR SEAT CUSHION ASSEMBLY (See page 72−32) INSTALL FLOOR PANEL BRACE REAR (See page 15−3) WhereEverybodyKnowsYourName 11−26 FUEL − FUEL SYSTEM (1MZ−FE/3MZ−FE) FUEL SYSTEM (1MZ−FE/3MZ−FE) 110UM−03 PRECAUTION 1. (a) (b) (c) PRECAUTION Before working on the fuel system, disconnect the negative (−) terminal cable from the battery. Do not smoke or be near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. 2. DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. (a) (b) Engine Room J/B C/OPN Relay A62391 Remove the C/OPN relay from the engine room J/B. Start the engine. After the engine has stopped, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system to lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and allow the air out of the fuel tank. (e) Disconnect the negative (−) terminal cable from the battery. (f) Reinstall the C/OPN relay. 3. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Try to prevent gasoline from spilling out. (2) Disconnect the fuel pump tube (see page 11−45). (3) Drain the fuel remaining inside the fuel pump tube. (4) (5) To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag. Put a container under the connection. B00679 WhereEverybodyKnowsYourName 11−27 FUEL New O−ring CORRECT − FUEL SYSTEM (1MZ−FE/3MZ−FE) (b) Observe the following precautions when removing and installing the fuel injectors. (1) Never reuse O−rings. (2) When installing a new O−ring on the injector, be careful not to damage it. (3) Coat new O−rings with grease or gasoline before installing. Never use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe contacts the O−ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connectors. (1) Remove the fuel pipe clamp from the connector. (2) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. Grommet Delivery Pipe Injector INCORRECT A91307 Delivery Pipe O−ring Grommet Spacer Insulator A62371 Fuel Pipe Clamp No.1 A60083 (3) Disconnect the connector from the hose while pinching part A with your fingers, as shown in the illustration. (4) If the connector and the pipe are stuck, pinch the fuel pipe, push and pull the connector to disconnect it and pull it out. Do not use any tools. If dirt or any other substance is found on the sealing surface that might interfere with the seal, clean the area thoroughly before assembly. A A B12941 (5) B12944 WhereEverybodyKnowsYourName 11−28 FUEL (6) Vinyl or Plastic Bag − FUEL SYSTEM (1MZ−FE/3MZ−FE) To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag. A79119 (e) Push A71366 Observe these precautions when connecting the fuel tube connector. (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a ”click” sound. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. (3) (4) (5) Pull After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart. Install the fuel pipe clamp to the connector. Check if there is any fuel leakage. A71366 4. (a) CHECK FOR FUEL LEAKS Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page 11−29). WhereEverybodyKnowsYourName 11−29 FUEL − FUEL SYSTEM (1MZ−FE/3MZ−FE) 110UN−03 ON−VEHICLE INSPECTION 1. (a) CHECK FUEL PUMP OPERATION AND FUEL LEAKS When using the hand−held tester: Check fuel pump operation. (1) Connect the hand−held tester to the DLC3. (2) Turn the ignition switch ON and push the hand−held tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the hand−held tester. (4) If you need help to select active test on the hand− held tester, refer to the hand−held tester is instruction manual. (5) Turn the ignition switch OFF. (6) Disconnect the hand−held tester from the DLC3. (b) Engine Room J/B FP +B C/OPN Relay A62390 When not using the hand−held tester: Check fuel pump operation. (1) Remove the C/OPN relay from the engine room J/B. (2) Using a service wire, connect terminals FP and +B of the engine room J/B. NOTICE: Pay close attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (d) Turn the ignition switch OFF. (e) Remove the servive wire from the engine room J/B. (f) Install the C/OPN relay to the engine room J/B. 2. (a) (b) Fuel Tube Connector (c) CHECK FUEL PRESSURE Check that the battery positive voltage is above 12 V. Disconnect the negative (−) terminal cable from the battery. Purchase a new fuel tube and take out the fuel tube connector from its pipe. Fuel tube: Part No. 23801−20190 A50710 WhereEverybodyKnowsYourName 11−30 FUEL (d) Fuel Pipe Clamp No.1 − FUEL SYSTEM (1MZ−FE/3MZ−FE) Remove the fuel pipe clamp from the fuel tube connector. A60083 (e) A A B12941 Disconnect the fuel tube connector from the fuel pipe by pinching part A with your fingers, as shown in the illustration. CAUTION:
Always read the precautions (see page 11−26) before disconnecting the fuel tube connector (quick type).
The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. (f) SST (Clip) SST SST (T joint) Fuel tube SST (Hose) Fuel Tube Connector A52613 Install SST (pressure gauge) and fuel tube connecter using SST as shown in the illustration. SST 09268−41047 (90467−13001, 95336−08070), 09268−45014 (09268−41200, 09268−41220, 09268−41250) (g) Wipe off any gasoline. (h) Reconnect the negative (−) battery cable. (i) When using hand−held tester: Operate the fuel pump (see step 1 (a)). (j) When not using hand−held tester: Operate the fuel pump (see step 1 (b)). (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) (n) Stop the engine. WhereEverybodyKnowsYourName 11−31 FUEL − FUEL SYSTEM (1MZ−FE/3MZ−FE) (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (p) After checking the fuel pressure, disconnect the negative (−) battery cable and carefully remove SST and fuel tube connector to prevent gasoline from spraying. (q) Reconnect the fuel inlet tube (fuel tube connector). CAUTION: Always read the precautions (see page 11−26) before connecting the fuel tube connector (quick type). WhereEverybodyKnowsYourName 11−32 FUEL − FUEL SYSTEM (1MZ−FE/3MZ−FE) 110UO−03 INSPECTION 1. (a) INSPECT FUEL INJECTOR ASSY Check the injector resistance. (1) Measure the resistance between the terminals. Standard: 13.4 to 14.2 Ω at 20
C (68
F) If the result is not as specified, replace the injector. (b) Check the injector injection. CAUTION:
This test involves high−pressure fuel and electricity.
Take every precaution regarding safe handling of both the fuel and the electricity.
Perform this test in a safe area, and avoid any sparks or flame.
Do not smoke. (1) Purchase the new fuel tube and take out the fuel tube connector from its pipe. Fuel tube: Parts No. 23801−20190 (2) Connect SST and the fuel tube connector to the fuel pipe. Fuel Tube Connector A50710 Fuel Tube Connector CAUTION: Always read the precautions (see page 11−26) before connecting the fuel tube connector (quick type). SST (Hose) B12947 (3) (4) SST(Hose) SST(Union) (5) O−Ring SST (Clamp) Vinyl Tube Install the O−ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and the union with SST (clamp) Put the injector into a graduated cylinder. HINT: Install a suitable vinyl tube onto the injector to contain the gasoline spray. (6) Operate the fuel pump (see page 11−29). A51873 WhereEverybodyKnowsYourName 11−33 FUEL − FUEL SYSTEM (1MZ−FE/3MZ−FE) (7) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842−30070 Standard: SST A52609 Injection Volume Difference Between Each Injector 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less NOTICE: Always turn on and off the voltage on the battery side, not the fuel pump side. If the injection volume is not as specified, replace the injector. (c) Check fuel leakage. (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less per 12 minutes B00069 2. (a) (−) A16628 (+) A91308 INSPECT FUEL PUMP Check the fuel pump resistance. (1) Measure the resistance between the terminals. Standard: 0.2 to 3.0 Ω at 20
C (68
F) (b) Check fuel pump operation. (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE:
These tests must be done within 10 seconds to prevent the coil from burning out.
Keep fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. WhereEverybodyKnowsYourName 11−34 FUEL − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) 110Z8−02 COMPONENTS 7.9 (81, 70 in.⋅lbf) x3 V−Bank Cover Sub−assy Fuel Vapor Feed Hose Assy Vacuum Hose MAF Meter Connector Air Cleaner Cap Sub−assy Vacuum Hose 5.0 (51, 44 in.⋅lbf) Air Cleaner Filter Element Sub−assy N·m (kgf·cm, ft·lbf) : Specified torque A88626 WhereEverybodyKnowsYourName 11−35 FUEL 1MZ−FE: − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) VSV Connector 7.8 (80, 69 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Pressure Feed Tube Assy x3 x2 Fuel Vapor Feed Hose Emission Control Valve Set 20 (204, 14) 28 (286, 21) x3 20 (204, 14) x2 x2 x2 Emission Control Valve Bracket Surge Tank Stay No. 1 x2 Engine Hunger No. 1 20 (204, 14) Intake Air Surge Tank Surge Tank Stay No. 2 Union to Check Valve Hose Throttle Motor Connector
Air Surge Tank to Intake Manifold Gasket Water Bypass Hose No. 3 Water Bypass Hose No. 2 N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A92440 WhereEverybodyKnowsYourName 11−36 FUEL 3MZ−FE: − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) VSV Connector 7.8 (80, 69 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Pressure Feed Tube Assy x3 x2 Fuel Vapor Feed Hose Emission Control Valve Set 28 (286, 21) 20 (204, 14) x3 20 (204, 14) x2 x2 x2 Emission Control Valve Bracket Surge Tank Stay x2 No. 1 Engine Hunger No. 1 20 (204, 14) Intake Air Surge Tank Surge Tank Stay No. 2 Union to Check Valve Hose Throttle Motor Connector
Air Surge Tank to Intake Manifold Gasket Water Bypass Hose No. 3 Water Bypass Hose No. 2 N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A92439 WhereEverybodyKnowsYourName 11−37 FUEL
Fuel Injector O−ring
Fuel Injector Grommet − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) 10 (102, 7) Fuel Injector Assy Fuel Injector Connector Fuel Delivery Pipe Sub−assy
Injector Vibration Insulator Delivery Pipe No. 1 Spacer 10 (102, 7) Fuel Delivery Pipe No. 2 20 (204, 14)
Fuel Pump Hose Gasket Fuel Pressure Pulsation Damper Assy
Injector Vibration Insulator 33 (337, 24) Fuel Pipe Sub−assy No. 1
Fuel Pipe No. 2 Gasket 33 (337, 24) Fuel Injector Connector Delivery Pipe No. 1 Spacer Fuel Pipe No. 2 Union Bolt N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A81676 WhereEverybodyKnowsYourName 11−38 FUEL − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) 110XI−02 REPLACEMENT 1. 2. 3. (a) 4. DISCHARGE FUEL SYSTEM PRESSURE (See page 11−26) DRAIN ENGINE COOLANT (See page 16−27) REMOVE FRONT SUSPENSION UPPER BRACE CENTER Remove the 2 nuts and upper brace. REMOVE V−BANK COVER SUB−ASSY (See page 10−18) (d) (c) 5. (a) (b) (c) (d) (e) (f) (d) (f) (b) (e) (b) (b) (a) (e) (b) A81684 (g) 6. (a) (a) (a) (b) REMOVE AIR CLEANER CAP SUB−ASSY Disconnect the MAF meter connector. Disconnect the 4 vacuum hoses. Disconnect the ventilation hose No. 2. Remove the fuel vapor feed hose from the 2 hose clamps. Loosen the 2 air cleaner cap bolts. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap. Remove the air cleaner filter element. REMOVE EMISSION CONTROL VALVE SET (1MZ−FE ENGINE TYPE) Disconnect the 3 VSV connectors. Remove the wire harness clamp. (b) (a) A79704 (d) (e) (e) (e) (f) (c) (c) (d) (e) (f) (g) Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Disconnect the 3 vacuum hoses. Remove the clamp. Remove the 2 nuts, and then remove the emission control valve set. 7. REMOVE EMISSION CONTROL VALVE SET (3MZ−FE ENGINE TYPE) Disconnect the 2 VSV connectors. Remove the wire harness clamp. A82469 (a) (b) (a) (a) (b) A79751 WhereEverybodyKnowsYourName 11−39 FUEL (d) (e) (e) (f) − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) (c) (d) (e) (f) (g) Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Disconnect the 2 vacuum hoses. Remove the clamp. Remove the 2 nuts and the emission control valve set. 8. (a) (b) (c) (d) REMOVE INTAKE AIR SURGE TANK Disconnect the throttle motor connector. Disconnect the water bypass hose No. 3. Disconnect the water bypass hose No. 2. Disconnect the union to check valve hose. (e) Disconnect the ventilation hose. (f) Remove the 3 nuts and separate the pressure feed tube. (g) (h) (i) Remove the 2 bolts and engine hunger No. 1. Remove the 2 bolts and surge tank stay No. 1. Remove the 2 bolts and surge tank stay No. 2. (c) A82428 (d) (a) (c) (b) A81623 (e) A79706 (f) A81678 (h) (g) (i) A81674 WhereEverybodyKnowsYourName 11−40 FUEL (j) (k) (l) − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) Using a socket hexagon wrench 8, remove the 4 bolts. Remove the 2 nuts, emission control valve bracket and intake air surge tank. Remove the gasket from the intake air surge tank. A82427 9. (a) (b) (b) (c) (c) SEPARATE FUEL PIPE SUB−ASSY NO.1 Remove the bolt and disconnect the fuel pipe No. 1. Remove the fuel pressure pulsation damper and 2 gaskets. Remove the fuel pipe No. 2 union bolt and 2 gaskets. 10. (a) REMOVE FUEL INJECTOR ASSY Disconnect the 6 fuel injector connectors. (a) A79710 A82436 (b) Remove the 4 bolts and 2 fuel delivery pipes together with the 6 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. A82437 (c)
2 Remove the 4 delivery pipe No. 1 spacers (
1) and 6 insulators (
2) from the intake manifold.
1
2 A82446 WhereEverybodyKnowsYourName 11−41 FUEL − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) (d) Pull out the fuel injector from the fuel delivery pipe. 11. (a) (b) INSTALL FUEL INJECTOR ASSY Install a new grommet to each injector. Apply a light coat of grease or gasoline to a new O−ring, and install it to each injector. A81137 New O−ring New Grommet A79762 (c) Apply a light coat of grease or gasoline on the place where the fuel delivery pipe contacts the O−ring. (d) Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe. NOTICE:
Be careful not to twist the O−ring.
After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O−ring. Turn Push A81139 (e) 12. (a) (b) Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold. (f) Place the 2 fuel delivery pipes and the 6 fuel injectors together on the intake manifold. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (g) Temporarily install the 4 bolts which are used to attach the Turn fuel delivery pipe to the intake manifold. A82447 NOTICE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O−ring. (h) Tighten the 4 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) (i) Connect the 6 fuel injector connectors. INSTALL FUEL PIPE SUB−ASSY NO.1 Install 2 new gaskets and the fuel pipe No. 2 union bolt. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) Install 2 new gaskets and the fuel pressure pulsation damper. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) WhereEverybodyKnowsYourName 11−42 FUEL (c) 13. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) 14. 15. 16. 17. 18. 19. 20. 21. 22. (a) − FUEL INJECTOR ASSY (1MZ−FE/3MZ−FE) Install the fuel pipe No. 1 with the bolt. Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf) INSTALL INTAKE AIR SURGE TANK Install a new gasket to the intake air surge tank. Install the intake air surge tank and emission control valve bracket with the 2 nuts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Using a socket hexagon wrench 8, tighten the 4 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Install the surge tank stay No. 2 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf) Install the surge tank stay No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf) Install the engine hunger No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf) Install the pressure feed tube with the 3 nuts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) Connect the ventilation hose. Connect the union to check valve hose. Connect the water bypass hose No. 2. Connect the water bypass hose No. 3. Connect the throttle motor connector. INSTALL EMISSION CONTROL VALVE SET (1MZ−FE ENGINE TYPE) Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL EMISSION CONTROL VALVE SET (3MZ−FE ENGINE TYPE) Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL AIR CLEANER CAP SUB−ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) CHECK CONNECTION OF VACUUM HOSE ADD ENGINE COOLANT (See page 16−27) CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) CHECK FOR FUEL LEAKS (See page 11−29) INSTALL V−BANK COVER SUB−ASSY (See page 10−18) INSTALL FRONT SUSPENSION UPPER BRACE CENTER Install the upper brace with the 2 nuts. Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) WhereEverybodyKnowsYourName 11−4 FUEL − FUEL SYSTEM (2AZ−FE)(From July, 2003) ON−VEHICLE INSPECTION 1. (a) CHECK FUEL PUMP OPERATION AND FUEL LEAKS When using the hand−held tester: Check fuel pump operation. (1) Connect the hand−held tester to the DLC3. (2) Turn the ignition switch ON and push the hand−held tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the hand−held tester. (4) If you need help to select active test on the hand− held tester, refer to the hand−held tester is instruction manual. (5) Turn the ignition switch OFF. (6) Disconnect the hand−held tester from the DLC3. 11023−08 (b) Engine Room J/B FP +B C/OPN Relay A62390 When not using the hand−held tester: Check fuel pump operation. (1) Remove the C/OPN relay from the engine room J/B. (2) Using a service wire, connect terminals FP and +B of the engine room J/B. NOTICE: Pay close attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (d) Turn the ignition switch OFF. (e) Remove the service wire from the engine room J/B. (f) Install the C/OPN relay to the engine room J/B. 2. (a) (b) Fuel Tube Connector (c) CHECK FUEL PRESSURE Check that the battery positive voltage is above 12 V. Disconnect the negative (−) terminal cable from the battery. Purchase a new fuel tube and take out the fuel tube connector from its pipe. Fuel tube: Part No. 23801−20190 A50710 WhereEverybodyKnowsYourName 11−5 FUEL (d) Fuel Pipe Clamp No.1 − FUEL SYSTEM (2AZ−FE)(From July, 2003) Remove the fuel pipe clamp from the fuel tube connector. A60083 (e) A A B12941 Disconnect the fuel tube connector from the fuel pipe by pinching part A with your fingers, as shown in the illustration. CAUTION:
Always read the precautions (see page 11−1) before disconnecting the fuel tube connector (quick type).
The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. (f) SST (Clip) SST SST (T joint) Fuel tube SST (Hose) Fuel Tube Connector A52613 Install SST (pressure gauge) and fuel tube connecter using SST as shown in the illustration. SST 09268−41047 (90467−13001, 95336−08070), 09268−45014 (09268−41200, 09268−41220, 09268−41250) (g) Wipe off any gasoline. (h) Reconnect the negative (−) battery cable. (i) When using hand−held tester: Operate the fuel pump (see step 1 (a)). (j) When not using hand−held tester: Operate the fuel pump (see step 1 (b)). (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) (n) Stop the engine. WhereEverybodyKnowsYourName 11−6 FUEL − FUEL SYSTEM (2AZ−FE)(From July, 2003) (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21psi) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (p) After checking the fuel pressure, disconnect the negative (−) battery cable and carefully remove SST and fuel tube connector to prevent gasoline from spraying. (q) Reconnect the fuel inlet tube (fuel tube connector). CAUTION: Always read the precautions (see page 11−1) before connecting the fuel tube connector (quick type). WhereEverybodyKnowsYourName 11−43 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) FUEL PUMP ASSY (1MZ−FE/3MZ−FE) 110XL−02 COMPONENTS Rear Seat Cushion Assembly Rear Floor Service Hole Cover Fuel Pump Connector Vapor Pressure Sensor Connector x8 Fuel Pump Tube Sub−assy 5.9 (60, 52 in.⋅lbf) Fuel Tank Bent Tube Set Plate Tube Joint Clip Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Set Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A79485 11−44 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) Vapor Pressure Sensor Assy Fuel Suction Plate Sub−assy Tube Joint Clip Fuel Pump Harness Fuel Sender Gage Assy Fuel Tank Fuel Filter
O−ring Fuel Pressure Regulator Assy Fuel Pump Assy Fuel Pump Filter
Fuel Pump Filter Clip Fuel Pump Cushion Rubber Fuel Suction Support No. 2
Non−reusable part A79486 WhereEverybodyKnowsYourName 11−45 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) 110XO−03 REPLACEMENT 1. 2. DISCHARGE FUEL SYSTEM PRESSURE (See page 11−26) REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72−32) (c) 3. (a) (b) (c) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear floor service hole cover. Disconnect the vapor pressure sensor connector. Disconnect the fuel pump connector. 4. (a) SEPARATE FUEL PUMP TUBE SUB−ASSY Remove the tube joint clip, and pull out the fuel pump tube. (b) A79487 Tube Joint Clip A79488 Fuel Tube Joint O−ring Nylon Tube Tube Joint Clip Fuel Suction Plate A60575 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and the connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. 5. (a) REMOVE FUEL TANK VENT TUBE SET PLATE Remove the 8 bolts and the set plate. A79489 WhereEverybodyKnowsYourName 11−46 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) 6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Remove the fuel suction tube from the fuel tank. NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gage. (b) Remove the gasket from the fuel suction tube. A79490 Cover 7. (a) (b) Tube Joint Clip REMOVE VAPOR PRESSURE SENSOR ASSY Remove the cover. Remove the tube joint clip, and pull out the vapor pressure sensor. A79491 8. (a) REMOVE FUEL SUCTION SUPPORT NO.2 Using a screwdriver with its tip wrapped in tape, detach the 5 snap claws from the claw holes, and remove the fuel suction support. NOTICE: Do not damage the fuel suction support. Tape A77832 9. REMOVE FUEL PUMP CUSHION RUBBER 10. (a) (b) REMOVE FUEL SENDER GAGE ASSY Disconnect the fuel sender gage connector. Using a screwdriver with its tip wrapped in tape, unfasten the clamp to release the fuel sender gage. Slide the fuel sender gage to remove it from the fuel pump. A79492 (a) Tape Slide A79494 WhereEverybodyKnowsYourName 11−47 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) 11. (a) (b) REMOVE FUEL SUCTION PLATE SUB−ASSY Disconnect the fuel pump connector. Using a screwdriver with its tip wrapped in tape, detach the 4 snap claws from the claw holes, and pull out the fuel suction plate. NOTICE: Do not damage the fuel suction support. Tape (a) A79493 (b) 12. (a) (b) REMOVE FUEL PUMP HARNESS Disconnect the connector. Using a small screwdriver, pry out the fuel pump harness. 13. (a) REMOVE FUEL PUMP Pull out the fuel pump from the fuel tank fuel filter. 14. (a) (b) REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Pull out the fuel pump filter from the fuel pump. 15. (a) REMOVE FUEL PRESSURE REGULATOR ASSY Pull out the fuel pressure regulator from the fuel tank fuel filter. Remove the O−ring from the fuel pressure regulator. (a) (b) A79495 A79496 A79497 (b) A65037 WhereEverybodyKnowsYourName 11−48 FUEL − FUEL PUMP ASSY (1MZ−FE/3MZ−FE) 16. INSTALL FUEL PRESSURE REGULATOR ASSY (a) Apply a light coat of gasoline or grease to a new O−ring, and install it to the fuel pressure regulator. (b) Push in the fuel pressure regulator to the fuel tank fuel filter. 17. INSTALL FUEL PUMP FILTER (a) Install the fuel pump filter with a new clip. 18. INSTALL FUEL PUMP (a) Apply a light coat of gasoline or grease to the O−ring of the fuel pump. (b) Push in the fuel pump to the fuel tank fuel filter. 19. INSTALL FUEL PUMP HARNESS 20. INSTALL FUEL SUCTION PLATE SUB−ASSY 21. INSTALL FUEL SENDER GAGE ASSY 22. INSTALL FUEL PUMP CUSHION RUBBER 23. INSTALL FUEL SUCTION SUPPORT NO.2 24. INSTALL VAPOR PRESSURE SENSOR ASSY 25. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Install a new gasket to the fuel suction tube. (b) Install the fuel suction tube. NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gage. 26. INSTALL FUEL TANK VENT TUBE SET PLATE (a) Align the mark of the set plate with the fuel suction tube. (b) Install the set plate with the 8 bolts. Torque: 5.9 N⋅m (60 kgf⋅cm, 52 in.⋅lbf) Mark 28. 29. 30. A79489 27. CONNECT FUEL PUMP TUBE SUB−ASSY (a) Install the fuel pump tube with the tube joint clip. NOTICE:
Check that there are no scratches or foreign objects Collar on the connecting part.
Check that the fuel tube joint is inserted securely. Tube Joint Clip
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel A81595 tube joint has not been pulled off. CHECK FOR FUEL LEAKS (See page 11−29) INSTALL REAR FLOOR SERVICE HOLE COVER INSTALL REAR SEAT CUSHION ASSEMBLY (See page 72−32) WhereEverybodyKnowsYourName 11−49 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) FUEL TANK ASSY (1MZ−FE/3MZ−FE) 110XN−02 COMPONENTS Rear Seat Cushion Assembly Rear Floor Service Hole Cover Fuel Pump Connector Vapor Pressure Sensor Connector x8 Fuel Pump Tube Sub−assy 5.9 (60, 52 in.⋅lbf) Fuel Tank Bent Tube Set Plate Tube Joint Clip Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Set Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part WhereEverybodyKnowsYourName A79485 11−50 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) Fuel Tube No. 1 Hose Clamp Fuel Tank To Filler Pipe Hose Fuel Tank Assy Fuel Tank Protector Lower Center 5.4 (55, 48 in.⋅lbf) x4 39 (400, 29) Fuel Tank Band Sub−assy No. 1 RH Pin 39 (400, 29) Fuel Tank Band Sub−assy No. 1 LH Pin 5.4 (55, 48 in.⋅lbf)
Exhaust Pipe Gasket Parking Brake Cable Assy No. 2 5.4 (55, 48 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) Parking Brake Cable Assy No. 3 5.4 (55, 48 in.⋅lbf)
56 (571, 41) Exhaust Pipe Assy Center
Exhaust Pipe Gasket Floor Panel Brace Rear 20 (204, 14) 56 (571, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A91351 WhereEverybodyKnowsYourName 11−51 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) Fuel Pump Tube Sub−assy
Fuel Tank Cushion No. 2 x7 Fuel tank Vent Hose Fuel Tank Assy Clip Nut x4 5.4 (55, 48 in.⋅lbf) Fuel Main Tube Support N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A79483 WhereEverybodyKnowsYourName 11−52 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) 110XK−03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. (a) DISCHARGE FUEL SYSTEM PRESSURE (See page 11−26) REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72−32) REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11−45) SEPARATE FUEL PUMP TUBE SUB−ASSY (See page 11−45) REMOVE FUEL TANK VENT TUBE SET PLATE (See page 11−45) REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11−45) DRAIN FUEL REMOVE FLOOR PANEL BRACE REAR (See page 15−7) REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts, 4 nuts, exhaust pipe and 2 gaskets. 10. (a) DISCONNECT PARKING BRAKE CABLE ASSY NO.2 Remove the set bolt and the set nut of the parking brake cable. 11. (a) DISCONNECT PARKING BRAKE CABLE ASSY NO.3 Remove the set bolt and the set nut of the parking brake cable. 12. (a) REMOVE FUEL TANK PROTECTOR LOWER CENTER Remove the 4 bolts and fuel tank protector. A79472 A79473 A79476 WhereEverybodyKnowsYourName 11−53 FUEL 13. (a) Pinch − FUEL TANK ASSY (1MZ−FE/3MZ−FE) REMOVE FUEL TANK ASSY Disconnect the fuel pump tube. (1) Pinch the tab of the retainer to remove the lock claws and pull down it as shown in the illustration. (2) Pull out the fuel tank main tube. Retainer Pinch A79474 Fuel Tube Connector Retainer Pipe O−ring A81596 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (b) Pinch Disconnect the fuel tube No. 1. (1) Pinch the tube connector and then pull out the fuel tube No. 1. Pinch A92181 Nylon Tube Tube Connector O−ring Pipe A75650 NOTICE:
Before this operation, check the connector for dirt, mud or other contamination.
Be careful of mud. The connector’s O−ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. WhereEverybodyKnowsYourName 11−54 FUEL (c) (d) (e) (f) Pinch (f) (g) − FUEL TANK ASSY (1MZ−FE/3MZ−FE) Set up a transmission jack underneath the fuel tank. Remove the 2 set bolts of the fuel tank bands. Remove the hose clamp and disconnect the fuel tank to filler pipe hose. Disconnect the fuel tank vent hose from the charcoal canister. (1) Push the connector deep into the charcoal canister to release the locking pin. (2) Pinch portion A. (3) Pull out the connector. Remove the fuel tank. Push Pinch A (e) A A91352 (h) Remove the 2 pins and 2 fuel tank bands as shown in the illustration. (i) Remove the 4 clip nuts. 14. (a) REMOVE FUEL TANK VENT HOSE Push the connector deep into the charcoal canister to release the locking pin. Pinch portion A. Pull out the connector. A79478 A79482 Push A (b) (c) A Pinch Pinch A79479 WhereEverybodyKnowsYourName 11−55 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) 15. (a) REMOVE FUEL PUMP TUBE SUB−ASSY Remove the fuel pump tube from the fuel main tube support. 16. (a) REMOVE FUEL MAIN TUBE SUPPORT Remove the bolt and tube support. A79480 A79481 17. 18. (a) 19. A79484 Fuel Tube Connector Pipe A91572 REMOVE FUEL TANK CUSHION NO.2 INSTALL FUEL TANK CUSHION NO.2 Install 7 new fuel tank cushions to the fuel tank. INSTALL FUEL MAIN TUBE SUPPORT Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 20. INSTALL FUEL PUMP TUBE SUB−ASSY 21. INSTALL FUEL TANK VENT HOSE 22. INSTALL FUEL TANK ASSY (a) Install the 4 clip nuts. (b) Install the 2 fuel tank bands with the 2 pins. (c) Connect the fuel tank vent hose. (d) Connect the fuel tank inlet pipe with the fuel filler pipe clamp. (e) Tighten the set 2 bolts of the fuel tank bands. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (f) Connect the fuel tube No. 1. (1) Push the fuel tube connector into the pipe until fuel tube connector makes ”click” sound. NOTICE:
Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart. WhereEverybodyKnowsYourName 11−56 FUEL − FUEL TANK ASSY (1MZ−FE/3MZ−FE) (g) Retainer A81598 23. 24. 25. 26. (a) 27. 28. 29. 30. 31. 32. 33. 34. 35. Connect the fuel pump tube. (1) Push in the fuel tube connector to the pipe until, and push up retainer to the claws lock. NOTICE:
Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart. INSTALL FUEL TANK PROTECTOR LOWER CENTER Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL PARKING BRAKE CABLE ASSY NO.3 Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL EXHAUST PIPE ASSY CENTER Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11−45) INSTALL FUEL TANK VENT TUBE SET PLATE (See page 11−45) CONNECT FUEL PUMP TUBE SUB−ASSY (See page 11−45) ADD FUEL CHECK FOR FUEL LEAKS (See page 11−29) CHECK FOR EXHAUST GAS LEAKS INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11−45) INSTALL REAR SEAT CUSHION ASSEMBLY (See page 72−32) INSTALL FLOOR PANEL BRACE REAR (See page 15−7) WhereEverybodyKnowsYourName 11−7 FUEL − FUEL SYSTEM (2AZ−FE)(From July, 2003) 11024−06 INSPECTION 1. (a) FUEL INJECTOR ASSY Check the injector resistance. (1) Measure the resistance between the terminals. Standard: 11.6 to 12.4 Ω at 20
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F) If the result is not as specified, replace the injector. (b) Check the injector injection. CAUTION:
This test involves high−pressure fuel and electricity.
Take every precaution regarding safe handling of both the fuel and the electricity.
Perform this test in a safe area, and avoid any sparks or flame.
Do not smoke. (1) Fuel Tube Connector Purchase a new fuel tube and take out the fuel tube connector from its pipe. Part No. 23801−20190 A50710 (2) Connect SST and fuel tube connector to the fuel pipe. SST 09268−41047 CAUTION: Always read the precautions (see page 11−1) before connecting the fuel tube connector (quick type). Fuel Tube Connector SST (Hose) B12947 (3) (4) Install the O−ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268−41047 (09268−41110, 09268−41300) (5) Put the injector into a graduated cylinder. SST (Hose) SST (Union) O−Ring SST (Clamp) Vinyl Tube A51875 HINT: Install a suitable vinyl tube onto the injector to contain the gasoline spray. (6) Operate the fuel pump (see page 11−14). WhereEverybodyKnowsYourName 11−8 FUEL − FUEL SYSTEM (2AZ−FE)(From July, 2003) (7) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842−30080 Standard: SST A50700 Injection Volume Difference Between Each Injector 76 to 91 cm3 (4.6 to 5.6 cu in.) per 15 seconds 16 cm3 (1.0 cu in.) or less NOTICE: Always turn on and off the voltage on the battery side, not the fuel pump side. If the injection volume is not as specified, replace the injector. (c) Check fuel leakage. (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less per 12 minutes B00069 2. (a) (−) A16628 (+) A91308 FUEL PUMP Check fuel pump resistance. (1) Measure the resistance between the terminals. Resistance: 0.2 to 3.0 Ω at 20
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F) (b) Check fuel pump operation. (1) Apply battery voltage to both terminals. Check that the pump operates. NOTICE:
These tests must be done within 10 seconds to prevent the coil from burning out.
Keep fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. WhereEverybodyKnowsYourName 11−9 FUEL − FUEL INJECTOR ASSY (2AZ−FE)(From July, 2003) FUEL INJECTOR ASSY (2AZ−FE)(From July, 2003) 1109L−04 COMPONENTS Fuel Vapor Feed Hose VSV Connector MAF Meter Connector Engine Wire Emission Tube, No. 1 Fuel Hose Fuel Delivery Pipe 20 (204, 15) 20 (204, 15) 7.0 (71, 62 in.⋅lbf) Air Cleaner Cap w/ Air Cleaner Hose
O−ring Fuel Injector Assy
Insulator Engine Cover Sub−assy No. 1 Ventilation Hose No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part A60820 WhereEverybodyKnowsYourName 55−11 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM 550BO−04 INSPECTION 1. (a) E34870 COOLER COMPRESSOR ASSY Connect the positive (+) lead from the battery to terminal 3 and the negative (−) lead to the body ground. (b) Check that the magnet clutch energized. If operation is not as specified, replace the magnet clutch assy. (c) Measure resistance between terminals 1 and 2. Standard resistance: 165 − 205 Ω at 20
C (68
F) If resistance is not as specified, replace the cooler compressor assy. 2. MAGNET−CLUTCH RELAY Condition Tester connection Specified condition Constant 1−2 Continuity Apply B + between terminals 1 and 2. 3−5 Continuity If continuity is not as specified, replace the magnet−clutch relay. E50315 WhereEverybodyKnowsYourName 55−12 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM 3. (a) I30157 MAX. HOT AIRMIX DAMPER SERVO SUB−ASSY Inspect servomotor operation. (1) Connect the positive (+) lead from the battery to terminal 4 and negative (−) lead to terminal 5, then check that the arm turns to ”COLD” side smoothly. (2) Connect the positive (+) lead from the battery to terminal 5 and negative (−) lead to terminal 4, then check that the arm turns to ”HOT” side smoothly. If operations are not as specified, replace the air mix servomotor. (b) Inspect position sensor resistance. Measure resistance between terminals at servomotor arm each position as shown in the chart. Tester connection MAX. COLD Condition Specified condition 1−2 Constant 4.2 − 7.8 kΩ 1−3 Arm position at ”COLD” 0.8 − 1.6 kΩ 1−3 Arm position at ”HOT” 3.4 − 6.2 kΩ If resistance is not as specified, replace the servomotor. I30332 Resistance (kΩ) 3.4 − 6.2 Arm position 0.8 − 1.6 MAX. HOT MAX. COLD I30161 FOOT FOOT/DEF 4. (a) B/L FACE DEF MODE DAMPER SERVO SUB−ASSY Inspect servomotor operation. (1) Connect the positive (+) lead from the battery to terminal 7 and the negative (−) lead to terminal 8. (2) Connect the negative (−) lead from the battery to each terminal as shown in the chart, and check that the shaft rotates at each position, as shown in the illustration. Connected terminal Position 1 DEF 2 FOOT/DEF 3 FOOT 5 B/L 6 FACE If operation is not as specified, replace the servomotor. I31408 WhereEverybodyKnowsYourName 55−13 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM 5. (a) RECIRCULATION DAMPER SERVO SUB−ASSY Inspect servomotor operation. (1) Connect the positive (+) lead from the battery to terminal 5 and negative (−) lead to terminal 1, then check that the arm turns to ”REC” side smoothly. (2) Connect the positive (+) lead from the battery to terminal 5 and negative (−) lead to terminal 2, then check that the arm turns to ”FRS” side smoothly. If operations are not as specified, replace the mode damper servomotor. FRS REC I31407 WhereEverybodyKnowsYourName 55−14 HEATER & AIR CONDITIONER 6. (a) (b) − + E50650 − AIR CONDITIONING SYSTEM COOLER THERMISTOR NO.1 Remove cooler thermistor No.1. Check resistance between terminals 1 and 2 of cooler thermistor No.1 at each temperature, as shown in the chart. Standard: Tester connection Condition Specified condition 1−2 −10°C (14°F) 8.00 to 10.00 kΩ 1−2 −5°C (23°F) 6.15 to 7.65 kΩ 1−2 0°C (32°F) 4.75 to 5.85 kΩ 1−2 5°C (41°F) 3.70 to 4.55 kΩ 1−2 10°C (50°F) 2.91 to 3.55 kΩ 1−2 15°C (59°F) 2.32 to 2.80 kΩ 1−2 20°C (68°F) 1.85 to 2.22 kΩ 1−2 25°C (77°F) 1.48 to 1.77 kΩ 1−2 30°C (86°F) 1.20 to 1.43 kΩ NOTICE: Even slightly touching the sensor may change the resistance value.Be sure to hold the connector of the sensor. HINT: As the temperature increases, the resistance decreases (see the chart below). Resistance (kΩ) 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 −20 −4 MIN MAX 0 32 20 68 40 (°C) 104 (°F) Temperature I40632 WhereEverybodyKnowsYourName 55−15 HEATER & AIR CONDITIONER 2 − AIR CONDITIONING SYSTEM 7. (a) BLOWER W/FAN MOTOR SUB−ASSY Connect the positive (+) lead from the battery to terminal 2 and negative (−) to terminal 1, then check that the motor operation smoothly. If operation is not as specified, replace the blower motor. 1 I31402 8. (a) BLOWER RESISTOR Measure resistance between terminals, as shown in the chart below. Tester connection Specified condition 1−2 1.398 − 1.605 Ω 1−3 0.465 − 0.535 Ω 1−4 3.069 − 3.531 Ω If resistance is not as specified, replace the blower resistor. E32877 9. HEATER BLOWER MOTOR RELAY ASSY Condition Tester connection Specified condition Constant 1−2 3−4 Continuity Apply B + between terminals 1 and 2. 3−5 Continuity If continuity is not as specified, replace the heater blower motor relay. E32993 WhereEverybodyKnowsYourName 55−16 HEATER & AIR CONDITIONER − REFRIGERANT REFRIGERANT 550BS−04 ON−VEHICLE INSPECTION 1. (a) INSPECT REFRIGERANT VOLUME Observe the sight glass on the cooler refrigerant liquid pipe A. Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ”HI”
A/C switch ON
Temperature control dial at ”MAX. COOL”
Fully open the doors Sight Glass I31521 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles present Insufficient* (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles present None, insufficient or too much Refer 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet. Correct or too much Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant clear Too much (1) Discharge refrigerant (2) Remove air and supply proper amount or purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Correct − *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. WhereEverybodyKnowsYourName 55−17 HEATER & AIR CONDITIONER 2. (a) − REFRIGERANT INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in witch the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 − 35 °C (86 − 95 °F)
Engine running at 1,500 rpm
Blower speed control switch at ”HI” position
Temperature control dial at ”COOL” position
A/C switch ON
Fully open doors (1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 − 0.25 MPa (1.5 − 2.5 kgf/cm2) High pressure side: 1.37 − 1.57 MPa (14 − 16 kgf/cm2) E50573 (2) Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I22117 Symptom Probable cause During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture in refrigerating system freezes at expansion valve orifice causing a temporary stop of cycle, however, when it melts, normal state is restored. Diagnosis
Drier in oversaturected state
Moisture in refrigerating system freezes at expansion valve orifice and blocks circulation of refrigerant WhereEverybodyKnowsYourName Remedy (1) Replace condenser (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant 55−18 HEATER & AIR CONDITIONER (3) − REFRIGERANT Insufficient cooling Condition: Cooling system does not function eftectively. I22118 Symptom
Pressure low on both low and high pressure sides
Bubbles seen thought sight glass continuously
Insufficient cooling performance Probable cause Diagnosis Gas leakage in refrigeration system (4)
Insufficient refrigerant
Refrigerant leaking Corrective Actions (1) Check for gas leakage and repair if necessary (2) Supply proper amount of new refrigerant (3) If indicated pressure value is close to a 0 when connected to gauge, create the vacuum after inspecting and repairing location of leak Poor circulation of refrigerant Condition: Cooling system close not function effectively. I22119 Symptom
Pressure low on both low and high pressure sides
Frost on pipe from condenser to unit Probable cause Refrigerant flow obstructed by dirt in receiver Diagnosis Receiver clogged WhereEverybodyKnowsYourName Corrective Action Replace condenser 55−19 HEATER & AIR CONDITIONER − (5) REFRIGERANT Refrigerant does not circulate Condition: Cooling system does not function. (Sometimes it way function) I22120 Symptom
Vacuum indicated on low pressure side, very low pressure indicated on high pressure side
Frost or dew seen on piping before and after receiver/ drier or expansion valve Probable cause Diagnosis
Refrigerant flow obstructed by moisture or dirt in refrigerating system Refrigerant does not circulate
Refrigerant flow obstructed by gas leaked from expansion valve (6) Corrective Actions (1) Check expansion valve (2) Clean out dirt in expansion valve by air blowing (3) Replace condenser (4) Evaporate air and supply proper amount of new refrigerant. (5) For gas leakage from expansion valve, replace expansion valve Refrigerant overcharged or insufficient cooling of condenser Condition: Cooling system does not function dftectively. I22121 Symptom
Pressure too high on both low and high pressure sides
No sir bubbles seen through the sight glass even when the engine rpm is lowered Probable cause
Unable to develop sufficient performance due to excessive use of refrigerating system
Insufficient cooling of condenser Diagnosis
Excessive refrigerant in cycle→too much refrigerant supplied
Condenser cooling insufficient→condenser fins clogged at cooling fan WhereEverybodyKnowsYourName Remedy (1) Clean condenser (2) Check cooling fan with cooling fan motor operation (3) If (1) and (2) are in normal state, check amount of refrigerant and supply proper amount of refrigerant 55−20 HEATER & AIR CONDITIONER (7) − REFRIGERANT Air present in refrigeration system Condition: Cooling system does not function. NOTE : These gauge indications are shown when the refrigerating system has been opens and the refrigerant charged without vacuum purging. Symptom Probable cause Diagnosis
Pressure too high on both low and high pressure sides
The low pressure piping too hot Air entered in refrigerating system to the touch
Bubbles seen through sight glass (8)
Air present in refrigerating system
Insufficient vacuum purging I22122 Corrective Actions (1) Check compressor oil to see if it is see if it is dirty or insufficient (2) Evacuate air and supply new refrigerant Expansion valve improperly Condition: Refrigerant functions insufficient. I22123 Symptom
Pressure too high on both low and high pressure sides
Frost or large amount of dew on piping on low pressure side Probable cause Trouble in expansion valve Diagnosis
Excessive refrigerant in low pressure piping
Expansion valve opened too wide WhereEverybodyKnowsYourName Corrective Actions Check expansion valve 55−21 HEATER & AIR CONDITIONER − REFRIGERANT (9) Defective compression compressor Condition : Refrigerant is not effective. I22124 Symptom Probable cause
Pressure too high on low high pressure sides
Pressure too low to on high pressure side Diagnosis Corrective Actions
Compression failure
Leakage from valve damaged or broken sliding parts Internal leak in compressor Repair or replace compressor Gauge readings (Reference) Pressure on low pressure side MPa (kgf/cm2) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.9) 0.3 (3.0) 0.27 (2.85) 0.2 (2.0) 1.2 (12.3) 0.22 (2.25) 0.2 (2.1) Blower LO Zone 1.25 (12.8) 0.14 (1.5) 0.5 (5.0) 1.32 (13.5) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) Pressure on HI pressure side MPa (kgf/cm2) I30081 WhereEverybodyKnowsYourName 55−2 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM 550BM−04 PROBLEM SYMPTOMS TABLE Use the table below to help you to find the cause of the problems. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page Whole functions of the A/C system does not operate. 1. 2. 3. 4. 5. 6. HTR fuse (50 A) HTR fuse (10 A) A/C fuse HTR relay A/C control assy Wire harness or connector − − − 55−11 55−4 − Air Flow Control : No blower operation 1. 2. 3. 4. Heater blower motor relay Blower w/ fan motor sub−assy A/C control assy Wire harness or connector 55−11 55−11 55−4 − Air Flow Control : No blower control 1. 2. 3. 4. Blower w/ fan motor sub−assy Blower resistor A/C control assy Wire harness or connector 55−11 55−11 55−4 − Air Flow Control : Insufficient air flow 1. Blower w/ fan motor sub−assy 2. A/C control assy 3. Wire harness or connector 55−11 55−4 − Temperature Control : No cool air comes out 1. 2. 3. 4. 5. 6. 7. 8. 9. Volume of refrigerant Drive belt tension Cooler compressor assy Refrigerant pressure Pressure switch No.1 Air mix damper servo sub−assy Condenser fan A/C control assy Wire harness or connector 55−16 55−26 55−11 55−16 55−4 55−11 − 55−4 − Temperature Control : No warm air comes out 1. 2. 3. 4. 5. 6. Engine coolant volume Air mix damper servo sub−assy Cooler thermistor No.1 A/C control assy Heater radiator unit sub−assy Wire harness or connector − 55−11 55−11 55−4 − − Temperature Control : Out coming air is warmer or cooler than the set temperature or response is slow. 1. Air mix damper servo sub−assy 2. A/C control assy 3. Wire harness or connector 55−11 55−4 − Temperature Control : No temperature control (only Max. cool or Max. warm) 1. Air mix damper servo sub−assy 2. A/C control assy 3. Wire harness or connector 55−11 55−4 − No air inlet control 1. Recirculation damper servo sub−assy 2. A/C control assy 3. Wire harness or connector 55−11 55−4 − No air outlet control 1. Mode damper servo sub−assy 2. A/C control assy 3. Wire harness or connector 55−11 55−4 − WhereEverybodyKnowsYourName 55−3 HEATER & AIR CONDITIONER No engine idle−up when A/C switch ON Brightness does not changes when rheostat volume or light control switch it turned. − AIR CONDITIONING SYSTEM 1. Cooler compressor assy 2. A/C control assy 3. 1MZ−FE, 3MZ−FE: ECM 4. Wire harness or connector 55−11 55−4 1. Illumination light system 2. A/C control assy 3. Wire harness or connector − 55−4 − WhereEverybodyKnowsYourName 55−4 − 55−22 HEATER & AIR CONDITIONER − REFRIGERANT 550BT−03 REPLACEMENT 1. (a) (b) (c) (d) 2. (a) (b) DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Turn the A/C switch ON. Operating the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 min., circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Let the refrigerant gas out. SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) CHARGE REFRIGERANT Using a vacuum pump, perform a vacuum purping. Charge refrigerant, HFC−134a (R134a). Standard: 550
50 g (19.37
1. 76 oz.) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) Amount to be charged Add. 100g Mean value in proper range
50 g (
1. 76 oz.) Hight Pressure Over charged Point where bubbles disappear Refrigerant Amount Sub−cool system I30082 3. 4. WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT WhereEverybodyKnowsYourName 55−23 HEATER & AIR CONDITIONER − REFRIGERANT LINE REFRIGERANT LINE 55158−03 COMPONENTS 3MZ−FE: Cooler Refrigerant Liquid Pipe A 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Suction Hose No. 1 9.8 (100, 87 in.⋅lbf) 5.4 (55, 49 in.⋅lbf) Cooler Refrigerant Discharge Hose No. 1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I31330 WhereEverybodyKnowsYourName 55−24 HEATER & AIR CONDITIONER − REFRIGERANT LINE 1MZ−FE: Cooler Refrigerant Liquid Pipe A 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Suction Hose No. 1 9.8 (100, 87 in.⋅lbf) 5.4 (55, 49 in.⋅lbf) Cooler Refrigerant Discharge Hose No. 1 I31330 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I40367 WhereEverybodyKnowsYourName 55−25 HEATER & AIR CONDITIONER − REFRIGERANT LINE 2AZ−FE: Cooler Refrigerant Liquid Pipe A 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Suction Hose No. 1 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 5.4 (55, 49 in.⋅lbf) Cooler Refrigerant Discharge Hose No. 1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I31331 WhereEverybodyKnowsYourName 55−26 HEATER & AIR CONDITIONER − V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 550BU−03 REPLACEMENT Bolt B Bolt C 1. (a) (b) (c) REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Loosen the bolt C. Loosen the bolt A. Loosen the bolt B and remove the cooler V belt No. 1. Bolt A I30370 2. (a) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Temporarily install the cooler V belt No. 1 as illustrated. I30370 Bolt B 3. (a) Measuring Position ADJUST V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Apply drive belt tension by turning the bolt B. Drive belt tension: New Belt: 165
27 lbf Used belt: 88
22 lbf TO HINT:
I30370
DENSO Boroughs
”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 installing the drive belt, check that it fits properly in the ribbed grooves. N01881 WhereEverybodyKnowsYourName HEATER & AIR CONDITIONER Wrong − V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 55−27
Check that the drive belt fits properly in the ribbed grooves. 4. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Tighten the bolt A. Torque: 17.5 N⋅m (178 kgf⋅cm, 12 ft⋅lbf) Tighten the bolt C. Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) Correct CH0086 Bolt C (a) (b) Bolt A I30370 WhereEverybodyKnowsYourName 55−28 HEATER & AIR CONDITIONER − AIR CONDITIONER CONTROL ASSEMBLY AIR CONDITIONER CONTROL ASSEMBLY 550BV−04 COMPONENTS Heater Control Housing Sub−assy Air Conditioning Control Bulb Heater Control Base Sub−assy I31555 WhereEverybodyKnowsYourName 55−29 HEATER & AIR CONDITIONER − AIR CONDITIONER CONTROL ASSEMBLY 550BW−03 OVERHAUL HINT: COMPONENTS: See page 55−28 1. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71−9) 4 Claws 2. (a) REMOVE HEATER CONTROL HOUSING SUB−ASSY Release the 4 fitting claws, remove the 5 screws. (b) Disconnect the connector, remove the heater control housing sub−assy. I31531 I31564 3. (a) REMOVE AIR CONDITIONING CONTROL BULB Remove the air conditioning control bulb from the heater control base sub−assy. 4. (a) REMOVE HEATER CONTROL BASE SUB−ASSY Remove the 9 screws and heater control base sub−assy. I31534 B 5. (a) INSTALL AIR CONDITIONING CONTROL BULB Install the air conditioning control bulb to the heater control base sub−assy. Bulb position: A C Position Part No. A 90010 − 03054 B 90010 − 03055 C 90010 − 03056 I31535 WhereEverybodyKnowsYourName 55−30 HEATER & AIR CONDITIONER − AIR CONDITIONING PANEL SUB−ASSY AIR CONDITIONING PANEL SUB−ASSY 550BY−04 COMPONENTS Heater Control Housing I31579 WhereEverybodyKnowsYourName 55−31 HEATER & AIR CONDITIONER − AIR CONDITIONING PANEL SUB−ASSY 550BZ−03 OVERHAUL HINT: COMPONENTS: See page 55−30 1. REMOVE AIR CONDITIONING PANEL SUB−ASSY (See page 71−9) 2. (a) (b) 10 Claws REMOVE HEATER CONTROL HOUSING Remove the 2 screws. Release the 10 fitting claws, remove the heater control housing. I31580 WhereEverybodyKnowsYourName 55−32 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY AIR CONDITIONING RADIATOR ASSY 550C0−03 COMPONENTS Instrument Panel Reinforcement Instrument Finish Panel Retainer Lower Console Box Mounting Bracket No. 1 Instrument Panel Brace Sub−assy No. 2 A/X Models Only: Air Duct Rear No. 2 Instrument Panel Brace Sub−assy Auto A/C Model: 9.8 (100, 87 in.⋅lbf) Air Duct Rear No. 1 Console Box Duct No. 1 Defroster Nozzle Assy Lower 1.5 (15, 12 in.⋅lbf) 1.5 (15, 12 in.⋅lbf)
O−Ring Piping Clamp Blower Assy
O−Ring 1.5 (15, 12 in.⋅lbf) Heater To Foot Duct No. 3 Heater To Foot Duct No. 1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Compressor Oil ND−OIL 8 or equivalent
Non−reusable part 1.5 (15, 12 in.⋅lbf) Air Conditioning Radiator Assy WhereEverybodyKnowsYourName I31556 55−33 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY Air Conditioning Tube Assy Packing Cooler Expansion Valve 3.5 (35, 30 in.⋅lbf) Cooler Evaporator Sub−assy No. 1
O−Ring Cooler Thermistor No. 1 Mode Damper Servo Sub−assy Air Mix Damper Servo Sub−assy Auto A/C Model: Piping Clamp Air Duct Sub−assy : Specified torque N⋅m (kgf⋅cm, ft⋅lbf) Compressor Oil ND−OIL 8 or equivalent
Non−reusable part Heater Radiator Unit Sub−assy WhereEverybodyKnowsYourName I31557 55−34 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY 550C1−03 OVERHAUL HINT: COMPONENTS: See page 55−32 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 71−9) SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) 2. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Install SST to piping clamp. SST 09870−00015 HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. (b) Push down SST and release the clamp lock. NOTICE: Be careful not to deform the tube, when pushing SST. (c) Pull SST slightly and push the release lever, then remove the piping clamp with SST. Pull Push SST Release Lever Disconnect the tube using hand I03839 (d) Disconnect the cooler refrigerant suction hose No. 1. NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system. Screw Driver I06919 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A SST 09870−00025 HINT: Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1. 4. (a) DISCONNECT HEATER OUTLET WATER HOSE Using pliers, grip the claws of clip and slide the clip and disconnect the heater outlet water hose. I31522 WhereEverybodyKnowsYourName 55−35 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY 5. DISCONNECT HEATER INLET WATER HOSE HINT: Disconnect in the same way as the heater outlet water hose. 6. REMOVE INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−9) HINT: Refer to the instructions for removal of the instrument panel safety pad sub−assy. 7. (a) (b) REMOVE AIR DUCT REAR NO.1 Remove the 2 screws, bolt and nut. Remove the air duct rear No. 1. 8. (a) (b) REMOVE AIR DUCT REAR NO.2 Remove the bolt and nut. A/X models: Remove the 2 screws, air duct rear No. 2 and console box mounting bracket No. 1. M/X models: Remove the screw, air duct rear No. 2 and console box mounting bracket No. 1. I31495 (c) I31496 9. (a) REMOVE CONSOLE BOX DUCT NO.1 (AUTO AIR CONDITIONING) Remove the clip and console box duct No. 1. I31497 10. 11. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY REMOVE WINDSHIELD WIPER RELAY ASSY WhereEverybodyKnowsYourName 55−36 HEATER & AIR CONDITIONER 12. − AIR CONDITIONING RADIATOR ASSY (a) REMOVE INSTRUMENT PANEL BRACE SUB−ASSY NO.1 Remove the 2 bolts and 2 earth wires. (b) Release the 2 clamps. (c) (d) Remove the bolt and screw. Remove the nut and instrument panel brace sub−assy No. 1. 13. REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER Remove the 2 bolts and instrument finish retainer lower. I31575 2 Clamps I31581 I31501 (a) I31502 14. (a) Clamp REMOVE INSTRUMENT PANEL BRACE SUB−ASSY NO.2 Remove the clamp, nut and passenger side junction block. I31503 WhereEverybodyKnowsYourName 55−37 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY (b) Remove the bolt and earth wire. (c) Remove the nut and clamp. (d) Remove the 2 nuts, bolt and instrument panel brace sub− assy No. 2. 15. (a) REMOVE HEATER TO FOOT DUCT NO.3 Remove the clip and heater to foot duct No. 3. 16. (a) REMOVE HEATER TO FOOT DUCT NO.1 Remove the clip and heater to foot duct No. 1. I31576 Clamp I31648 I31504 I31499 I31500 WhereEverybodyKnowsYourName 55−38 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY 17. (a) DISCONNECT STEERING COLUMN ASSY Remove the 3 nuts and driver side junction block. (b) Remove the 2 nuts and steering side connector block. (c) (d) Release the 2 clamps. Remove the 3 bolts, disconnect the steering column assy. 18. (a) REMOVE INSTRUMENT PANEL REINFORCEMENT Disconnect the 7 clamps and the wire harness. I31505 I31577 2 Clamps I31506 7 Clamps I31507 WhereEverybodyKnowsYourName 55−39 HEATER & AIR CONDITIONER (b) − AIR CONDITIONING RADIATOR ASSY Remove the 3 nuts, disconnect the 3 earth wires. I31649 (c) Remove the 3 caps, 7 bolts and instrument panel reinforcement. I31508 19. (a) (b) Clamp REMOVE BLOWER ASSY Disconnect the connectors. Remove the screw, clamp and blower connector holder. I31563 WhereEverybodyKnowsYourName 55−40 HEATER & AIR CONDITIONER 6 Clamps − AIR CONDITIONING RADIATOR ASSY (c) Disconnect the 6 clamps and the wire harness. (d) Remove the 2 screws, 2 nuts and blower assy. 20. (a) REMOVE DEFROSTER NOZZLE ASSY LOWER Release the 4 fitting claws, remove the defroster nozzle assy lower. 21. (a) (b) REMOVE AIR CONDITIONING RADIATOR ASSY Disconnect the connectors. Remove the 2 nuts and air conditioning radiator assy. 22. (a) REMOVE MODE DAMPER SERVO SUB−ASSY Remove the 3 screws and mode damper servo sub−assy. I31772 I31509 4 Claws I31510 I31511 I31512 WhereEverybodyKnowsYourName 55−41 HEATER & AIR CONDITIONER − AIR CONDITIONING RADIATOR ASSY 23. REMOVE HEATER RADIATOR UNIT SUB−ASSY (a) Release the 2 fitting claws, remove the piping clamp. (b) Remove the heater radiator unit sub−assy. NOTICE: Prepare a support plate and waste to catch the leaked coolant. 2 Claws I31513 24. (a) REMOVE AIRMIX DAMPER SERVO SUB−ASSY Remove the 3 screws and air mix damper servo sub− assy. 25. (a) REMOVE AIR CONDITIONING TUBE ASSY Remove the packing. (b) Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and air conditioning tube assy. Remove the 2 O−rings from the air conditioning tube assy. I31514 I31515 (c) I31516 26. (a) REMOVE COOLER EXPANSION VALVE Remove the cooler expansion valve from the cooler evaporator sub−assy No. 1. I31517 WhereEverybodyKnowsYourName 55−42 HEATER & AIR CONDITIONER 27. − AIR CONDITIONING RADIATOR ASSY REMOVE COOLER THERMISTOR NO.1 Claw 28. (a) REMOVE COOLER EVAPORATOR SUB−ASSY NO.1 Auto A/C model: Release the fitting claw, remove the 3 screws and air duct sub−assy. (b) (c) Remove the 12 screws and heater case LH. Remove the cooler evaporator sub−assy No. 1 from the heater case RH. (d) Remove the 2 O−rings from the cooler evaporator sub− assy No. 1. 29. (a) INSTALL COOLER EVAPORATOR SUB−ASSY NO.1 Apply compressor oil to the contact surfaces of 2 new O− rings and the cooler expansion valve and install them. Compressor oil: ND−OIL 8 or equivalent I31518 I31519 I31520 I31520 WhereEverybodyKnowsYourName 55−43 HEATER & AIR CONDITIONER (b) (c) − AIR CONDITIONING RADIATOR ASSY Install the cooler evaporator sub−assy No. 1 to the heater case RH. Install the heater case LH with the 12 screws. I31519 Claw (d) Auto A/C model: Install the air duct sub−assy with the 3 screws. 30. (a) INSTALL COOLER EXPANSION VALVE Install the cooler expansion valve to the cooler evaporator No. 1. 31. (a) INSTALL AIR CONDITIONING TUBE ASSY Apply compressor oil to the contact surfaces of 2 new O− rings and the air conditioning tube assy and install them. Compressor oil: ND−OIL 8 or equivalent Using a hexagon wrench 4 mm (0.16 in.), install the air conditioner tube assy and 2 hexagon bolts to the cooler evaporator sub−assy No. 1. Torque: 3.5 N⋅m (35 kgf⋅cm, 30 in.⋅lbf) I31518 I31517 (b) I31516 (c) Install the packing. HINT: Securely attach so that the gap in the packing will not be mode. I31515 WhereEverybodyKnowsYourName 55−44 HEATER & AIR CONDITIONER 32. (a) (b) − AIR CONDITIONING RADIATOR ASSY INSTALL AIR CONDITIONING RADIATOR ASSY Install the air conditioning radiator assy with the 2 nuts. Torque: 1.5 N⋅m (15 kgf⋅cm, 12 in.⋅lbf) Connect the connector. I31511 (2) (3) (1) 33. INSTALL DEFROSTER NOZZLE ASSY LOWER (a) Install the defroster nozzle assy lower. NOTICE: After locating the pin (1) in the illustration, install (2), then (3). (2) (3) I31552 34. (a) INSTALL BLOWER ASSY Install the blower assy with the 2 screws and 2 nuts. Torque: 1.5 N⋅m (15 kgf⋅cm, 12 in.⋅lbf) (b) Install the 6 clamps, connect the wire harness. (c) Install the blower connector holder with the screw and clamp. Connect the connectors. I31509 6 Clamps I31772 (d) Clamp I31563 WhereEverybodyKnowsYourName 55−45 HEATER & AIR CONDITIONER 35. (a) − AIR CONDITIONING RADIATOR ASSY INSTALL INSTRUMENT PANEL REINFORCEMENT Install the instrument panel reinforcement with the 7 bolts and 3 caps. I31508 (b) Install the 3 earth wires with the 3 nuts. I31649 WhereEverybodyKnowsYourName 55−46 HEATER & AIR CONDITIONER (c) − AIR CONDITIONING RADIATOR ASSY Install the 7 clamps, connect the wire harness. 7 Clamps 2 Clamps I31507 36. (a) (b) INSTALL STEERING COLUMN ASSY Install the steering column assy with the 3 bolts. Install the 2 clamps. (c) Install the steering side connector block with the 2 nuts. Torque: 8.4 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (d) Install the driver side junction block with the 3 nuts. Torque: 8.4 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) I31506 I31577 I31505 WhereEverybodyKnowsYourName 55−47 HEATER & AIR CONDITIONER 37. (a) − AIR CONDITIONING RADIATOR ASSY INSTALL INSTRUMENT PANEL BRACE SUB−ASSY NO.2 Install the instrument panel brace sub−assy No. 2 with the 2 nuts and bolt. I31504 Clamp (b) Install the nut and clamp. (c) Install the earth wire with the bolt. (d) Install the passenger side junction block with the nut and clamp. Torque: 8.4 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) 38. INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER Install the instrument finish panel retainer lower with the 2 bolts. I31648 I31576 Clamp I31503 (a) I31502 WhereEverybodyKnowsYourName 55−48 HEATER & AIR CONDITIONER 39. (a) (b) − AIR CONDITIONING RADIATOR ASSY INSTALL INSTRUMENT PANEL BRACE SUB−ASSY NO.1 Install the instrument panel brace sub−assy No. 1 with the nut. Install the bolt and screw. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) (Screw) I31501 2 Clamps (c) Install the 2 clamps. (d) Install the 2 earth wires with the 2 bolts. I31581 I31575 40. INSTALL INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−9) 41. Wrong Connect (a) Gap (b) I06878 INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Lubricate new O−ring with compressor oil and install them to the hose. Compressor oil: ND−OIL 8 or equivalent Install the cooler refrigerant suction hose No.1 and piping clamp. HINT: After connection, check the fitting for claw of the piping clamp. 42. INSTALL COOLER REFRIGERANT LIQUID PIPE A HINT: Install in the same way as the cooler refrigerant suction hose No. 1. WhereEverybodyKnowsYourName 55−49 HEATER & AIR CONDITIONER 43. 44. 45. 46. 47. − AIR CONDITIONING RADIATOR ASSY ADD COOLANT 3MZ−FE: (See page 16−27) 1MZ−FE: (See page 16−27) 2AZ−FE: (See page 16−6) CHARGE REFRIGERANT (See page 55−22) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) Specified amount: 550
50 g (19.37
1.76 oz.) WARM UP ENGINE CHECK FOR ENGINE COOLANT LEAKS 3MZ−FE: (See page 16−27) 1MZ−FE: (See page 16−27) 2AZ−FE: (See page 16−6) INSPECT LEAKAGE OF REFRIGERANT (See page 55−22) WhereEverybodyKnowsYourName 55−4 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM 551IK−01 ON−VEHICLE INSPECTION 1. (a) 1 3 2 4 Low pressure side High pressure side ON (Continuity) INSPECT PRESSURE SWITCH NO.1 Magnetic clutch control: Inspect pressure switch operation. (1) Set on the manifold gauge set. (2) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (−) lead to terminal 1. (3) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 196 kpa 3,140 kpa 2 (2.0 kgf/cm2, 28 psi) (32.0 kgf/cm , 455 psi) OFF (No continuity) OFF (No continuity) I30146 (b) Cooling fan control: Inspect pressure switch operation. (1) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (−) lead to terminal 3. (2) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 1 2 3 4 1,226 kpa (12.5 kgf/cm2, 178 psi) OFF (No continuity) ON (Continuity) 1,520 kpa (15.5 kgf/cm2, 220 psi) I30291 WhereEverybodyKnowsYourName 55−5 HEATER & AIR CONDITIONER 2. (a) − AIR CONDITIONING SYSTEM INSPECT AIR CONDITIONING CONTROL PANEL SUB−ASSY Disconnect the connector from controller and inspect the connector on wire harness side, as shown in the chart below. Wire Harness Side: H11 H10 I36548 Terminals No. (Symbols) Wiring Color Tester Description Condition Specification +B (H10−1) − Body ground W−R − Body ground Power supply for air conditioning panel sub− assy (Back−up) Always 10 to 14 V IG+ (H10−2) − Body ground L−B − Body ground Power supply for air conditioning panel sub− assy (IG) Ignition switch OFF → ON Below 1.0 V → 10 to 14 V GND (H10−32) − Body ground W−B − Body ground Ground for air conditioning panel sub−assy Always Below 1 Ω E (H11−1) − Body ground W−B − Body ground Ground for air conditioning panel sub−assy Always Below 1 Ω If the circuit is not as specified, inspect the circuits connected to other parts. (b) Connect the connector to heater controller and inspect wire harness side from the back side, as shown in the chart below. From Back Side: H10 H11 I36549 Symbols (Terminals No.) Wiring Color Tester Description Condition Specification +B (H10−1) − GND (H10−32) W−R − W−B Power supply for air conditioning panel sub− assy (Back−up) Always 10 to 14 V IG+ (H10−2) − GND (H10−32) L−B − W−B Power supply for air conditioning panel sub− assy (IG) Ignition switch OFF → ON Below 1.0 V → 10 to 14 V A/CB (H10−4) − GND (H10−32) L−B − W−B Heater relay signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) Below 1.0 V → 10 to 14 V WhereEverybodyKnowsYourName 55−6 HEATER & AIR CONDITIONER − AIR CONDITIONING SYSTEM Terminals No. (Symbols) Wiring Color Tester Description Condition Specification 1 (H10−6) − GND (H10−32) LG−B − W−B Hazard warning switch signal Hazard warning switch: OFF → ON 10 to 14 V → Below 1.0 V TCOL (H10−7) − GND (H10−32) P−L − W−B Air mix servomotor control signal Ignition switch: ON Air mix control dial: Max.hot → Max.cool Below 1.0 V → 10 to 14 V THOT (H10−8) − GND (H10−32) P − W−B Air mix servomotor control signal Ignition switch: ON Air mix control dial: Max.cool → Max.hot Below 1.0 V → 10 to 14 V REC (H10−10) − GND (H10−32) L − W−B Air inlet servomotor control signal Ignition switch: ON Air inlet control switch: FRESH → RICIRCULATION 10 to 14 V → Below 1.0 V R−L − W−B Air inlet servomotor control signal Ignition switch: ON Air inlet control switch: RECIRCULATION → FRESH 10 to 14 V → Below 1.0 V W − W−B A/C switch operation signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON Below 1.0 V → 10 to 14 V ACID (H10−13) − GND (H10−32) Y−B − W−B A/C indicator light up signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON Below 1.0 V → 10 to 14 V DEF (H10−17) − GND (H10−32) B−W − W−B Air outlet servomotor operation voltage Ignition switch: ON Mode dial: Except DEF → DEF 10 to 14 V → Below 1.0 V F/D (H10−18) − GND (H10−32) LG−R − W−B Air outlet servomotor operation voltage Ignition switch: ON Mode dial: Except FOOT/DEF → FOOT/DEF 10 to 14 V → Below 1.0 V L−R − W−B Air outlet servomotor operation voltage Ignition switch: ON Mode dial: Except FOOT → FOOT 10 to 14 V → Below 1.0 V BR−W − W−B Air outlet servomotor operation voltage Ignition switch: ON Mode dial: Except BI−LEVEL → BI−LEVEL 10 to 14 V → Below 1.0 V GR − W−B Air outlet servomotor operation voltage Ignition switch: ON Mode dial: Except FACE → FACE 10 to 14 V → Below 1.0 V S5 (H10−25) − SG (H10−30) V − B−W Power supply for air mix damper position sensor Ignition switch: ON 4.5 to 5.5 V TSET (H10−27) − SG (H10−30) L − B−W Air mix damper position sensor signal Ignition switch: ON Temperature dial: Max. COOL → Max. HOT 4.0 V → 1.0 V SG (H10−30) − GND (H10−32) B−W − W−B Ground for air mix damper position sensor Always Below 1.0 Ω GND (H10−32) − Body ground W−B − Body ground Ground for main power supply Always Below 1.0 Ω E (H11−1) − Body ground W−B − Body ground Ground for blower control switch Always Below 1.0 Ω LO (H11−3) − E (H11−1) L−W − W−B Blower switch signal Ignition switch: ON Blower switch: OFF → LO 10 to 14 V → Below 1.0 V M1 (H11−5) − E (H11−1) L−O − W−B Blower switch signal Ignition switch: ON Blower switch: LO → M1 10 to 14 V → Below 1.0 V FRS (H10−11) − GND (H10−32) A/C (H10−12) − GND (H10−32) FOOT (H10−19) − GND (H10−32) B/L (H10−20) − GND (H10−32) FACE (H10−21) − GND (H10−32) WhereEverybodyKnowsYourName 55−7 HEATER & AIR CONDITIONER Terminals No. (Symbols) Wiring Color − AIR CONDITIONING SYSTEM Tester Description Condition Specification M2 (H11−6) − E (H11−1) L−B − W−B Blower switch signal Ignition switch: ON Blower switch: M1 → M2 10 to 14 V → Below 1.0 V HI (H11−7) − E (H11−1) L − W−B Blower switch signal Ignition switch: ON Blower switch: M2 → HI 10 to 14 V → Below 1.0 V If circuit is as specified, replace the controller with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 3. (a) INSPECT AIR CONDITIONING AMPLIFIER (2AZ−FE) Disconnect the connector from controller and inspect the connector on wire harness side, as shown in the chart below. Wire Harness Side: H38 I36566 Terminals No. (Symbols) GND (H38−5) − Body ground Wiring Color W−B − Body ground Tester Description Ground for air conditioning amplifier Condition Specification Below 1.0 Ω Always If the circuit is not as specified, inspect the circuits connected to other parts. (b) Connect the connector to air conditioning amplifier and inspect wire harness side from the back side, as shown in the chart below. From Back Side: H38 I36565 Symbols (Terminals No.) AC1 (A38−1) − GND (A38−5) Wiring Color Y−B − W−B Tester Description Engine idle−up demand signal Condition Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON WhereEverybodyKnowsYourName Specification 10 to 14 V → Below 1.0 V 55−8 HEATER & AIR CONDITIONER Symbols (Terminals No.) Wiring Color − AIR CONDITIONING SYSTEM Tester Description Condition Specification PRS (A38−2) − GND (A38−5) L−W − W−B Pressure switch signal Ignition switch: START Refrigerant pressure: Normally → Less than 196 kpa (2.0 kgf/cm2, 28 psi) or more than 3,140 kpa (32.0 kgf/cm2, 455 psi) IGN (A38−4) − GND (A38−5) B−O − W−B Engine revolution signal Engine is running Pulse generation (see waveform 1) GND (A38−5) − Body ground W−B − Body ground Ground for air conditioning amplifier Always Below 1.0 Ω ACT (A38−7) − GND (A38−5) R − W−B Magnet clutch ON permission signal Ignition switch: ON Magnet clutch: OFF → ON Below 1.0 V → 10 to 14 V A/C switch signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON Below 1.0 V → 10 to 14 V A/C evaporator temperature sensor signal Ignition switch: OFF → ON see page 55−11 A/C indicator signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON Below 1.0 V → Below 10 to 14 V B − W−B Magnet clutch relay signal Ignition switch: ON Blower switch: OFF → ON (LO, M1, M2, HI) A/C switch: OFF → ON 10 to 14 V → Below 1.0 V SG (A38−13) − GND (A38−5) Y−G − W−B Ground for A/C evaporator temperature sensor signal Always Below 1.0 Ω LOCK (A38−14) − GND (A38−5) W−L − W−B Compressor revolution signal Ignition switch: ON A/C switch: ON Pulse generation (see waveform 2) A/C (A38−8) − GND (A38−5) W − W−B TE (A38−9) − GND (A38−5) W−L − W−B (*1) L−W − W−B (*2) LED (A38−10) − GND (A38−5) MGC (A38−12) − GND (A38−5) Y−B − W−B 10 to 14 V → Below 1.0 V If circuit is as specified, replace the controller with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. WhereEverybodyKnowsYourName 55−9 HEATER & AIR CONDITIONER 4. − AIR CONDITIONING SYSTEM INSPECT ECM (1MZ−FE, 3MZ−FE) From Back Side: E10 E8 E9 E7 E6 I36550 Symbols (Terminal No.) Wiring Color Tester Description Condition Specification HP (E7−1) − E2 (E10−28) L−B − BR Pressure switch signal Ignition switch: START Refrigerant pressure: Normally → Less than 196 kpa (2.0 kgf/cm2, 28 psi) or more than 3,140 kpa 32.0 kgf/cm2, 455 psi) LCKI (E8−23) − E2 (E10−28) W−L − BR Compressor revolution signal Ignition switch: ON A/C switch: ON Pulse generation (see waveform 3) E2 (E10−28) − Body ground BR − Body ground Ground for ECM Always Below 1.0 V THE (E8−32) − E2 (E10−28) L−W − BR A/C evaporator temperature sensor signal Ignition switch: OFF → ON see page 55−11 ACLD (E7−33) − E2 (E10−28) B − BR Engine idle−up demand signal Ignition switch: ON A/C switch: OFF → ON Below 1.0 V → 10 to 14 V A/CS (E7−31) − E2 (E10−28) P−L − BR A/C switch signal Ignition switch: ON A/C switch: OFF → ON Below 1.0 V → 10 to 14 V 10 to 14 V → Below 1.0 V If circuit is as specified, replace the controller with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. WhereEverybodyKnowsYourName 55−10 HEATER & AIR CONDITIONER OCV Signal Waveform 5V /Division GND 1 msec./Division GND waveform 1: Measure the waveform between terminal IGN of the A/C amplifier assy connector and body ground. OK: A waveform should be output as shown in the illustration. waveform 2: Measure the waveform between terminal LOCK of the A/C amplifier assy connector and body ground. OK: A waveform should be output as shown in the illustration. I31459 200 mV /Division GND 10 msec./Division AIR CONDITIONING SYSTEM I45555 200 mV /Division 10 msec./Division − waveform 3: Measure the waveform between terminal LCKI of the ECM connector and body ground. OK: A waveform should be output as shown in the illustration. I31459 WhereEverybodyKnowsYourName 55−50 HEATER & AIR CONDITIONER − BLOWER ASSY BLOWER ASSY 550C2−03 COMPONENTS 1.5 (15, 12 in.⋅lbf) Blower Assy 1.5 (15, 12 in.⋅lbf) Heater To Foot Duct No. 1 Recirculation Damper Servo Sub−assy Cowl Wire No. 2 Air Refiner Element Blower Resistor Blower w/ fan Motor Sub−assy Auto A/C Model: Blower Motor Control Instrument Panel Wire No. 3 N⋅m (kgf⋅cm, ft⋅lbf) Instrument Panel Wire No. 3 : Specified torque I31558 WhereEverybodyKnowsYourName 55−51 HEATER & AIR CONDITIONER − BLOWER ASSY 550C3−03 OVERHAUL HINT: COMPONENTS: See page 55−50 1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−9) 2. REMOVE HEATER TO FOOT DUCT NO.1 (See page 71−9) 3. REMOVE BLOWER ASSY (See page 55−34) 4. REMOVE CLEAN AIR FILTER Clamp 5. (a) REMOVE COWL WIRE NO.2 Remove the clamp and cowl wire No. 2. 6. REMOVE RECIRCULATION DAMPER SERVO SUB−ASSY Remove the 3 screws and recirculation damper servo sub−assy. I31523 (a) I31524 7. (a) Manual A/C model: (b) REMOVE INSTRUMENT PANEL WIRE NO.3 Manual A/C model: Disconnect the connectors, remove the 3 clamps and instrument panel wire No. 3. Auto A/C model: Disconnect the connectors, remove the 2 clamps and instrument panel wire No. 3. 3 Clamps Auto A/C model: I31529 I31528 2 Clamps I31585 WhereEverybodyKnowsYourName 55−52 HEATER & AIR CONDITIONER 8. (a) − BLOWER ASSY REMOVE BLOWER RESISTOR (MANUAL AIR CONDITIONING) Remove the 2 screws and blower resistor. I31526 9. (a) REMOVE BLOWER MOTOR CONTROL (AUTO AIR CONDITIONING) Remove the 2 screws and blower motor control. 10. (a) REMOVE BLOWER W/FAN MOTOR SUB−ASSY Remove the 3 screws and blower w/fan motor sub−assy. I31525 I31527 11. 12. INSTALL BLOWER ASSY (See page 55−34) INSTALL INSTRUMENT PANEL SAFETY PAD SUB−ASSY (See page 71−9) WhereEverybodyKnowsYourName 55−53 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) COOLER COMPRESSOR ASSY (3MZ−FE) 55159−02 COMPONENTS Cooler Compressor Bracket Magnet Clutch Assy Cooler Compressor Assy
Snap Ring
Snap Ring 18 (184, 13) Magnet Clutch Washer N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part I31774 WhereEverybodyKnowsYourName 55−54 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) 5515A−02 REPLACEMENT HINT: COMPONENTS: See page 55−53 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55−22) SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) 2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55−26) 3. REMOVE GENERATOR ASSY (See page 19−42) 4. I31543 DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant discharge hose No.1. (b) Remove the O−ring from the cooler refrigerant discharge hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. I31542 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant suction hose No.1. (b) Remove the O−ring from the cooler refrigerant suction hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 6. (a) (b) REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector and clamp. Remove the 2 bolts, nut and cooler compressor bracket. I31544 WhereEverybodyKnowsYourName 55−55 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) (c) Remove the 3 bolts and compressor and magnetic clutch. 7. (a) REMOVE COOLER COMPRESSOR BRACKET Remove the screw, earth wire and cooler compressor bracket. I31546 I40085 8. REMOVE MAGNET CLUTCH ASSY (a) Remove the bolt and bracket. (b) Place the compressor and magnetic clutch in vise. NOTICE: Do not get the bracket and harness caught in the vise. I30363 (c) SST (d) Using SST, hold the magnet clutch hub. SST 95047−10400 Remove the bolt, magnet clutch hub and magnet clutch washer. HINT: There is no set number of magnet clutch washers since they are used for adjusting. E66758 (e) Using a snap ring expander, remove the snap ring and magnet clutch rotor. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (f) Disconnect the connector. E37091 WhereEverybodyKnowsYourName 55−56 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) (g) Using a snap ring expander, remove the snap ring and magnet clutch stator. 9. (a) INSTALL MAGNET CLUTCH ASSY Fit the parts as shown in the illustration and install the magnet clutch stator. I30400 I30631 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (c) Connect the connector. I32461 (d) I31582 Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. NOTICE:
Do not expand the snap ring by more than 30.5 mm when installing it.
Do not damage the seal cover of the bearing when removing the snap ring. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly. WhereEverybodyKnowsYourName 55−57 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) (f) Using SST, hold the magnet clutch hub and install the bolt. SST 95047−10400 Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub. SST E66759 10. (a) (b) I37852 INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnet clutch hub. Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 − 0.60 mm (0.014 − 0.024 in.) If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers. (c) Remove the compressor and magnetic clutch from the vise. (d) Install the bolt and bracket. I30363 11. (a) INSTALL COOLER COMPRESSOR BRACKET Install the earth wire and cooler compressor bracket with the screw. I40085 WhereEverybodyKnowsYourName 55−58 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (3MZ−FE) 12. (a) INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.) ) − (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
Be sure to use ND−OIL8 for compressor oil. 13. (a) TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Temporarily tighten the compressor and magnetic clutch with the 3 bolts. I31546 14. (a) (A) (B) FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Tighten the compressor and magnetic clutch with the bolt (A) and bolt (B). Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) I31561 (b) (E) (D) Install the cooler compressor bracket with the 2 bolts and nut. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (Bolt (C)) 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (Nut (D)) 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) (Bolt (E)) (C) I31544 WhereEverybodyKnowsYourName 55−59 HEATER & AIR CONDITIONER (c) (d) 15. (F) I31562 (a) (b) (c) I31542 − COOLER COMPRESSOR ASSY (3MZ−FE) Tighten the compressor and magnetic clutch with the bolt (F). Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) connect the connector. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL8 or equivalent Install a O−ring to the cooler refrigerant suction hose No.1. (d) Install the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) 16. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL8 or equivalent Install a O−ring to the cooler refrigerant discharge hose No.1. (a) (b) (c) (d) Install the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I31543 17. 18. 19. 20. 21. INSTALL GENERATOR ASSY (See page 19−42) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55−26) CHARGE REFRIGERANT (See page 55−22) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55−22) WhereEverybodyKnowsYourName 55−60 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (1MZ−FE) COOLER COMPRESSOR ASSY (1MZ−FE) 550C4−03 COMPONENTS Cooler Compressor Bracket Magnet Clutch Assy Cooler Compressor Assy
Snap Ring
Snap Ring 18 (184, 13) Magnet Clutch Washer N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part I31774 WhereEverybodyKnowsYourName 55−61 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (1MZ−FE) 550C5−03 REPLACEMENT HINT: COMPONENTS: See page 55−60 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55−22) SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) 2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55−26) 3. REMOVE GENERATOR ASSY (See page 19−42) 4. I31543 DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant discharge hose No. 1. (b) Remove the O−ring from the cooler refrigerant discharge hose No. 1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. I31542 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant suction hose No. 1. (b) Remove the O−ring from the cooler refrigerant suction hose No. 1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 6. (a) (b) REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector and clamp. Remove the 2 bolts, nut and cooler compressor bracket. (c) Remove the 3 bolts and compressor and magnetic clutch. I31544 I31546 WhereEverybodyKnowsYourName 55−62 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (1MZ−FE) 7. (a) REMOVE COOLER COMPRESSOR BRACKET Remove the screw, earth wire and cooler compressor bracket. 8. (a) (b) REMOVE MAGNET CLUTCH ASSY Remove the bolt and bracket. Place the compressor and magnetic clutch in vise. (c) (d) Using a vise pliers, hold the magnet clutch hub. Remove the bolt, magnet clutch hub and magnet clutch washer. (e) Using a snap ring expander, remove the snap ring and magnet clutch rotor. Disconnect the connector. E58517 I30363 I31547 (f) E37091 (g) Using a snap ring expander, remove the snap ring and magnet clutch starter. I30400 WhereEverybodyKnowsYourName 55−63 HEATER & AIR CONDITIONER 9. − COOLER COMPRESSOR ASSY (1MZ−FE) REMOVE COOLER COMPRESSOR ASSY 10. (a) INSTALL MAGNET CLUTCH ASSY Matching the parts shown in the illustration, install the magnet clutch starter. (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. Connect the connector. I30631 (c) I30400 (d) Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly. I31582 (f) Using a vise pliers, hold the magnet clutch hub and install the bolt. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) I31548 WhereEverybodyKnowsYourName 55−64 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (1MZ−FE) 11. (a) (b) I32105 INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnet clutch hub. Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 − 0.60 mm (0.014 − 0.024 in.) If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers. (c) Remove the compressor and magnetic clutch from the vise. (d) Install the bolt and bracket. I30363 12. (a) INSTALL COOLER COMPRESSOR BRACKET Install the earth wire and cooler compressor bracket with the screw. E58517 WhereEverybodyKnowsYourName 55−65 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (1MZ−FE) 13. (a) INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 +0.51 fl.oz.) ) − (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
Be sure to use ND−OIL8 for compressor oil. 14. (a) TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Temporarily the compressor and magnetic clutch with the 3 bolts. I31546 15. (a) (A) (B) FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Tighten the compressor and magnetic clutch with the bolt (A) and bolt (B). Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) I31561 (b) (E) (D) Install the cooler compressor bracket with the 2 bolts and nut. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (Bolt (C)) 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (Nut (D)) 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) (Bolt (E)) (C) I31544 WhereEverybodyKnowsYourName 55−66 HEATER & AIR CONDITIONER (c) (d) 16. (F) I31562 (a) (b) (c) I31542 − COOLER COMPRESSOR ASSY (1MZ−FE) Tighten the compressor and magnetic clutch with the bolt (F). Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) connect the connector. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL 8 or equivalent Install a O−ring to the cooler refrigerant suction hose No. 1. (d) Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm,87 in.⋅lbf) 17. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL 8 or equivalent Install a O−ring to the cooler refrigerant discharge hose No.1. (a) (b) (c) (d) Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm,87 in.⋅lbf) I31543 18. 19. 20. 21. 22. INSTALL GENERATOR ASSY (See page 19−42) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55−26) CHARGE REFRIGERANT (See page 55−22) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55−22) WhereEverybodyKnowsYourName 55−67 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (2AZ−FE) COOLER COMPRESSOR ASSY (2AZ−FE) 550C6−03 COMPONENTS Magnet Clutch Assy Cooler Compressor Assy
Snap Ring
Snap Ring Magnet Clutch Washer 18 (184, 13) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part I31629 WhereEverybodyKnowsYourName 55−68 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (2AZ−FE) 550C7−03 REPLACEMENT HINT: COMPONENTS: See page 55−67 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55−22) SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) 2. REMOVE FAN AND GENERATOR V BELT (See page 14−5) SST 09249−63010 3. REMOVE GENERATOR ASSY (See page 19−17) 4. I31551 DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant discharge hose No. 1. (b) Remove the O−ring from the cooler refrigerant discharge hose No. 1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. I31550 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant suction hose No. 1. (b) Remove the O−ring from the cooler refrigerant suction hose No. 1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 6. (a) (b) REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the nut. (c) Using a torque socket wrench (E8), remove the bolt. E57139 E57140 WhereEverybodyKnowsYourName 55−69 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (2AZ−FE) (d) Remove the 3 bolts and compressor and magnetic clutch. 7. (a) (b) REMOVE MAGNET CLUTCH ASSY Remove the bolt and bracket. Place the compressor and magnetic clutch in vise. (c) (d) Using a vise pliers, hold the magnet clutch hub. Remove the bolt, magnet clutch hub and magnet clutch washer. (e) Using a snap ring expander, remove the snap ring and magnet clutch rotor. Disconnect the connector. E57145 I30371 E57141 (f) E37091 (g) Using a snap ring expander, remove the snap ring and magnet clutch starter. I30400 WhereEverybodyKnowsYourName 55−70 HEATER & AIR CONDITIONER 8. − COOLER COMPRESSOR ASSY (2AZ−FE) REMOVE COOLER COMPRESSOR ASSY 9. (a) INSTALL MAGNET CLUTCH ASSY Matching the parts shown in the illustration, install the magnet clutch starter. (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. Connect the connector. I30631 (c) I30400 (d) Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly. I31582 (f) Using a vise pliers, hold the magnet clutch hub and install the bolt. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) E57142 WhereEverybodyKnowsYourName 55−71 HEATER & AIR CONDITIONER − COOLER COMPRESSOR ASSY (2AZ−FE) 10. (a) (b) E57143 INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnet clutch hub. Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 − 0.60 mm (0.014 − 0.024 in.) If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers. (c) Remove the compressor and magnetic clutch from the vise. (d) Install the bolt and bracket. I30371 11. (a) INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.) ) − (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
Be sure to use ND−OIL8 for compressor oil. WhereEverybodyKnowsYourName 55−72 HEATER & AIR CONDITIONER 12. (a) − COOLER COMPRESSOR ASSY (2AZ−FE) TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Temporarily the compressor and magnetic clutch with the 3 bolts. E57145 13. E57140 FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (a) Using a torque socket wrench (E8), install the bolt. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (b) Tighten the compressor and magnetic clutch with the 3 bolts and nut. Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (c) Connect the connector. NOTICE: Tighten the bolts and nuts in following order shown in the illustration to install the compressor magnetic clutch. 14. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL 8 or equivalent (c) Install a O−ring to the cooler refrigerant suction hose No. 1. (d) 15. (a) (b) I31550 (c) Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the nut . Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O−ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND−OIL 8 or equivalent Install a O−ring to the cooler refrigerant discharge hose No. 1. WhereEverybodyKnowsYourName 55−73 HEATER & AIR CONDITIONER (d) − COOLER COMPRESSOR ASSY (2AZ−FE) Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I31551 16. 17. 18. 19. 20. INSTALL GENERATOR ASSY (See page 19−17) INSTALL FAN AND GENERATOR V BELT (See page 14−5) SST 09249−63010 CHARGE REFRIGERANT (See page 55−22) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) Specified amount: 550
50 g (19.37
1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55−22) WhereEverybodyKnowsYourName 55−74 HEATER & AIR CONDITIONER − COOLER CONDENSER ASSY COOLER CONDENSER ASSY 550C8−03 ON−VEHICLE INSPECTION 1. INSPECT COOLER CONDENSER ASSY (a) If a fin of the cooler condenser assy is dirty, clean it with water and dry it with compressor air. NOTICE: Do not damage the fin of the condenser assy. (b) If a fin of the condenser assy is bent, make it straight using a screwdriver or pliers. 2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check pipe joints for gas leakage. (b) If gas leakage is detected in a joint, check the torque of the joint. WhereEverybodyKnowsYourName 55−75 HEATER & AIR CONDITIONER − COOLER CONDENSER ASSY 550C9−03 COMPONENTS 1MZ−FE: Air Cleaner Inlet Assy 2AZ−FE: Air Cleaner Inlet Assy 1MZ−FE: Air Cleaner Inlet No. 1 Radiator Support Upper Hood Lock Release Lever Protector 9.8 (100, 85 in.⋅lbf) 9.8 (100, 85 in.⋅lbf)
O−ring
O−ring 5.4 (55, 47 in.⋅lbf) Cooler Condenser Assy Cooler Dryer Filter
O−ring Cap 12 (125, 9) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Compressor oil ND−OIL 8 or equivalent
Non−reusable parts WhereEverybodyKnowsYourName I31559 55−76 HEATER & AIR CONDITIONER − COOLER CONDENSER ASSY 550CA−04 OVERHAUL HINT: COMPONENTS: See page 55−75 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55−22) SST 07110−58060 (07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) 2. I31538 REMOVE COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the cooler condenser assy. (b) Remove the O−ring from the cooler refrigerant discharge hose No. 1. NOTICE: Seat the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 3. I31539 4. 5. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A (a) Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the cooler condenser assy. (b) Remove the O−ring from the cooler refrigerant liquid pipe A. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. REMOVE AIR CLEANER INLET ASSY 3MZ−FE: (See page 16−36) 1MZ−FE: (See page 16−36) 2AZ−FE: (See page 16−15) REMOVE RADIATOR SUPPORT UPPER 3MZ−FE: (See page 16−36) 1MZ−FE: (See page 16−36) 2AZ−FE: (See page 16−15) 6. (a) REMOVE COOLER CONDENSER ASSY Remove the 2 nuts and cooler condenser assy. I31540 WhereEverybodyKnowsYourName 55−77 HEATER & AIR CONDITIONER − COOLER CONDENSER ASSY 7. (a) REMOVE COOLER DRYER Using hexagon wrench 10 mm (0.39 in.), remove the cap and filter from the modulator. (b) Remove the 2 O−rings from the cap. (c) Using a needle nose pliers, remove the cooler dryer. SST 99999−60018 8. (a) INSTALL COOLER DRYER Using a needle nose pliers, install the cooler dryer. (b) (c) Install 2 new O−rings to the cap. Sufficiently apply compressor oil to the fit surfaces of the O−ring and the cap. Compressor oil: ND−OIL 8 or equivalent (d) Using hexagon wrench 10 mm (0.39 in.), install the cap to the cooler condenser assy. Torque: 12 N⋅m (125 kgf⋅cm, 9 ft⋅lbf) SST 99999−60018 10 mm (0.39 in.) Hexagon Wrench Modulator I30086 E50132 E57114 E50386 E50132 10 mm (0.39 in.) Hexagon Wrench Modulator I30086 WhereEverybodyKnowsYourName 55−78 HEATER & AIR CONDITIONER 9. (a) − COOLER CONDENSER ASSY INSTALL COOLER CONDENSER ASSY Install the cooler condenser assy with the 2 nuts. Torque: 9.8 N⋅m (100 kgf⋅cm, 85 in.⋅lbf) I31541 10. INSTALL RADIATOR SUPPORT UPPER 3MZ−FE: (See page 16−36) 1MZ−FE: (See page 16−36) 2AZ−FE: (See page 16−15) 11. INSTALL COOLER REFRIGERANT LIQUID PIPE A (a) Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy. (b) Sufficiently apply compressor oil to the new O−ring and pipe joint. Compressor oil: ND−OIL 8 or equivalent (c) Install a O−ring to the cooler refrigerant liquid pipe A. (d) Connect the cooler refrigerant liquid pipe A to the cooler condenser assy with the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 47 in.⋅lbf) 12. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy. Sufficiently apply compressor oil to the new O−ring and hose joint. Compressor oil: ND−OIL 8 or equivalent Install a O−ring to the cooler refrigerant discharge hose No. 1. (a) I31539 (b) (c) (d) Connect the cooler refrigerant discharge hose No. 1 to the cooler condenser assy with the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 47 in.⋅lbf) I31538 WhereEverybodyKnowsYourName 55−79 HEATER & AIR CONDITIONER 13. 14. 15. − COOLER CONDENSER ASSY CHARGE REFRIGERANT (See page 55−22) SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050, 07117−88060, 07117−88070, 07117−88080) Specified amount: 550
50 g (19.37
1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55−22) WhereEverybodyKnowsYourName 74−1 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM 7403Y−03 LOCATION Slide Roof Housing Sub−assy Slide Roof Motor Switch Slide Roof Drive Gear Sub−assy (Sliding Roof Control Relay) B56178 WhereEverybodyKnowsYourName 74−12 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMMK Made) SLIDING ROOF (TMMK Made) 74042−03 COMPONENTS Sliding Roof Glass Sub−assy Sliding Roof Weatherstrip Sliding Roof Side Garnish RH Sliding Roof Side Garnish LH Roof Wind Deflector Panel Sub−assy Roof Drip Channel Rear Sliding Roof Lift Arm RH Sliding Roof Drive Cable RH Roof Drip Channel Guide RH Removable Roof Hinge RH Roof Drip Channel Guide LH Sliding Roof Drive Cable LH Removable Roof Hinge LH Roof Wind Deflector Spring Sliding Roof Lift Arm LH Roof Wind Deflector Spring Sliding Roof Housing Drain End Cap RH Sunshade Trim Sub−assy Sliding Roof Housing Drain End Cap LH Sliding Roof Housing Bracket No.1 Sliding Roof Drive Gear Sub−assy Slide Roof Rail Sub−assy B56195 WhereEverybodyKnowsYourName 74−13 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMMK Made) REPLACEMENT HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. 74043−06 1. (a) (b) REMOVE SLIDING ROOF GLASS SUB−ASSY Disengage the claws and turn the sliding roof side garnish as shown in the illustration. Using a torx wrench (T25), remove the 4 screws and sliding roof glass. B56782 2. 3. (a) 4. (a) (b) REMOVE SLIDING ROOF WEATHERSTRIP REMOVE SLIDING ROOF DRIVE GEAR SUB−ASSY Using a torx wrench (T25), remove the 3 screws and sliding roof drive gear. REMOVE SLIDE ROOF RAIL SUB−ASSY Disconnect the 4 drain hoses from the housing. Remove the 6 nuts and 4 bolts, then remove the slide roof rail as shown in the illustration. Nut Position Bolt Position B56783 WhereEverybodyKnowsYourName 74−14 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMMK Made) 5. REMOVE SLIDING ROOF SIDE GARNISH RH (a) Using a screwdriver, remove the sliding roof side garnish. HINT: Tape the screwdriver tip before use. (b) Use the same procedures described above on the other side. 6. REMOVE SLIDING ROOF SIDE GARNISH LH 7. REMOVE ROOF DRIP CHANNEL REAR (a) Remove the 2 screws and roof drip channel rear. 8. REMOVE SLIDING ROOF HOUSING DRAIN END CAP RH (a) Using a screwdriver, remove the sliding roof housing drain end cap. HINT: Tape the screwdriver tip before use. (b) Use the same procedures described above on the other side. 9. REMOVE SLIDING ROOF HOUSING DRAIN END CAP LH 10. REMOVE SUNSHADE TRIM SUB−ASSY (a) Pull out the sunshade trim in the vehicle rear direction. 11. REMOVE ROOF DRIP CHANNEL GUIDE RH (a) Disengage the roof drip channel guide and sliding roof lift arm, and then pull out the roof drip channel guide in the vehicle rear direction. (b) Use the same procedures described above on the other side. 12. REMOVE ROOF DRIP CHANNEL GUIDE LH 13. REMOVE REMOVABLE ROOF HINGE RH (a) Remove the stopper screw and removable roof hinge. (b) Use the same procedures described above on the other side. 14. REMOVE REMOVABLE ROOF HINGE LH 15. REMOVE SLIDING ROOF DRIVE CABLE RH 16. REMOVE SLIDING ROOF DRIVE CABLE LH 17. REMOVE SLIDING ROOF LIFT ARM RH (a) Pull out the sliding roof lift arm in the vehicle rear direction. (b) Use the same procedures described above on the other side. 18. REMOVE SLIDING ROOF LIFT ARM LH 19. (a) A B56784 REMOVE ROOF WIND DEFLECTOR SPRING Remove the rivet. (1) Use a drill of less than φ 4 mm (0.16 in.). (2) Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges. A: 5 mm (0.20 in.) NOTICE:
Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
Be careful when undertaking this task as the cut rivet is hot. (3) Even if the flange is taken off, continue drilling and push−cut the remaining fragments with the drill. WhereEverybodyKnowsYourName 74−15 SLIDING ROOF/CONVERTIBLE 20. 21. (a) − SLIDING ROOF (TMMK Made) REMOVE ROOF WIND DEFLECTOR PANEL SUB−ASSY REMOVE SLIDING ROOF HOUSING BRACKET NO.1 Remove the 4 bolts and 4 sliding roof housing bracket. 22. (a) INSTALL ROOF WIND DEFLECTOR SPRING Using an air riveter or hand riveter with a nose piece, strike the rivets into the body panel. NOTICE:
If the rivet is not positioned perpendicularly, it will bend the mandrel.
When the trigger is pulled, it may damage SST. B56787 23. (a) INSTALL SLIDING ROOF GLASS SUB−ASSY Check for a difference in level between the sliding roof (weatherstrip) and roof panel. Corner of rear side: 0
1.5 mm (0
0.059 in.) B56786 (b) Check for a difference in level between the sliding roof (glass) and roof panel. NOTICE: The clearance should be thoroughly even. B56785 (c) 24. 25. (a) (b) Adjust the roof panel. (1) Using a torx driver T25, loosen the screw to adjust the sliding roof panel position. When the adjustment has done, tighten the screw there. RESET THE SLIDING ROOF POSITION (See page 74−7) INSPECT FOR LEAKS Adjusting the sliding roof, check there is no water leak. In case of water leak, readjust the sliding roof. WhereEverybodyKnowsYourName 74−2 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF SYSTEM 74040−03 PROBLEM SYMPTOMS TABLE Symptom Suspected Area PWR NO.1 fuse Sliding roof motor switch Sliding roof drive gear Wire harness Faulty sliding of sliding roof See page Sliding roof system does not operate 1. 2. 3. 4. 5. Sliding roof operation is abnormal 1. Sliding roof motor switch 2. Sliding roof drive gear 3. Wire harness 74−6 74−3 − Sliding roof system stops operation halfway (No foreign object is caught in the motor) 1. 2. 3. 4. 74−6 74−3 − 74−7 Sliding roof motor switch Sliding roof drive gear Wire harness Sliding roof relay WhereEverybodyKnowsYourName − 74−6 74−3 74−3 − 74−3 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF SYSTEM 7403Z−03 ON−VEHICLE INSPECTION 1. (a) INSPECTION SLIDING ROOF FUNCTION Check the AUTO sliding open operation function. (1) Turn the ignition switch ON. (2) Slide close and tilt down the roof glass to the fully closed position. (3) Check that the roof glass automatically slides open and stops just before the roof glass is fully opened by operating the sliding roof switch OPEN for 0.3 seconds or more. (b) Check the AUTO sliding close operation function. (1) Turn the ignition switch ON. (2) Check that the roof glass automatically slides close to the fully closed position by operating the sliding roof switch CLOSE for 0.3 seconds or more. (3) The roof glass stops sliding when the sliding roof switch is operated CLOSE or OPEN while the glass is moving. (c) Check the AUTO tilting UP operation function. (1) Turn the ignition switch ON. (2) Slide close and tilt down the roof glass to the fully closed position. (3) Check that the roof glass automatically tilts up to the fully up position by operating the sliding roof switch UP for 0.3 seconds or more. (d) Check the AUTO tilting DOWN operation function. (1) Turn the ignition switch ON. (2) Check that the roof glass automatically tilts down by operating the sliding roof switch DOWN when the roof glass is in the up position. (e) Check the operation function after key−OFF. (1) After turning the ignition switch from ON to OFF, check that the roof glass can be operated via the sliding roof switch. However, operation is disabled after either of the front doors is opened. (2) When approximately 45 seconds have passed after the ignition switch is turned from ON to OFF, check that the roof glass can not be operated via the sliding roof switch. (3) After turning the ignition switch from ON to OFF with either of the front doors open, check that AUTO operation stops immediately. (f) Check the jam protection function. NOTICE:
Do not check this function using a part of your body such as a hand.
Pay thorough attention that nothing gets caught by accident in this process.
The roof might be deformed if something hard, such as a handle of hammer, is inserted in between. HINT: The jam protection functions operate only during the following AUTO operations; AUTO close or AUTO down operation and AUTO close or AUTO down operation after key−OFF. (1) Fully close the roof glass. (2) Insert the handle of the hammer when the roof glass is almost in the fully closed position. HINT: Wrap the hammer handle well with cloth or something before use. WhereEverybodyKnowsYourName 74−4 SLIDING ROOF/CONVERTIBLE (3) − SLIDING ROOF SYSTEM When trying to operate the roof glass to the fully closed position via the AUTO close or down function, check that the glass movement is reversed by detecting the handle, so that the hammer handle is not caught HINT:

The reverse movement when the roof glass is sliding close stops when the glass slides open 200 mm or before the glass reaches the fully open position (for a maximum 20 seconds). The reverse movement when the roof glass is tilting down stops when the glass is in the fully up position or 2 seconds have passed. 2. Wire Harness Side (a) 1 2 4 5 3 6 7 INSPECT SLIDING ROOF RELAY AND SWITCH (TMMK MADE) Inspect the sliding roof relay and switch. (1) Disconnect the connector from the sliding roof relay and inspect the connector on the wire harness side. 8 B56738 Standard: Terminals No. Wiring color Condition Specified condition 5 ⇔ Body ground W−B ⇔ − Constant Continuity 7⇔5 L−W ⇔ W−B Constant 10 − 14 V 3⇔5 R−L ⇔ W−B Ignition switch OFF → ON 1⇔5 R−W ⇔ W−B Sliding roof switch → OPEN or DOWN No continuity → Continuity 2⇔5 R−Y ⇔ W−B Sliding roof switch → CLOSE or UP No continuity → Continuity 0 V → 10 − 14 V If the value is not as specified, there may be a malfunction on the wire harness side. (2) Connect the connector, and inspect the voltage between the terminals of the connector. Standard: Terminals No. Wiring color Condition 1⇔5 R−W ⇔ W−B Ignition switch OFF → ON Sliding roof switch → OPEN or DOWN 10 − 14 V → 0 V 2⇔5 R−Y ⇔ W−B Ignition switch OFF → ON Sliding roof switch → CLOSE or UP 10 − 14 V → 0 V If the value is not as specified, the sliding roof drive gear may be defective. WhereEverybodyKnowsYourName Specified condition 74−5 SLIDING ROOF/CONVERTIBLE 3. Wire Harness Side (a) 1 2 5 6 7 8 3 4 9 10 − SLIDING ROOF SYSTEM INSPECT SLIDING ROOF CONTROL ECU (TMC MADE) Inspect the sliding roof control ECU. (1) Disconnect the connector from the ECU. (2) Inspect the connector on the wire harness side. B52070 Standard: Symbols (Terminals No.) Wiring color E (7) ⇔ Body ground W−B ⇔ − Constant Condition Specified condition Continuity B (5) ⇔ E (7) L−W ⇔ W−B Constant IG (8) ⇔ E (7) R−L ⇔ W−B Ignition switch OFF → ON DWN (9) ⇔E (7) R−W ⇔ W−B Sliding roof switch → OPEN or DOWN No continuity → Continuity UP (10) ⇔ E (7) R−Y ⇔ W−B Sliding roof switch → CLOSE or UP No continuity → Continuity 10 − 14 V 0 V → 10 − 14 V If the value is not as specified, there may be a malfunction on the wire harness side. (3) Connect the connector, and inspect the voltage between the terminals of the connector. Standard: Symbols (Terminals No.) Wiring color Condition DWN(9) ⇔ E (7) R−W ⇔ W−B Ignition switch OFF → ON Sliding roof switch → OPEN or DOWN UP(10) ⇔ E (7) R−Y ⇔ W−B Ignition switch OFF → ON Sliding roof switch → CLOSE or UP Specified condition 10 − 14 V → 0 V 10 − 14 V → 0 V If the value is not as specified, sliding roof drive gear or communication line may be defective. WhereEverybodyKnowsYourName 74−6 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF SYSTEM 74041−03 INSPECTION 1. (a) INSPECT SLIDE ROOF MOTOR SWITCH Check the slide roof motor switch continuity. Standard: Terminals No. 1 2 3 4 5 Switch position Specified condition 2⇔4 CLOSE/UP Continuity 2⇔3 OPEN/DOWN Continuity If the continuity is not as specified, replace the switch. B56056 WhereEverybodyKnowsYourName 74−7 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF SYSTEM 7404C−03 RESET 1. RESET SLIDING ROOF POSITION NOTICE: When the battery negative (−) terminal is disconnected or PWR No.1 fuse is removed due to the repair, the sliding roof position memory is erased. After reconnecting the battery negative (−) terminal, make sure to reset the zero point. If the sliding roof has not been reset, the sliding roof AUTO operation functions will not operate. Vehicle type TMC made CAMRY TMMK made CAMRY (a) (b) (c) Condition Proceed to
Battery negative (−) terminal is disconnected.
Component parts of sliding roof are replaced.
PWR No.1 fuse is removed. Reset A
Sliding roof dose not stop at the fully closed position even if AUTO close switch is operated. Reset B
Battery negative (−) terminal is disconnected.
PWR No.1 fuse is removed. Reset A
Component parts of sliding roof are replaced.
Sliding roof dose not stop at the fully closed position even if AUTO close switch is operated. Reset C Reset A (1) To reset the sliding roof to the zero point, push and hold the switch on the TILT UP position until the sliding roof tilts all the way up and tilts down a little automatically. (2) Confirm ”one−touch side open and close” and ”one−touch tilt up and down” functions by pushing the switch briefly to the SLIDE/OPEN position and TILT/UP position. Reset B (1) Push and hold the switch on the TILT UP/CLOSE position until the sliding roof stops. (2) Continue to push and hold the switch on the TILT UP/CLOSE position for 10 seconds or more. The sliding roof closes to the fully closed position. (3) Continue to push and hold the switch on the TILT UP/CLOSE position until the sliding roof tilts all the way up and tilts down a little automatically. (4) Confirm ”one−touch side open and close” and ”one−touch tilt up and down” functions by pushing the switch briefly to the SLIDE/OPEN position and TILT/UP position. Reset C (1) To reset the sliding roof to the zero point, push and hold the switch on the TILT UP position until the sliding roof tilts all the way up and tilts down a little automatically. (2) Release the switch. Within 5 seconds, re−push and hold the switch on the TILT UP/CLOSE position. (3) The sliding roof automatically moves to the fully open position and then reverses towards the closed position. (4) Release the switch. (5) Confirm ”one−touch side open and close” and ”one−touch tilt up and down” functions by pushing the switch briefly to the SLIDE/OPEN position and TILT/UP position. WhereEverybodyKnowsYourName 74−8 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMC Made) SLIDING ROOF (TMC Made) 74044−03 COMPONENTS Sliding Roof Weatherstrip Sliding Roof Glass Sub−assy Roof Side Rail Garnish Pad RH Roof Side Rail Garnish Pad LH Sliding Roof Drive Gear Sub−assy Sliding Roof Housing Sub−assy Sliding Roof Side Garnish RH Sliding Roof Side Garnish LH Sunshade Trim Sub−assy B56179 WhereEverybodyKnowsYourName 74−9 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMC Made) 74045−04 REPLACEMENT HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. 1. REMOVE ROOF HEADLINING ASSY (See page 76−22) 2. (a) (b) 3. REMOVE ROOF SIDE RAIL GARNISH PAD RH (W/O CURTAIN SHIELD AIR BAG) Remove the 7 screws and roof side rail garnish pad. Use the same procedures described above on the other side. REMOVE ROOF SIDE RAIL GARNISH PAD LH (W/O CURTAIN SHIELD AIR BAG) 4. REMOVE SLIDING ROOF SIDE GARNISH RH (a) Using a screwdriver, remove the sliding roof side garnish. HINT: Tape the screwdriver tip before use. (b) Use the same procedures described above on the other side. B56180 5. 6. (a) 7. 8. (a) (b) 9. (a) (b) (c) REMOVE SLIDING ROOF SIDE GARNISH LH REMOVE SLIDING ROOF GLASS SUB−ASSY Using a torx wrench (T25), remove the 4 screws and sliding roof glass. REMOVE SLIDING ROOF WEATHERSTRIP REMOVE SLIDING ROOF DRIVE GEAR SUB−ASSY Remove the 2 bolts. Disconnect the clamp and then remove the sliding roof drive gear. REMOVE SLIDING ROOF HOUSING SUB−ASSY Disconnect the 4 drain hoses from the housing. w/o curtain shield airbag: Remove the 6 nuts and 4 bolts, then remove the housing as shown in the illustration. w/ curtain shield airbag: Remove the 6 nuts and 8 bolts, then remove the housing as shown in the illustration. WhereEverybodyKnowsYourName 74−10 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMC Made) w/o Curtain Shield Airbag w/ Curtain Shield Airbag Nut Position Bolt Position 10. (a) (b) (c) B56181 REMOVE SUNSHADE TRIM SUB−ASSY Remove the screw and stopper. Remove the sunshade trim. Use the same procedures described above on the other side. 11. (a) ADJUST FULLY CLOSED POSITION Using a screwdriver, slide the drive cable of the sliding roof to align the matchmarks. HINT: Tape the tip of the screwdriver before use. B56182 12. (a) INSTALL SLIDING ROOF GLASS SUB−ASSY Check for a difference in level between the sliding roof (weatherstrip) and roof panel. Corner of rear side: 0
1.5 mm (0
0.059 in.) B56183 WhereEverybodyKnowsYourName 74−11 SLIDING ROOF/CONVERTIBLE − SLIDING ROOF (TMC Made) (b) B56184 13. 14. (a) (b) Check for a difference in level between the sliding roof (glass) and roof panel. NOTICE: The clearance should be thoroughly even. (c) Adjust the roof panel. (1) Using a torque driver T25, loosen a screw to adjust the sliding roof panel position. When the adjustment has done, tighten the screw there. RESET THE SLIDING ROOF POSITION (See page 74−7) INSPECT FOR LEAKS Adjusting the sliding roof, check there is no water leak. In case of water leak, readjust the sliding roof. WhereEverybodyKnowsYourName 28−1 TIRE & WHEEL − WHEEL AND TIRE SYSTEM WHEEL AND TIRE SYSTEM 2805N−01 INSPECTION 1. (a) (b) INSPECT TIRE Check the tires for wear and proper inflation pressure. Cold tire inflation pressure: Tire size Front, Rear kPa (kgf/cm2, psi) P205/65R15 92T P205/65R15 92H 205/65R15 94V P215/60R16 94V 200 (2.0, 29) P215/55R17 93V 210 (2.1, 30) Using a dial indicator, check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less R03031 (A) 2. ROTATE TIRES HINT:
Rotate tires as shown in the illustration.
Rotate as shown in (B) if the spare tire is included in the rotation. (B) Front F13676 3. (a) (b) INSPECT WHEEL BALANCE Check and adjust the Off−the−car balance. If necessary, check and adjust the On−the−car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less C80976 4. 5. INSPECT BEARING LOOSENESS (SEE PAGE 30−2) INSPECT AXLE HUB RUNOUT (SEE PAGE 30−2) WhereEverybodyKnowsYourName 28−2 TIRE & WHEEL − WHEEL AND TIRE SYSTEM 2805O−01 HOW TO PROCEED WITH TROUBLESHOOTING 1. 2. VEHICLE PULLING DIAGNOSIS (SEE PAGE 26−2) DIAGNOSIS OF TIRE VIBRATION Check that the wheel nuts are fully tightened NG NG Repair Inspect bearing looseness OK Inspect axle hub runout OK Check tire pressure OK Return the vehicle to customer OK Check wheel balance OK NG NG Inspect bearing looseness Adjustment Replace tire(s) Adjustment Inspect axle hub runout NG Repair NG OK Check wheel balance 3. DIAGNOSIS OF IRREGULAR TIRE WEAR Check tire pressure OK Check wheel alignment NG NG Adjustment Adjustment OK Tire rotation or replace tire(s) NG Check wheel alignment OK WhereEverybodyKnowsYourName 99−1 MAINTENANCE − OUTSIDE VEHICLE OUTSIDE VEHICLE 9900V−28 GENERAL MAINTENANCE Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required. It is recommended that the owner perform these checks. The procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance requirements vary depending on the country.
Check the maintenance schedule in the owner’s manual supplement.
Following the maintenance schedule is mandatory.
Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed, whichever reaches the specification first.
Maintain similar intervals between periodic maintenance unless noted.
Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES (a) Check the tire pressure with a gauge. Make adjustments if necessary. (b) Check the surfaces of tires for cuts, damage or excessive wear. 3. WHEEL NUTS (a) Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION (a) Check the maintenance schedule in the owner’s manual supplement. 5. WINDSHIELD WIPER BLADES (a) Check the blades for wear or cracks when they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS (a) Check under the vehicle for leaking fuel, oil, water and other fluids. (b) If you smell gasoline fumes or notice any leaks, locate the cause and correct it. 7. DOORS AND ENGINE HOOD (a) Check if all of the doors and the tailgate operate smoothly and if all the latches lock securely. (b) When the primary latch is released, check if the engine hood secondary latch prevents the hood from opening. WhereEverybodyKnowsYourName 99−2 MAINTENANCE − INSIDE VEHICLE INSIDE VEHICLE 9900W−28 GENERAL MAINTENANCE Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required. It is recommended that the owner perform these checks. The procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance requirements vary depending on the country.
Check the maintenance schedule in the owner’s manual supplement.
Following the maintenance schedule is mandatory.
Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed, whichever reaches the specification first.
Maintain similar intervals between periodic maintenance unless noted.
Failng to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS (a) Check if the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink. Also, check if they have enough brightness. (b) Check if the headlights are aimed properly. 3. WARNING LIGHTS AND BUZZERS (a) Check if all the warning lights and buzzers are working. 4. HORN (a) Check if the horn is working. 5. WINDSHIELD GLASS (a) Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check if the wind washers are aimed properly. Also, check if the washer fluid hits the center of the operating rage of each wiper on the windshield. (b) Check if the wipers streak or not. 7. WINDSHIELD DEFROSTER (a) When the heater or air conditioner is on the defroster setting, check if air comes out of the defroster outlet. 8. REAR VIEW MIRROR (a) Check if the rear view mirror is securely mounted. 9. SUN VISORS (a) Check if the sun visors move freely and are securely mounted. 10. STEERING WHEEL (a) Check if the steering wheel has the proper freeplay. Also check for steering difficulty, freeplay in the steering wheel and unusual noises. 11. SEATS (a) Check if the seat adjusters, seatback recliner and other front seat controls operate smoothly. (b) Check if all the latches lock securely in all positions. (c) Check if the locks hold securely in all latched positions. (d) Check if the head restraints move up and down smoothly and if the locks hold securely in all latched positions. (e) When the rear seatbacks are folded down, check if the latches lock securely. WhereEverybodyKnowsYourName 99−3 MAINTENANCE 12. (a) (b) 13. (a) 14. (a) (b) 15. (a) (b) (c) 16. (a) 17. (a) (b) 18. (a) (b) − INSIDE VEHICLE SEAT BELTS Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. Check if the belt webbing is not cut, frayed, worn or damaged. Replace if neccessary. ACCELERATOR PEDAL Check the pedal for smooth operation, uneven pedal effort and catching. CLUTCH PEDAL (See page 42−7) Check the pedal for smooth operation. Check if the pedal has the proper freeplay. BRAKE PEDAL (See page 32−14) Check the pedal for smooth operation. Check if the pedal has the proper reserve distance and freeplay. Start the engine and check the brake booster function. BRAKES In a safe place, check if the vehicle remains straight when applying the brakes. PARKING BRAKE (See page 33−2) Check that the lever has the proper range of motion. On a low incline, check if the parking brake alone can stabilize the vehicle. AUTOMATIC TRANSAXLE ”PARK” MECHANISM Check the lock release button of the selector lever for proper and smooth operation. On a low incline, check if the parking brake alone can satabilize the vehicle. WhereEverybodyKnowsYourName 99−4 MAINTENANCE − UNDER HOOD UNDER HOOD 9900X−15 GENERAL MAINTENANCE 1.




2. (a) 3. (a) 4. (a) (b) 5. (a) 6. (a) 7. (a) 8. (a) 9. (a) (b) 10. (a) (b) (c) GENERAL NOTES Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown. Every service item in the periodic maintenance schedule must be performed. Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months). Maintenance service after the last period should be performed at the same interval as before unless noted. Failure to do even one of the items can cause the engine to run poorly and increase the exhaust emissions. WINDSHIELD WASHER FLUID Check if there is sufficient fluid in the tank. ENGINE COOLANT LEVEL Check if the coolant level is between the ”FULL” and ”LOW” lines on the see−through reservoir. RADIATOR AND HOSES Check if the front of the radiator is clean and not blocked by leaves, dirt or bugs. Check the hoses for cracks, kinks, rot or loose connections. BATTERY ELECTROLYTE LEVEL Check if the electrolyte level of all the battery cells is between the upper and lower level lines on the case. BRAKE FLUID LEVEL Check if the brake fluid levels are near the upper level line on the see−through reservoirs. ENGINE DRIVE BELT Check the drive belt for fraying, cracks, wear or oiliness. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. POWER STEERING FLUID LEVEL Check the level on the dipstick. The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature. AUTOMATIC TRANSMISSION FLUID LEVEL Park the vehicle on a level surface. With the engine idling and the parking brake applied, shift the selector into all the positions from ”P” to ”L”, and then shift into the ”P” position. Pull out the dipstick and wipe off the fluid with a clean shop rag. Re−insert the dipstick and check that the fluid level is in the ”HOT” range. Perform this check with the fluid at the normal driving temperature: 70 to 80°C (158 to 176°F). (d) HINT: Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at high speed, in hot weather, in heavy traffic or pulling a trailer. 11. EXHAUST SYSTEM (a) If any change in the sound of the exhaust or the smell of the exhaust fumes is noticed, locate and correct the cause. WhereEverybodyKnowsYourName 99−5 MAINTENANCE − ENGINE ENGINE 9900Y−15 ON−VEHICLE INSPECTION HINT: Inspect these items on a cooled down engine. 1. REPLACE TIMING CHAIN (2AZ−FE:14−75) 2. REPLACE TIMING BELT (1MZ−FE/3MZ−FE: See page 14−218) 3. INSPECT DRIVE BELT (2AZ−FE: See page 14−5, 1MZ−FE/3MZ−FE: See page 14−140) 4. REPLACE SPARK PLUGS (2AZ−FE: See page 18−3, 1MZ−FE/3MZ−FE: See page 18−9) 5. (a) (b) Outside Inside A59673 6. (a) 7. 8. 9. 10. (a) 11. (a) 12. INSPECT AIR FILTER Remove the air filter. Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. (c) Clean the filter with compressed air. First blow from the inside thoroughly, and then blow from the outside of the filter. (d) Reinstall the air filter. REPLACE AIR FILTER Replace the air filter with a new one. REPLACE ENGINE OIL AND OIL FILTER (2AZ−FE: See page 17−3, 1MZ−FE/3MZ−FE: See page 17−25) REPLACE ENGINE COOLANT (2AZ−FE: See page 16−6, 1MZ−FE/3MZ−FE: See page 16−27) INSPECT GASKET IN FUEL TANK CAP (2AZ−FE: See page 12−1, 1MZ−FE/3MZ−FE: See page 12−18) INSPECT FUEL LINES AND CONNECTIONS AND FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. INSPECT VALVE CLEARANCE (2AZ−FE: See page 14−7, 1MZ−FE/3MZ−FE: See page 14−142) WhereEverybodyKnowsYourName 99−6 MAINTENANCE − BRAKE BRAKE 9900Z−22 ON−VEHICLE INSPECTION 2. 3. 4. 5. 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well−lighted area. Turn the front wheels fully to the right or left before beginning. (a) Check all the brake lines and hoses for:
Damage
Wear
Deformation
Cracks P09958
Corrosion
Leaks
Bends
Twists (b) Check all the clamps for tightness and the connections for leakage. (c) Check if the hoses and lines are not near sharp edges, moving parts and the exhaust system. (d) Check if the lines are installed pass through the center of the grommets. INSPECT FRONT BRAKE PADS AND DISCS (See page 32−35) INSPECT REAR BRAKE PADS AND DISCS (See page 32−44) INSPECT REAR BRAKE LININGS, DISCS AND DRUMS (See page 32−44, 32−50) INSPECT OR CHANGE BRAKE FLUID (See page 32−4) Fluid: SAE J1703 or FMVSS No.116 DOT3 WhereEverybodyKnowsYourName 99−7 MAINTENANCE − CHASSIS CHASSIS 9901A−15 ON−VEHICLE INSPECTION 1. (a) (b) INSPECT STEERING LINKAGE Check the steering wheel free play. (see page 50−3) Check the steering linkage for looseness or damage. (1) Check if the tie rod ends do not have excessive play. (2) Check if the dust seals and boots are not damaged. (3) Check if the boot clamps are not loose. 2. INSPECT STEERING GEAR HOUSING OIL (a) Check the steering gear housing for oil leakage. If oil is leaking, find the cause and repair it. 3. INSPECT BALL JOINTS AND DUST COVERS (a) Inspect the ball joints for excessive looseness. (1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires. (2) Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. (3) Check that the front wheels are pointing straight ahead. Use chocks. (4) Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is any play, replace the ball joint. (b) Check the dust cover for damage. 4. INSPECT DRIVE SHAFT BOOTS (a) Check the drive shaft boots for loose clamps, grease leakage, kink or damage. 5. CHECK TRANSAXLE OIL (FLUID) (a) Visually check the transaxle for oil (fluid) leakage. If oil is leaking, find the cause and repair it. 6. ROTATE TIRES (See page 28−1) WhereEverybodyKnowsYourName 99−8 MAINTENANCE − BODY BODY 9901B−12 ON−VEHICLE INSPECTION 1. (a) (b) 2. (a) (b) (c) (d) (e) Canada: TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the bolts and nuts on the chassis parts listed below, if necessary.
Front axle and suspension
Drive train
Rear axle and suspension
Brake system
Engine mounting
Other chassis parts Tighten the bolts and nuts on the body parts listed below, if necessary.
Seat belt system
Seats
Doors and hood
Body mountings
Fuel tank
Exhaust pipe system
Other body parts REPLACE AIR CONDITIONING FILTER Remove the glove compartment assembly. Remove the filter case from the filter outlet. Remove the filter from the filter case. Replace the filter with a new one. The installation procedures are the removal procedures in reverse order. WhereEverybodyKnowsYourName 33−1 PARKING BRAKE − PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM 3304S−02 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area 1. Parking brake pedal or lever travel (Out of adjustment) 2. Parking brake wire (Sticking) Brake drag 3. Parking brake shoe clearance (Out of adjustment) 4. Parking brake shoe lining (Cracked or distorted) 5. Tension or return spring (Damaged) WhereEverybodyKnowsYourName See page 33−2 33−10 33−14 33−17 33−19 33−19 33−19 33−10 PARKING BRAKE − PARKING BRAKE CABLE ASSY NO.1 (From August, 2002) PARKING BRAKE CABLE ASSY NO.1 (From August, 2002) 3304W−03 REPLACEMENT HINT: COMPONENTS: See page 33−3 and 71−9 1. REMOVE FRONT DOOR SCUFF PLATE LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) 2. REMOVE COWL SIDE TRIM SUB−ASSY LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) 3. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER (PEDAL TYPE PARKING BRAKE)(See page 71−16) 4. REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) 5. REMOVE CONSOLE PANEL UPPER REAR(See page 71−16) 6. REMOVE CONSOLE BOX CARPET(See page 71−16) 7. REMOVE RR CONSOLE BOX(See page 71−16) 8. REMOVE INSTRUMENT PANEL ASH RECEPTACLE ASSY(See page 71−16) 9. REMOVE CONSOLE PANEL UPPER(See page 71−16) 10. REMOVE CONSOLE BOX FRONT(See page 71−16) 11. REMOVE AIR DUCT REAR NO.1(See page 71−16) 12. REMOVE AIR DUCT REAR NO.2(See page 71−16) 13. REMOVE CONSOLE BOX DUCT NO.1(See page 71−16) 14. REMOVE SHIFT LEVER SHAFT HOUSING ASSY(See page 71−16) 15. REMOVE YAWRATE SENSOR (W/ VSC)(See page 32−71) 16. Turn Buckle (a) (b) REMOVE PARKING BRAKE CABLE ASSY NO.1 (PEDAL TYPE PARKING BRAKE) Loosen the turn buckle, disconnect the parking brake cable assy No.1 from the parking brake cable assy No.4. Remove the 2 bolts and console box mounting bracket No.2. C90470 (c) Remove the lock nut, adjusting nut, clip and disconnect the parking brake cable assy No.1 from the parking brake control pedal assy. F41010 WhereEverybodyKnowsYourName PARKING BRAKE (d) − PARKING BRAKE CABLE ASSY NO.1 (From August, 2002) 33−11 Remove the 2 nuts, 2 bolts, clip and parking brake cable assy No.1. F41687 17. (a) (b) REMOVE PARKING BRAKE CABLE ASSY NO.1 (LEVER TYPE PARKING BRAKE) Remove the lock nut and adjusting nut from the parking brake cable assy No.1. Remove the 2 bolts and console box mounting bracket No.2. F41000 (c) Remove the 2 bolts and separate the parking brake cable No.1 from the parking brake equalizer. 18. INSTALL PARKING BRAKE CABLE ASSY NO.1 (PEDAL TYPE PARKING BRAKE) Install the parking brake cable assy No.1 with the 2 nuts, 2 bolts and clip. (a) F41688 F41687 WhereEverybodyKnowsYourName 33−12 PARKING BRAKE (b) (c) − PARKING BRAKE CABLE ASSY NO.1 (From August, 2002) Install the parking brake cable assy No.1 with the clip, adjusting nut and lock nut to the parking brake control pedal assy. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Install the console box mounting bracket No.2 with the 2 bolts. Torque: 12.5 N⋅m (128 kgf⋅cm, 9 ft⋅lbf) F41010 Turn Buckle (d) Tighten the turn buckle, connect the parking brake cable assy No. 1 to the parking brake cable assy No.4. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 19. INSTALL PARKING BRAKE CABLE ASSY NO.1 (LEVER TYPE PARKING BRAKE) Install the parking brake cable assy No.1 with the 2 bolts to the parking brake equalizer. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Install the console box mounting bracket No.2 with the 2 bolts. Torque: 12.5 N⋅m (128 kgf⋅cm, 9 ft⋅lbf) C90470 (a) (b) F41688 (c) Install the parking brake cable assy No.1 with the adjusting nut and lock nut to the parking brake lever assy. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) F41000 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32−71) INSTALL SHIFT LEVER SHAFT HOUSING ASSY(See page 71−16) INSTALL CONSOLE BOX DUCT NO.1(See page 71−16) INSTALL AIR DUCT REAR NO.2(See page 71−16) INSTALL AIR DUCT REAR NO.1(See page 71−16) INSTALL CONSOLE BOX FRONT(See page 71−16) INSTALL CONSOLE PANEL UPPER(See page 71−16) INSTALL INSTRUMENT PANEL ASH RECEPTACLE ASSY(See page 71−16) INSTALL RR CONSOLE BOX(See page 71−16) INSTALL CONSOLE BOX CARPET(See page 71−16) WhereEverybodyKnowsYourName PARKING BRAKE 30. 31. 32. 33. 34. 35. 36. 37. − PARKING BRAKE CABLE ASSY NO.1 (From August, 2002) 33−13 INSTALL CONSOLE PANEL UPPER REAR(See page 71−16) INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) INSTALL INSTRUMENT PANEL SUB−ASSY UPPER (PEDAL TYPE PARKING BRAKE)(See page 71−16) INSTALL COWL SIDE TRIM SUB−ASSY LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) INSTALL FRONT DOOR SCUFF PLATE LH (PEDAL TYPE PARKING BRAKE)(See page 71−16) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)(See page 33−2) INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE)(See page 33−2) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (W/ VSC)(See page 05−987) WhereEverybodyKnowsYourName 33−14 PARKING BRAKE − PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE CABLE ASSY NO.3 3304X−05 REPLACEMENT HINT:

COMPONENTS: See page 33−3 For parking brake cable No.2, employ the same procedure to the RH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the 2 bolts and separate the rear disc brake caliper assy LH. 1. 2. (a) HINT: Do not the flexible hose from the brake caliper assy LH. 3. REMOVE REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE)(See page 32−50) 4. REMOVE REAR DISC (DISC REAR BRAKE TYPE)(See page 33−19) 5. REMOVE PARKING BRAKE SHOE(See page 33−19) 6. REMOVE PARKING BRAKE CABLE HEAT INSULATOR (a) Remove the 3 nuts and parking brake heat insulator. 7. (a) REMOVE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 bolts and disconnect the parking brake cable assy No.3 from the backing plate. (b) Remove the 2 nuts, bolt and parking brake cable assy No.3. C90471 C90462 F41690 WhereEverybodyKnowsYourName 33−15 PARKING BRAKE − PARKING BRAKE CABLE ASSY NO.3 (c) Disconnect the parking brake cable assy No.3 from the parking brake equalizer. 8. (a) INSTALL PARKING BRAKE CABLE ASSY NO.3 Connect the parking brake cable assy No.3 to the parking brake equolizer. Install the parking brake cable assy No.3 with the 2 nuts and bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) (b) C90462 F41690 (c) Install the parking brake cable assy No.3 with the 2 bolts to the backing plate. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) C90471 9. (a) 10. 11. INSTALL PARKING BRAKE CABLE HEAT INSULATOR Install the parking brake heat insulator with the 3 nuts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) APPLICATION HIGH TEMPERATURE GREASE(See page 33−19) INSTALL PARKING BRAKE SHOE(See page 33−19) WhereEverybodyKnowsYourName 33−16 PARKING BRAKE 12. 13. 14. 15. 16. (a) 17. 18. 19. − PARKING BRAKE CABLE ASSY NO.3 CHECK PARKING BRAKE INSTALLATION(See page 33−19) INSTALL REAR BRAKE DRUM SUB−ASSY (DRUM REAR BRAKE TYPE)(See page 32−50) INSTALL REAR DISC (DISC REAR BRAKE TYPE)(See page 33−19) ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33−19) INSTALL REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper with the 2 bolts. Torque: 47 N⋅m (480 kgf⋅cm, 35 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)(See page 33−2) INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE)(See page 33−2) WhereEverybodyKnowsYourName PARKING BRAKE − PARKING BRAKE CABLE ASSY NO.4 (From August, 2002) 33−17 PARKING BRAKE CABLE ASSY NO.4 (From August, 2002) 3304Y−03 REPLACEMENT HINT: COMPONENTS: See page 33−3 1. REMOVE CONSOLE PANEL UPPER REAR(See page 71−16) 2. REMOVE CONSOLE BOX CARPET(See page 71−16) 3. REMOVE RR CONSOLE BOX(See page 71−16) 4. REMOVE CONSOLE BOX MOUNTING BRACKET NO.2 (a) Remove the 2 bolts and console box mounting bracket No.2. 5. REMOVE YAWRATE SENSOR (W/ VSC)(See page 32−71) 6. (a) Turn Buckle (b) REMOVE PARKING BRAKE CABLE ASSY NO.4 Loosen the turn buckle, disconnect the parking brake cable assy No.4 from the parking brake cable assy No.1. Disconnect the parking brake cable assy No.4 from the parking brake equolizer. C90470 (c) Remove the 2 bolts and parking brake cable assy No.4. 7. (a) INSTALL PARKING BRAKE CABLE ASSY NO.4 Install the parking brake cable No.4 with the 2 bolts. Torque: 12.5 N⋅m (128 kgf⋅cm, 9 ft⋅lbf) Connect the parking brake cable assy No.4 to the parking brake equolizer. C90464 (b) C90464 WhereEverybodyKnowsYourName 33−18 PARKING BRAKE (c) Turn Buckle − PARKING BRAKE CABLE ASSY NO.4 (From August, 2002) Tighten the turn buckle, connect the parking brake cable assy No.4 to the parking brake cable assy No.1. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) C90470 8. 9. (a) 10. 11. 12. 13. 14. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32−71) INSTALL CONSOLE BOX MOUNTING BRACKET NO.2 Install the console box mounting bracket No.2 with the 2 bolts. Torque: 12.5 N⋅m (128 kgf⋅cm, 9 ft⋅lbf) INSTALL RR CONSOLE BOX(See page 71−16) INSTALL CONSOLE BOX CARPET(See page 71−16) INSTALL CONSOLE PANEL UPPER REAR(See page 71−16) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33−2) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (W/ VSC)(See page 05−987) WhereEverybodyKnowsYourName 33−19 PARKING BRAKE − PARKING BRAKE ASSY PARKING BRAKE ASSY 33050−02 OVERHAUL HINT:

COMPONENTS: See page 33−3 Overhaul the RH side by the same procedures with LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the 2 bolts and separate the rear disc brake caliper assy LH. 1. 2. (a) HINT: Do not disconnect the flexible hose from the brake caliper. 3. REMOVE REAR DISC (a) Release the parking brake, and remove the rear disc. HINT:
Put matchmarks on the disc and the axle hub.
If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. Contract C64523 4. (a) INSPECT BRAKE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) 5. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING Using a needle−nose pliers, remove the 2 return tension springs. F06409 (a) F40318 6. (a) 7. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING Slide out the front shoe and remove the compression spring. REMOVE PARKING BRAKE SHOE STRUT LH WhereEverybodyKnowsYourName 33−20 PARKING BRAKE 8. (a) (b) (c) (d) − PARKING BRAKE ASSY REMOVE PARKING BRAKE SHOE Release the cup claw and remove the front and rear parking brake shoe. Disconnect the parking brake cable from the shoe lever. Remove the tension spring and shoe adjuster screw set from the front and rear shoe. Remove the 2 shoe hold−down springs, 4 cups and 2 pins. F40319 (e) (f) Using a screwdriver, remove the C−washer. Remove the shim and shoe lever from the parking brake shoe. F40320 9. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe. BR5332 10. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. BR0828 11. (a) APPLICATION HIGH TEMPERATURE GREASE Apply the high temperature grease to the shoe attached surface of backing plate. WhereEverybodyKnowsYourName 33−21 PARKING BRAKE 12. (a) − PARKING BRAKE ASSY INSTALL PARKING BRAKE SHOE Install the shoe lever and shim to the rear shoe with a new C−washer. (b) Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) − R00343 (c) (d) (e) (f) (g) Apply the high temperature grease to the adjusting bolt. Install the shoe adjusting screw set and tension spring to the front and rear shoe. Install the 2 pins, 4 cups and 2 shoe hold−down springs. Connect the parking brake cable to the shoe lever. Install the front and rear parking brake shoe. F41705 13. 14. INSTALL PARKING BRAKE SHOE STRUT LH INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 15. (a) INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING Using a needle nose pliers, install the 2 return tension springs. F40318 WhereEverybodyKnowsYourName 33−22 PARKING BRAKE − PARKING BRAKE ASSY 16. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. NOTICE: There should be no oil or grease adhering to the friction surface of the shoe lining and disc. RH LH Front Front F40322 17. INSTALL REAR DISC 18. (a) (b) Expand (c) Contract F40026 19. (a) 20. 21. 22. (d) (e) ADJUST PARKING BRAKE SHOE CLEARANCE Temporarily install the hub nuts. Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks. Contract the shoe adjuster until the disc can rotate smoothly. Standard : Return 8 notches Check shoe is no brake drag. Install the hole plug. INSTALL REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper with the 2 bolts. Torque: 47 N⋅m (480 kgf⋅cm, 35 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)(See page 33−2) INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE) (See page 33−2) WhereEverybodyKnowsYourName 33−2 PARKING BRAKE − PARKING BRAKE SYSTEM 3304T−02 ADJUSTMENT 1. 2. 3. 4. (a) 5. (a) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33−19) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE) Slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel: 3 − 6 clicks at 300 N (31 kgf, 68.3 lbf) INSPECT PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE) Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel: 6 − 9 clicks at 200 N (20 kgf, 44.1 lbf) 6. (a) (b) (c) Lock Nut Adjusting Nut (d) F41011 (e) (f) (g) 7. (a) (b) (c) Lock Nut (d) (e) (f) ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE) Depress the parking brake pedal 3 notches to make a room for the procedure, and loosen the lock nut. Return the parking brake pedal to the original position. Turn the adjusting nut until the parking brake pedal travel is correct. Depress the parking brake pedal 3 notches to make a room for the procedure, and tighten the lock nut. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Return the parking brake pedal to the original position. Check whether parking brake drags or not. When operating the parking brake pedal, check that the parking brake pedal indicator light lights up. ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE) Remove the console panel upper. Remove the air duct rear No. 1. Loosen the lock nut and turn the adjusting nut until the lever travel is correct. Tighten the lock nut. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Install the air duct rear No.1. Install the console panel upper. Adjusting Nut F40014 WhereEverybodyKnowsYourName 33−3 PARKING BRAKE − PARKING BRAKE (From August, 2002) PARKING BRAKE (From August, 2002) 3304Z−02 COMPONENTS Parking Brake Lever Sub−assy: Lock Nut 5.0 (51, 44 in.⋅lbf) Parking Brake Lever Sub−assy 23 (235, 17) Adjusting Nut 23 (235, 17) Parking Brake Switch Assy 23 (235, 17) Parking Brake Cable Assy No.1 Air Duct Rear No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName F41002 33−4 PARKING BRAKE − PARKING BRAKE (From August, 2002) Parking Brake Control Pedal Assy: 39 (398, 29) Parking Brake Control Pedal Assy Parking Brake Switch Assy Return Spring Damper Adjusting Nut Tension Spring Parking Brake Cable Assy No.1 Lock Nut 5.4 (55, 48 in.⋅lbf) Clip 39 (398, 29) 39 (398, 29) Parking Pedal Pad N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque WhereEverybodyKnowsYourName F41008 33−5 PARKING BRAKE − PARKING BRAKE (From August, 2002) Parking Brake Cable: Parking Brake Control Pedal Models: Parking Brake Cable Assy No.4 Consol Box Mounting Bracket No.2 12.5 (128, 9) 8.0 (85, 73 in.⋅lbf) 8.0 (85, 73 in.⋅lbf) 12.5 (128, 9) Parking Brake Cable Assy No.3 Parking Brake Equalizer 5.4 (55, 48 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) 5.4 (55, 48 in.⋅lbf) 7.8 (80, 69 in.⋅lbf) Parking Brake Cable Heat Insulator 5.4 (55, 48 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque C90467 F41686 WhereEverybodyKnowsYourName 33−6 PARKING BRAKE − PARKING BRAKE (From August, 2002) Parking Brake Assy: Rear Disc Brake Caliper Assy LH 47 (480, 35) Shoe Hold−down Spring Pin
C−Washer Shim Parking Brake Shoe Return Tension Spring Parking Brake Shoe Strut Compression Spring Parking Brake Shoe Parking Brake Shoe Lever Parking Brake Shoe Strut LH Parking Brake Shoe Return Tension Spring Shoe Hold−down Spring Adjusting Bolt Adjusting Bolt Shoe Adjusting Screw Set Parking Brake Shoe Shoe Hold−down Spring Cup Rear Disc N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non−reusable part High Temperature grease C90458 WhereEverybodyKnowsYourName Hole Plug F41967 PARKING BRAKE − PARKING BRAKE LEVER SUB−ASSY (From August, 2002) 33−7 PARKING BRAKE LEVER SUB−ASSY (From August, 2002) 3304U−05 REPLACEMENT HINT: COMPONENTS: See page 33−3 and 71−9 1. REMOVE CONSOLE PANEL UPPER(See page 71−16) 2. REMOVE AIR DUCT REAR NO.1(See page 71−16) 3. REMOVE PARKING BRAKE LEVER SUB−ASSY (a) Disconnect the parking brake switch connector. (b) Remove the lock nut and adjusting nut. (c) (d) Remove the 2 bolts. Using a screwdriver, disconnect the parking brake cable No. 1 and remove the parking brake lever sub−assy. F41001 4. (a) 5. (a) REMOVE PARKING BRAKE SWITCH ASSY Remove the screw and parking brake switch assy. INSTALL PARKING BRAKE SWITCH ASSY Install the parking brake switch assy with the screw. 6. (a) (b) (c) INSTALL PARKING BRAKE LEVER SUB−ASSY Connect the parking brake cable to the lever and install the adjusting nut and lock nut. Install the paking brake lever sub−assy with the 2 bolts. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Connect the parking brake switch connector. F41001 7. 8. 9. 10. INSTALL AIR DUCT REAR NO.1(See page 71−16) INSTALL CONSOLE PANEL UPPER(See page 71−16) CHECK PARKING BRAKE LEVER TRAVEL(See page 33−2) ADJUST PARKING BRAKE LEVER TRAVEL(See page 33−2) WhereEverybodyKnowsYourName 33−8 PARKING BRAKE − PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CONTROL PEDAL ASSY 3304V−03 OVERHAUL HINT: COMPONENTS: See page 33−3 and 71−9 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL(See page 71−16) 2. REMOVE COMBINATION METER ASSY(See page 71−16) 3. REMOVE FRONT DOOR SCUFF PLATE LH(See page 71−16) 4. REMOVE COWL SIDE TRIM SUB−ASSY LH(See page 71−16) 5. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER(See page 71−16) 6. REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH(See page 71−16) 7. (a) (b) REMOVE PARKING BRAKE CONTROL PEDAL ASSY Disconnect the parking brake switch connector. Remove the 2 bolts, nut and parking brake control pedal assy. 8. REMOVE PARKING BRAKE CABLE ASSY NO.1 (a) Remove the lock nut, adjusting nut, clip and parking brake assy No. 1. F41009 F41010 9. (a) 10. 11. 12. REMOVE PARKING BRAKE SWITCH ASSY Remove the screw and parking brake switch assy. REMOVE TENSION SPRING REMOVE RETURN SPRING DAMPER REMOVE PARKING PEDAL PAD WhereEverybodyKnowsYourName 33−9 PARKING BRAKE 13. 14. 15. 16. (a) − PARKING BRAKE CONTROL PEDAL ASSY INSTALL PARKING PEDAL PAD INSTALL RETURN SPRING DAMPER INSTALL TENSION SPRING INSTALL PARKING BRAKE SWITCH ASSY Install the parking brake switch assy with the screw. 17. INSTALL PARKING BRAKE CABLE ASSY NO.1 (a) Install the parking brake cable assy No.1 with the clip, adjusting nut and lock nut. F41010 18. (a) (b) INSTALL PARKING BRAKE CONTROL PEDAL ASSY Install the parking brake control pedal assy with the 2 bolts and nut. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) Connect the parking brake switch connector. F41009 19. 20. 21. 22. 23. 24. 25. INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH(See page 71−16) INSTALL INSTRUMENT PANEL SUB−ASSY UPPER(See page 71−16) INSTALL COWL SIDE TRIM SUB−ASSY LH(See page 71−16) INSTALL FRONT DOOR SCUFF PLATE LH(See page 71−16) INSTALL COMBINATION METER ASSY(See page 71−16) INSTALL INSTRUMENT CLUSTER FINISH PANEL(See page 71−16) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33−2) WhereEverybodyKnowsYourName INTAKE − INTAKE AIR CONTROL SYSTEM (2AZ−FE (PZEV)) (From July, 2003) 13−1 INTAKE AIR CONTROL SYSTEM (2AZ−FE (PZEV)) (From July, 2003) 1306I−02 ON−VEHICLE INSPECTION 1. (a) (b) (c) (d) CHECK INTAKE MANIFOLD RUNNER VALVE ASSY Connect the hand−held tester to the DLC3. Turn the ignition switch ON. Select IACV MOTOR from the ACTIVE TEST menu. Check that the voltage output (IACV POSITION) in the DATA LIST indicates the standard value. Standard: Condition Specified Codition IAC valve open 3.0 to 4.2 V IAC valve close 0.3 to 1.0 V WhereEverybodyKnowsYourName 13−12 INTAKE − INTAKE AIR CONTROL VALVE ASSY NO.1 (1MZ−FE) INTAKE AIR CONTROL VALVE ASSY NO.1 (1MZ−FE) 1307R−02 REPLACEMENT 1. 2. 3. 4. 5. DRAIN ENGINE COOLANT (See page 16−27) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ PERFORMANCE ROD) REMOVE V−BANK COVER SUB−ASSY (See page 14−164) REMOVE AIR CLEANER CAP SUB−ASSY REMOVE THROTTLE BODY ASSY (See page 10−18) 6. (a) (b) (c) (b) REMOVE INTAKE AIR CONTROL VALVE ASSY Disconnect the union to check valve hose. Disconnect the fuel vapor feed hose No. 2. Disconnect the vacuum hose. (a) (c) A79547 Remove the 5 bolts, nut and IAC valve. Remove the gasket from the intake air surge tank. A INSTALL INTAKE AIR CONTROL VALVE ASSY Install a new gasket to the intake air surge tank. Install the IAC valve with the 5 bolts and nut. B A Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt A and nut A A 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for bolt B A (c) Connect the vacuum hose. A79548 (d) Connect the fuel vapor feed hose No. 2. (e) Connect the union to check valve hose. 8. INSTALL THROTTLE BODY ASSY (See page 10−18) 9. INSTALL AIR CLEANER CAP SUB−ASSY 10. ADD ENGINE COOLANT (See page 16−27) 11. CHECK FOR ENGINE COOLANT LEAKS (See page 16−21) 12. INSTALL V−BANK COVER SUB−ASSY (See page 14−164) 13. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ PERFORMANCE ROD) Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) A (d) (e) 7. (a) (b) WhereEverybodyKnowsYourName INTAKE − INTAKE AIR CONTROL VALVE ASSY NO.2 (1MZ−FE/3MZ−FE) 13−13 INTAKE AIR CONTROL VALVE ASSY NO.2 (1MZ−FE/3MZ−FE) 1307P−02 REPLACEMENT 1. (a) (b) Lever (c) REMOVE INTAKE AIR CONTROL VALVE ASSY NO.2 Remove the 3 bolts and nut. Rotate the lever to the closed position as shown in the illustration and pull out the IAC valve. Remove the gasket from the intake air surge tank. A81629 2. (a) (b) INSTALL INTAKE AIR CONTROL VALVE ASSY NO.2 Install a new gasket to the intake air surge tank. Install the IAC valve with the 3 bolts and nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) WhereEverybodyKnowsYourName 13−2 INTAKE − INTAKE AIR CONTROL SYSTEM (2AZ−FE (PZEV)) (From July, 2003) 1306J−02 INSPECTION 1. (a) INSPECT INTAKE MANIFOLD RUNNER VALVE ASSY Check the intake manifold runner valve. (1) Check that intake manifold runner valve shaft is not rickety. NOTICE: Do not adjust the screw. Do not adjust A66035 (b) Check the intake manifold runner valve operation. (1) Apply battery positive and negative voltages across the terminals. Standard: Measuring Condition Operation Battery positive − Terminal 4 Battery negative − Terminal 5 Close Battery positive − Terminal 5 Battery negative − Terminal 4 Open (2) Check that the intake manifold runner valve opens and closes smoothly. If the result is not as specified, replace the intake manifold runner valve assy. NOTICE: Do not apply the battery voltage to the intake manifold runner valve for more than 1 minute. Close Open A66036 (c) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard: Tester Connection Specified Condition 4−5 3.0 to 10 Ω at 20
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F) If the result is not as specified, replace the intake manifold runner valve assy. A66037 WhereEverybodyKnowsYourName INTAKE − 13−3 INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) 1306L−02 COMPONENTS w/ Performance Rod: Front Suspension Upper Brace Center 80 (815, 59) 7.0 (71, 62 in.⋅lbf) x4 Spacer Engine Cover Sub−assy No. 1 MAF Meter Connector Fuel Vapor Feed Hose VSV Connector Air Cleaner Cap Sub−assy 5.0 (51, 44 in.⋅lbf) Air Cleaner Filter Element Sub−assy N·m (kgf·cm, ft·lbf) : Specified torque A79456 WhereEverybodyKnowsYourName 13−4 INTAKE − INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) IACl Valve Assy
Gasket IACl Valve Connector
Gasket Intake Manifold 30 (306, 22) Throttle Motor Connector x2 Fuel Tube Sub−assy x3 x2 Water By−pass Hose Water By−pass Hose No. 2 30 (306, 22) N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part A79457 WhereEverybodyKnowsYourName INTAKE − INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) 13−5 1306M−02 REPLACEMENT 1. 2. DRAIN ENGINE COOLANT (See page 16−6) REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ PERFORMANCE ROD) 3. (a) REMOVE ENGINE COVER SUB−ASSY NO.1 Remove the 2 nuts and engine cover. 4. (a) (b) (c) (d) (e) (f) (g) REMOVE AIR CLEANER CAP SUB−ASSY Disconnect the MAF meter connector. Disconnect the VSV connector. Disconnect the fuel vapor feed hose No. 2. Disconnect the ventilation hose. Disconnect the fuel vapor feed hose No. 1. Loosen the 2 air cleaner cap bolts. Lock the air cleaner hose clamp and remove the air cleaner cap together with the air cleaner hose. A79458 (e) (d) (a) (g) (c) (f) (b) (f) A79459 5. (a) (b) REMOVE INTAKE MANIFOLD Disconnect the ventilation hose No. 2. Disconnect the union to connector tube hose. (a) (b) A79460 WhereEverybodyKnowsYourName 13−6 INTAKE (c) (d) (g) − INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) (c) (d) (e) (f) (g) Disconnect the throttle motor connector. Remove the wire harness from the wire harness clamp. Remove the fuel tube from the fuel pipe support. Disconnect the water by−pass hose No. 2 Disconnect the water by−pass hose. (h) In order to remove the intake manifold, Uniformly remove the 5 bolts and 2 nuts in the sequence shown in the illustration. Remove the gasket from the intake manifold. (e) (f) A79461 (i) 5 6 7 4 3 2 1 A79462 6. (a) (b) 7. (a) (b) REMOVE INTAKE AIR CONTROL VALVE ASSY Disconnect the IAC valve connector. Remove the IAC valve and gasket from the cylinder head. INSTALL INTAKE AIR CONTROL VALVE ASSY Install a new gasket and the IAC valve to the cylinder head. Connect the IAC valve connector. A79463 2 1 8. (a) (b) 3 4 5 6 7 A79464 (c) (d) (e) (f) INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold with the 5 bolts and 2 nuts. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Connect the water by−pass hose. Connect the water by−pass hose No. 2 Install the fuel tube to the fuel pipe support. Install the wire harness to the wire harness clamp. WhereEverybodyKnowsYourName INTAKE 9. 10. 11. 12. 13. − INTAKE MANIFOLD RUNNER VALVE ASSY (2AZ−FE (PZEV)) (From July, 2003) (g) Connect the throttle motor connector. (h) Connect the union to connector tube hose. (i) Connect the ventilation hose No. 2. INSTALL AIR CLEANER CAP SUB−ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) ADD ENGINE COOLANT (See page 16−6) CHECK FOR ENGINE COOLANT LEAKS (See page 16−1) INSTALL ENGINE COVER SUB−ASSY NO.1 Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ PERFORMANCE ROD) Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) WhereEverybodyKnowsYourName 13−7 13−8 INTAKE − INTAKE AIR CONTROL SYSTEM (1MZ−FE/3MZ−FE) INTAKE AIR CONTROL SYSTEM (1MZ−FE/3MZ−FE) 1307S−01 ON−VEHICLE INSPECTION 1. (a) IAC Valve No. 1 (b) (c) (d) CHECK INTAKE AIR CONTROL SYSTEM Using a 3−way connector, connect a vacuum gauge to the actuator hose. Connect the hand−held tester to the DLC3. Start the engine. On the hand−held tester, enter the ACTIVE TEST mode. Standard: Switch Condition Vacuum VSV ON Approx. 27.6 kPa (200 mmHg, 7.9 in.Hg) VSV OFF 0 kPa (0 mmHg, 0 in.Hg) IAXC Valve No. 2 Throttle Valve Open Position (%) A60540 IAC Valve No. 1: Closed (ON) IAC Valve No. 2: Closed (ON) IAC Valve No. 1: Closed (OFF) IAC Valve No. 2: Closed (ON) 100 (e) (f) Move the shift lever to the P position. While operating the accelerator pedal, check open and closed status of the IAC valve No. 1 (IMZ−FE only) and No. 2. HINT: Values indicated in the illustration are for reference only. The throttle valve open position varies by engine speed. 35.7 IAC Valve No. 1: Open (OFF) IAC Valve No. 2: Open (OFF) 0 3,000 4,100 (1MZ−FE) 4,300 (3MZ−FE) Engine Speed (rpm) A81923 WhereEverybodyKnowsYourName 13−9 INTAKE − INTAKE AIR CONTROL SYSTEM (1MZ−FE/3MZ−FE) 1307T−01 INSPECTION 1. INSPECT INTAKE AIR CONTROL VALVE ASSY NO.1 (1MZ−FE ONLY) (a) With vacuum of 26.7 kPa (200 mm Hg, 7.9 in. Hg) applied to the actuator, check that the IAC valve closes. (b) 1 minute after applying the vacuum, check that the IAC valve remains closed. If the result is not as specified, replace the IAC valve assy No. 1. NOTICE: Do not adjust the screw. Do not adjust A61680 Lever Valve Actuator Rod A85563 2. (a) INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2 Apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to the actuator. Check if the actuator rod pulls the lever and causes the valve to rotate open, as shown in the illustration. (b) One minute after applying the vacuum, check that the actuator rod does not return. If the result is not as specified, replace the IAC valve assy No. 2. 3. (a) INSPECT INTAKE AIR CONTROL VALVE ASSY NO.3 Apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to the actuator. Check if the valve rotates open, as shown in the illustration. (b) Apply the vacuum for one minute. The actuator should continue to be keeping the valve open. If the result is not as specified, replace the IAC valve assy No. 3. Valve A85561 WhereEverybodyKnowsYourName 13−10 INTAKE − INTAKE AIR CONTROL SYSTEM (1MZ−FE/3MZ−FE) 4. C A B A85559 33 to 39 Ω Ohmmeter INSPECT VACUUM SWITCHING VALVE ASSY FOR ACIS (a) Cover port C with your finger, and check that air flows from port B to port A. (b) Cover ports C with your finger, and check that air does not flow from port A to port B. (c) Cover port A and C with your fingers, and apply 60 kPa (450 mmHg, 18 in.Hg) of vacuum to port B. Check that there is no change in the vacuum after one minute. If the result is not as specified, replace air cleaner cap. 5. INSPECT VALVE ASSY, VACUUM SWITCHING FOR IAC VALVE NO.1 (1MZ−FE ONLY) AND NO.2 (a) Check the VSV resistance. Standard: Tester Connection Specified Condition 1−2 33 to 39 Ω at 20
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F) 1 − Body ground 2 − Body ground 10 kΩ or higher If the result is not as specified, replace the VSV assy. Ohmmeter 10 kΩ or higher A85555 A85556 A85570 Air (b) Filter Check VSV operation. (1) Check that air flows from port E to the filter. E FI6393 (2) Apply battery voltage across the terminals. (3) Check that air flows from port E to port F. If the result is not as specified, replace the VSV assy. Air E F Battery S04523 WhereEverybodyKnowsYourName 13−11 INTAKE 6. Ohmmeter 37 to 44 Ω at 20
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F) (a) − INTAKE AIR CONTROL SYSTEM (1MZ−FE/3MZ−FE) INSPECT VACUUM SWITCHING VALVE ASSY FOR IAC VALVE ASSY NO. 3 Check the VSV resistance. Standard: Tester Connection Specified Condition 1−2 37 to 44 Ω at 20
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F) 1 − Body ground 2 − Body ground 10 kΩ or higher If the result is not as specified, replace the VSV assy No. 3. Ohmmeter 10 kΩ or higher A85557 A85558 A85569 (b) Filter E Check VSV operation. (1) Check that air flows from port E to the filter. Air A75333 (2) Apply battery voltage across the terminals. Check that air flows from port E to F. If the result is not as specified, replace the VSV assy No. 3. F E Air Battery A75334 WhereEverybodyKnowsYourName