Toyota - Tacoma Regular - Workshop Manual - 1997 - 1997

Page 897 Components For Removal And Installation Part 2 Of 2 Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4851 Brake Pad: Service and Repair Front Brake Components (4WD) REPLACEMENT 1. Remove front wheel. 2. Inspect pad lining thickness. 3. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 brake pads. - 4 anti-squeal shims. CAUTION: The anti-rattle spring can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 4. Install new pads. CAUTION: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. (a) Draw out a small amount of brake fluid from the reservoir. Page 2871 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Front Wheel Speed Sensor: Service and Repair Front Front Speed Sensor Components REMOVAL 1. Remove speed sensor. Disconnect Speed Sensor Connector (a) Disconnect the speed sensor connector. (b) Remove the 2 clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Remove Clamp Bolts (c) Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kg.cm 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. CAUTION: Make sure that: Page 3754 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 751 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2715 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 677 * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 4368 Electronically Controlled Transmission And A/T Indicator (Part 3 Of 3) Page 1164 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................... SH Energy Conserving II, SJ Energy Conserving, or ILAC Multigrade Above 0° F (-18°C) .................................. .............................................................................................................................................................. ... 10W-30 All Temperatures ................................................................................................................ .......................................................................................... 5w-30 Page 895 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2274 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4719 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Catalytic Converter: Specifications TWC to Front Exhaust Pipe 46 ft.lb TWC to Tailpipe 35 ft.lb Page 2699 Oxygen Sensor: Mechanical Specifications Heated Oxygen Sensor to Exhaust Pipe 14 ft.lb Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 193 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Supercharger - Squeak/Rattle Noises From Idler Pulley Idler Pulley: All Technical Service Bulletins Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 8 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 543 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 2295 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 4436 6. Inspect reverse idler gear and shift arm clearance. Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm. Standard Clearance: 0.05-0.35 mm (0.0020-0.0138 inch) Maximum Clearance: 0.50 mm (0.0197 inch) If the clearance exceeds the Maximum, replace the shift arm or reverse idler gear. Page 3045 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 576 Page 1182 6. Check fluid pressure reading with valve opened. a. With the engine idling, open the valve fully. b. Measure the fluid pressure at engine speeds of 1,000 RPM and 3,000 RPM. Fluid pressure difference: 490 kPa (71 psi) or less NOTICE: Do not turn the steering wheel. 7. Check pressure reading with steering wheel turned to full lock. With the engine idling and valve fully opened, turn the wheel to full lock. Fluid pressure: 8,336 kPa (1,209) Minimum NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. 8. Disconnect SST. a. Disconnect the SST. b. Connect the pressure feed tube. 9. Bleed power steering system. 10. Install air cleaner assembly. Tighten the 3 bolts. Page 2254 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4206 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4164 f. Apply adhesive Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent to 2 or 3 threads of the mount bolt end. g. Tighten the shaft retainer with the 2 bolts. Torque to 24 Nm (17 ft. lbs.) h. Using a pin punch and hummer, install the slotted spring pin to the shift fork. i. shift the fork deeply and keep the differential lock condition. j. Install the steel ball, spring and spring seat. k. Clean the threads of 2 plugs and plug holes with toluene or trichloroethylene. l. Apply adhesive Part No. 08833-00080, THREE BOND 1344, LOCTITE 242, or equivalent, to the plug threads. m. Using a hexagon wrench, install and tighten the screw plugs. Torque to 22 Nm (16 ft. lbs.) Disassembly Counter Gear: Service and Repair Disassembly Remove hub sleeve No.3, shifting key and spring from synchronizer ring. a. Remove the synchronizer ring assembly from the hub sleeve No.3. b. Turn the reverse synchronizer pull ring. c. Remove the reverse synchronizer ring and 5th synchronizer ring from the synchronizer pull ring and cone ring. Specifications Engine Oil Pressure: Specifications OIL PRESSURE (NORMAL OPERATING TEMPERATURE) At Idle Speed ....................................................................................................................................... ........................................ 29 kPa (4.3 psi) or more At 3,000 rpm ....................................................... .................................................................................................................... 245 - 520 kPa (36 - 75 psi) Page 67 WIRING DIAGRAM Inspection Procedure / ECT Communication Circuit - Solenoid #2 (1 Of 5) Inspection Procedure / ECT Communication Circuit - Solenoid #2 (2 Of 5) Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 177 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2923 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 2596 Step 2 Step 3 Step 4 INSPECTION PROCEDURE Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3180 EGR Temperature Sensor: Mechanical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) EGR Sensor to EGR Valve 14 ft.lb Page 3444 Throttle Body: Testing and Inspection Component Inspection THROTTLE BODY INSPECTION 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner. clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration. do not clean the throttle position sensor and IAC valve. 2. INSPECT THROTTLE VALVE (a) Apply vacuum to the throttle opener. (b) Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. Throttle valve fully closed angle: 10° 3. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener (b) Insert a thickness gauge between the throttle stop screw and stop lever. Ohmmeter Connection Reference Page 2984 Page 3891 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 24) Page 2805 Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Locations Page 899 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 2510 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4257 b. Using a press, remove the rear axle shaft with the bearing retainer from the backing plate. c. Remove the SST. 4. Inspect axle shaft. If the rear axle shaft or flange are damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft. Maximum shaft runout: 2.0 mm (0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) 5. Remove outer oil seal. Using SST 09308-00010, remove the oil seal. 6. Replace rear axle bearing. a. Using SST 09223-56010, 09950-60010 (09951-00560), remove the bearing. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 942 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2368 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 596 Intake Air Temperature Sensor: Description and Operation Figure 1 Reference CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value and the higher the intake air temperature, the lower the thermistor resistance value (See Fig.1.). The intake air temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3221 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2804 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 754 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4005 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2364 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Service and Repair Front Crankshaft Seal: Service and Repair NOTE: There are 2 methods (A and B) to replace the oil seal which are as follows: A. If oil pump is removed from cylinder block. (a) Using a screwdriver, pry out the oil seal. (b) Using Special Service Tool (SST) Transmission Bearing Replacer # 09309 - 37010 or equivalent and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. (c) Apply Multipurpose (MP) grease to the oil seal lip. B. If oil pump is installed to cylinder block. (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST Transmission Bearing Replacer # 09309 - 37010 or equivalent and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. Page 3253 D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system. 2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank. 3. Road test the vehicle to verify normal operation. Page 382 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1888 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 2256 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1401 If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. CAUTION: Do not grind off more than the minimum. Page 3073 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Locations ABS Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3099 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 186 Glossary Of Term And Symbols (Part 1 Of 2) Page 2662 Page 3460 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2651 Applicable Vehicles Page 438 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4058 Clutch Disc: Testing and Inspection 1. Inspect clutch disc for wear or damage using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 inch) If necessary, replace the clutch disc. 2. Inspect clutch disc runout. Using a dial indicator, check the disc runout. Maximum Runout: 0.8 mm (0.031 inch) If necessary, replace the clutch disc. Page 4794 Wheel Speed Sensor: Service and Repair Rear Rear Speed Sensor Components REMOVAL 1. Remove speed sensor. Disconnect Speed Sensor Connector (a) Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. (b) Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Remove Clamp Bolts (c) Remove the 2 mountings bolt and speed sensor. Torque: 8.0 Nm (71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. CAUTION: Make sure that: There are no foreign objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. Page 494 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 295 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Testing and Inspection EGR Backpressure Transducer: Testing and Inspection EGR VACUUM MODULATOR INSPECTION 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR Disconnect these vacuum hoses: (1) Vacuum hose from R port (2) Vacuum hose from Q port (3) Vacuum hose from P port 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q and check that the air passes through to the air filter side freely. (c) Start the engine and maintain speed at 3,500 RPM. (d) Repeat the above test. Check that there is a strong resistance to air flow. 3. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the vacuum hoses: (1) Vacuum hose to R port (2) Vacuum hose to Q port (3) Vacuum hose to P port Page 1072 (c) Install the starter wire bracket with the 2 bolts. 13. Install crankshaft pulley. (a) Align the pulley set key with the key groove of the pulley, and slide the pulley. (b) Using SST Crankshaft Pulley Holding Tool # 09213 - 54015 (Bolt # 90119 - 08216), Companion Flange Holding Tool # 09330 - 00021 or equivalents, install and torque the bolt. Torque: 250 Nm (184 ft. lbs.) 14. Install fan bracket. (a) Install the fan bracket with the bolt and nut. (b) Install the PS pump adjusting strut with the nut. 15. Install No. 2 timing belt cover. (a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: ^ Using a screwdriver and gasket scraper, remove all the old gasket material. ^ Thoroughly clean all components to remove all the loose material. ^ Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. (b) Install the timing belt cover with the 6 bolts. Torque: 9 Nm (80 inch lbs.) (c) Connect the 4 high-tension cord clamps and camshaft position sensor connector to the No. 2 timing belt cover. 16. Install oil dipstick and guide. (a) Install a new O-ring to the dipstick guide. (b) Install the oil dipstick and guide to the cylinder block. (c) Install the bolt to the generator bracket. Torque: 8 Nm (71 inch lbs.) 17. w/ A/C: Install A/C compressor bracket. Torque: 47 Nm (35 ft. lbs.) 18. w/ A/C: Connect A/C compressor to engine. 19. Connect PS pump to engine. 20. Install fan with fluid coupling and fan pulleys. Page 1290 this, these steps should be carried out. A. Intake. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Place the intake camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head. (c) Apply MP grease to a new oil seal lip. (d) Install the oil seal to the camshaft. (e) Remove any old packing FIPG material. (f) Apply seal packing to the No. 1 bearing cap as shown. Seal packing: Part No. 08826 - 00080 or equivalent. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Page 3583 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 711 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4467 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3417 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Page 2736 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2976 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1288 Camshaft: Service and Repair Installation 1. Install camshafts of RH cylinder head. CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out. A. Intake. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Place the intake camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head. (c) Apply Multipurpose (MP) grease to a new oil seal lip. (d) Install the oil seal to the camshaft. (e) Remove any old packing Formed In Place Gasket (FIPG) material. (f) Apply seal packing to the No. 1 bearing cap as shown. Seal packing: Part No. 08826 - 00080 or equivalent. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Page 2198 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3116 Catalytic Converter: Testing and Inspection EXHAUST PIPE ASSEMBLY INSPECTION 1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE. THREE - WAY CATALYTIC CONVERTER INSPECTION CHECK FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts the three-way catalytic converter. repair or replace it. HEAT INSULATOR INSPECTION 1. CHECK HEAT INSULATOR FOR DAMAGE 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR Brakes - Pad Knock Noise Brake Pad: All Technical Service Bulletins Brakes - Pad Knock Noise BRAKES BR005-97 March 14, 1997 Title: 4RUNNER AND TACOMA 4X4 BRAKE PAD KNOCK NOISE Models: '97 4Runner, & '97 Tacoma Introduction A brake pad modification has been made on 4Runner and Tacoma 4x4 models to reduce pad knocking noise. This problem usually occurs upon first pedal application after changing driving direction (i.e. forward to reverse). Affected Vehicles ^ 1997 4Runner starting VINs: JT3GM84R * V0004296 JT3HM84R * V0007803 JT3GN86R * V0010776 JT3HN86R * V0027427 JT3HN87R * V0027427 ^ 1997 Tacoma (4x4) starting VIN 4TA **** N * VZ220360 Modification Detail The steel backing plate of the brake pad was widened from 119.3 mm to 119.55 mm in order to reduce the pad movement in the brake caliper. Parts Information MODEL PART NUMBER 4Runner 04465-35190 Tacoma (4x4) 04465-35080 Page 4421 b. Install the synchronizer inner ring, middle ring and outer ring to each gear. c. Check the braking effect of the synchronizer ring. turn the synchronizer ring in one direction while pushing it to the gear cone. check that the ring locks. If it does not lock, replace the synchronizer ring. d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum Clearance: 0.8 mm (0.031 inch) If the clearance is less than the minimum, replace the synchronizer ring. 4. Inspect shift fork and hub sleeve clearance. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or hub sleeve. Page 1214 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2414 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4620 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3196 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 4633 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Page 2647 Page 112 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 836 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2001 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Automatic Transmission Input Shaft: Service and Repair Automatic Transmission NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY Remove oil seal rings remove the 2 oil seal rings. INSPECTION Inspect input shaft. a. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum Diameter: 47.59 mm (1.8736 inch) b. Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum Inside Diameter: 39.14 mm (1.5409 inch) If the inside diameter exceeds the Maximum, replace the input shaft. ASSEMBLY Install oil seal rings install the 2 oil seal rings. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 445 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4146 4. Measure drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.) 5. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) If necessary, disassemble and inspect the differential. 6. Check tooth contact between ring gear and drive pinion. Without Differential Lock Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid .............................................................................................................................................. ........................................................ 2.2L (4.6 pints) Page 3631 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2939 CHART 12 CHART 13 Page 1111 Hose/Line HVAC: Specifications REFRIGERANT LINES Receiver x Liquid tube: ........................................................................................................................ .......................................................................... 6.0 N.m (61 kg.cm, 53 in.lb) Condenser x Discharge tube: .............................................................................................................. ...................................................................................... 10 N.m (100 kg.cm, 7 ft.lb) Condenser x Liquid tube: ..................................................................................................................... ............................................................................. 14 N.m (140 kg.cm, 10 ft.lb) Compressor x Discharge tube: ............................................................................................................ ........................................................................................ 10 N.m (100 kg.cm, 7 ft.lb) Compressor x Suction tube: ................................................................................................................ .................................................................................... 10 N.m (100 kg.cm, 7 ft.lb) Cooling unit x Liquid tube: ................................................................................................................... ............................................................................... 14 N.m (140 kg.cm, 10 ft.lb) Cooling unit x Suction tube: ................................................................................................................. ................................................................................. 32 N.m (330 kg.cm, 24 ft.lb) Expansion valve x Evaporator: ............................................................................................................ ...................................................................................... 5.4 N.m (55 kg.cm, 48 in.lb) Suction line: ......................................................................................................................................... ......................................................... 32 N.m (330 kg.cm, 24 ft.lb) Liquid line: ........................................................................................................................................... ....................................................... 14 N.m (140 kg.cm, 10 ft.lb) Page 4663 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 22) Parts Location Parts Location Page 890 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3954 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4799 Loosen/Tighten Bleeder Plug Insert other end of the tube in a half-full container of brake fluid. NOTE: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. Bleed brake line. (a) Slowly depress the brake pedal several times. (b) While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning (LSP) & By-Pass Valve (BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 750 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 633 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4500 Page 2286 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3770 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2683 CHART 24 Page 748 Glossary Of Term And Symbols (Part 1 Of 2) Page 4721 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3214 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1810 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2593 Idle Speed/Throttle Actuator - Electronic: Description and Operation CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed and a VSV for idle up control is also added (for air conditioning). Page 2082 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2650 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2138 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 812 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2349 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using Special Service Tool (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) Environmental Impact Information Engine Oil: Environmental Impact Information CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4168 1.50 mm (0.0590 inch) 1.55 mm (0.0610 inch) 1.60 mm (0.0630 inch) 1.65 mm (0.0650 inch) 1.70 mm (0.0669 inch) 1.75 mm (0.0689 inch) 1.80 mm (0.0709 inch) 1.85 mm (0.0728 inch) 1.90 mm (0.0748 inch) HINT: Select thrust washers which will ensure that the backlash is within the specifications. b. Install the side gears with the thrust washers, pinion gears, pinion gear thrust washers and pinion shaft. HINT: Align the holes of the differential case and pinion shaft. c. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch) If the backlash is not within the specification, replace the thrust washers. d. Using a pin punch and hammer, drive in the straight pin through the holes in the differential case and pinion shaft e. Using a chisel and hammer, stake the out side of the differential case pin hole. 2. Install side bearings. Using SST 09950-60010 (09951-00480, 09951-00640) 09950-70010 (09951-07150) and a press, install the side bearings into the differential case. 3. Install ring gear on differential case. a. Clean the contact surfaces of the differential case and ring gear. Page 2931 O2S Application Table O2S Failure Threshold Charts Service and Repair Oil Filter: Service and Repair WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. Drain engine oil. (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. Replace oil filter. (a) Using Special Service Tool (SST) Oil Filter Wrench # 09228 - 07501 or equivalent, remove the oil filter. (b) Clean the oil filter contact surface on the oil filter mounting. (c) Lubricate the filter rubber gasket with clean engine oil. (d) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. (e) Then using SST Oil Filter Wrench # 09228 - 07501 or equivalent, tighten it an additional 3/4 turn to seat the filter. 3. Fill with engine oil. (a) Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (29 ft. lbs.) (b) Fill with new engine oil. Page 3861 Second Brake Page 2784 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Specifications Camshaft: Specifications DIMENSIONS Cam Lobe Height: Intake ........................................................................................................................................................... 42.31 - 42.41 mm (1.6657 - 1.6697 inch) Exhaust ........................................................................................................................................................ 41.96 - 42.06 mm (1.6520 - 1.6559 inch) Circle Runout: Maximum ............................................................................................................................................. .................................... 0.06 mm (0.0024 inch) Journal Diameter: Standard .................................................................................................................................................. 26.949 - 26.965 mm (1.0610 - 1.0616 inch) Journal Oil Clearance: Maximum ............................................................................................................................................. .................................... 0.10 mm (0.0039 inch) Standard ...................................................................................................................................................... 0.035 - 0.072 mm (0.0014 - 0.0028 inch) Thrust Clearance: Maximum ............................................................................................................................................. .................................... 0.12 mm (0.0047 inch) Standard ...................................................................................................................................................... 0.033 - 0.080 mm (0.0013 - 0.0031 inch) TIGHTENING SPECIFICATIONS Timing Pulley To Camshaft ................................................................................................................. ............................................... 110 Nm (81 ft. lbs.) Page 2088 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2692 CHART 30 Page 4596 a. Turn the ring and push it in to check the braking action. b. Measure the clearance between the synchronizer ring back and the input shaft spline end. Standard Clearance: 1.05-1.85 mm (0.0413-0.0728 inch) Minimum Clearance: 0.80 mm (0.0315 inch) If the clearance is less than the minimum, replace the synchronizer ring. ASSEMBLY Install oil seal rings install the 2 oil seal rings. HINT: ^ Apply gear oil to the oil seal ring. ^ hang securely to eliminate clearance. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2228 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2587 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 934 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 2316 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 4537 Location Of Connector Joining Wire Harness And Wire Harness (Fig 38) Ground Points Ground Points Page 1552 Timing Belt Tensioner: Testing and Inspection INSPECTION 1. Visually check the seal portion of the tensioner for oil leakage. NOTE: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. 2. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. CAUTION: Never hold the tensioner push rod facing downward. 3. Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. Page 692 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2635 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2144 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3944 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2792 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4053 2. CHECK BALL 3. STRAINER, SPRING AND VALVE Page 124 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 687 Glossary Of Term And Symbols (Part 1 Of 2) Page 3002 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3462 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1958 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2774 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 903 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 283 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4616 J: 2.50-2.55 mm (0.0984-0.1004 inch) K: 2.55-2.60 mm (0.1004-0.1024 inch) L: 2.60-2.65 mm (0.1024-0.1043 inch) M: 2.65-2.70 mm (0.1043-0.1063 inch) N: 2.70-2.75 mm (0.1063-0.1083 inch) P: 2.75-2.80 mm (0.1083-0.1102 inch) Q: 2.80-2.85 mm (0.1102-0.1122 inch) R: 2.85-2.90 mm (0.1122-0.1142 inch) S: 2.90-2.95 mm (0.1142-0.1161 inch) T: 2.95-3.00 mm (0.1161-0.1181 inch) U: 3.00-3.05 mm (0.1181-0.1201 inch) Page 3290 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION FUEL PRESSURE REGULATOR REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a shop rag under the pressure regulator. 4. REMOVE FUEL PRESSURE REGULATOR (a) Remove holding bolt the engine wire to the LH cylinder head cover. (b) Disconnect the protector from the bracket on the RH cylinder head cover and lift up the engine wire. Page 2428 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1831 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Testing and Inspection Backup Lamp Relay: Testing and Inspection BACK-UP LIGHT RELAY INSPECTION INSPECT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1825 Step 7 INSPECTION PROCEDURE Page 1253 Wheel Fastener: Service and Repair Rear HUB BOLT REPLACEMENT 1. Remove wheel and brake drum. 2. Remove hub bolt. Using SST, 09650-17011 3. Install hub bolt. Install a washer and nut to a new hub bolt as shown and install the hub bolt with torquing the nut. 4. Install brake drum and wheel. Torque to 110 Nm (83 ft. lbs.) Page 1626 Coolant: Fluid Type Specifications Coolant Classification Type: Ethylene Glycol Based Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2433 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 833 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2223 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2074 Page 3288 Components For Removal And Installation Part 2 Of 2 Page 2957 Specifications Idle Speed/Throttle Actuator - Electronic: Specifications At Cold At Hot Terminals +B and RSC or RSO 17.0 - 24.5 ohms at 14 - 122 deg F 21.5 - 28.5 ohms at 122 - 212 deg F Page 4841 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ Type "B": Has a flat upper and lower edge on the brake pad backing plate. Type "A" Brake Pad A. Remove the anti-squeal spring, clip and pad guide pin. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 3525 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4302 ASSEMBLY HINT: When replacing the propeller shaft, install the new parts facing, as shown in the illustration. 1. Install center support bearing on intermediate shaft. Install the center support bearing and spacer. HINT: Install the center support bearing with the cutout toward the rear. 2. Install flange on intermediate shaft. a. Coat the splines of the intermediate shaft with MP grease. b. Place the flange on the shaft and align the matchmarks. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. c. Install the spacer. Page 4714 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Door Lock Control Relay Inspection Power Door Lock Relay: Testing and Inspection Door Lock Control Relay Inspection DOOR LOCK CONTROL RELAY INSPECTION 1. INSPECT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Page 2967 Oxygen Sensor: Mechanical Specifications Heated Oxygen Sensor to Exhaust Pipe 14 ft.lb Page 2067 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Modified ENGINE EG011-99 October 15, 1999 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed to reduce the possibility of moisture contacting the ceramic element. Applicable Vehicles ^ 1996-1999 model year Tacomas built before the VIN listed. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. Page 3764 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2881 Intake Air Temperature Sensor: Description and Operation Figure 1 Reference CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value and the higher the intake air temperature, the lower the thermistor resistance value (See Fig.1.). The intake air temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Specifications Clutch Slave Cylinder: Specifications TIGHTENING SPECIFICATIONS Bleeder Plug ........................................................................................................................................ ............................................. 11 N.m (96 inch lbs.) Release Cylinder Installation Bolt .................................................................................................................................................. 13 N.m (108 inch lbs.) Diagram Information and Instructions Brake Signal: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1286 Camshaft: Service and Repair Disassembly 1. Disassemble exhaust camshafts. (a) Mount the hexagonal wrench head portion of the camshaft in a vise. CAUTION: Be careful not to damage the camshaft. (b) Using Special Service Tool (SST) Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 5 # 09963 - 00500) or equivalents, turn the sub-gear clockwise and remove the service bolt. (c) Using snap ring pliers, remove the snap ring. (d) Remove these parts: - Wave washer. - Camshaft sub-gear. - Camshaft gear spring. NOTE: Arrange the camshaft sub-gears and gear springs (RH and LH side). Page 2129 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1693 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Page 1210 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 4548 Differential: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4921 Using Special Service Tool (SST) # 09023 - 00100, disconnect the 5 brake lines from the Anti-Lock Brake System (ABS) actuator. Torque: 15 Nm (11 ft. lbs.) 2. Disconnect connectors. Disconnect the 2 connectors from the actuator. 3. Remove control relay from actuator bracket. 4. Remove ABS actuator. (a) Remove the 2 bolts, 2 nuts and ABS actuator assembly. Torque: 19 Nm (14 ft. lbs.) (b) Remove the bolt and connector clamp. (c) Remove the 3 nuts and ABS actuator from the actuator bracket. Torque: 5.4 Nm (48 inch lbs.) (d) Remove the 3 holders and cushions from the ABS actuator. INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system. Refer to Brakes. See: Brake Bleeding/Service and Repair Check for leaks. Page 3166 Fillpipe Restrictor: Testing and Inspection Remove the fuel filler cap and check the fillpipe restrictor for tampering. On models with more that one fuel tank, check each tank filler tube. Page 540 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3059 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1879 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 814 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 653 CHART 11 Page 53 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3710 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Page 1647 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Specifications Canister Purge Solenoid: Specifications Resistance 29 - 33 ohms at 68 deg F Page 944 Page 2251 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4387 Counter Gear: Service and Repair Bearing Replacement If necessary, replace counter gear front bearing. a. Using a snap ring expander, remove the snap ring. b. Using SST 09950-00020 and a press, remove the bearing. c. Replace the side race. d. Using a socket wrench and press, install a new bearing and side race. Page 786 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2951 CHART 24 Page 1460 Engine Oil: Service and Repair WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. Drain engine oil. (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. Replace oil filter. (a) Using Special Service Tool (SST) Oil Filter Wrench # 09228 - 07501 or equivalent, remove the oil filter. (b) Clean the oil filter contact surface on the oil filter mounting. (c) Lubricate the filter rubber gasket with clean engine oil. (d) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. (e) Then using SST Oil Filter Wrench # 09228 - 07501 or equivalent, tighten it an additional 3/4 turn to seat the filter. 3. Fill with engine oil. (a) Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (29 ft. lbs.) (b) Fill with new engine oil. Page 1044 Compression Check: Testing and Inspection NOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature. 2. Remove ignition coils. 3. Remove spark plugs. Using a 16 mm plug wrench, remove the 6 spark plugs. 4. Check cylinder compression pressure. (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (174 psi) or more. Minimum pressure: 1,000 kPa (145 psi) Difference between each cylinder: 100 kPa (15 psi) or less. (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. Reinstall spark plugs. Torque: 20 Nm (14 ft. lbs.) 6. Reinstall ignition coils. Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 851 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 729 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 3854 Forward Clutch Page 818 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 58 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2086 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3694 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Testing and Inspection Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) Connect a voltmeter to terminals PTNK and E2 of the ECM and measure the output voltage under ambient atmospheric pressure. - Apply vacuum (2.0 kPa, 15 mm Hg. 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V - Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V - Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 1900 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1172 Engine Oil: Service and Repair WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. Drain engine oil. (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. Replace oil filter. (a) Using Special Service Tool (SST) Oil Filter Wrench # 09228 - 07501 or equivalent, remove the oil filter. (b) Clean the oil filter contact surface on the oil filter mounting. (c) Lubricate the filter rubber gasket with clean engine oil. (d) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. (e) Then using SST Oil Filter Wrench # 09228 - 07501 or equivalent, tighten it an additional 3/4 turn to seat the filter. 3. Fill with engine oil. (a) Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (29 ft. lbs.) (b) Fill with new engine oil. Page 1746 Water Pump: Testing and Inspection 1. Inspect water pump. (a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. Inspect fluid coupling. (a) Remove the 4 nuts and fan from the fluid coupling. (b) Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. (c) Install the fan and fluid coupling with the 4 nuts. Torque: 7.4 Nm (65 inch lbs.) 3. Inspect fan pulley bracket. Check the turning smoothness of the fan pulley. If necessary, replace the fan pulley bracket. 4. Inspect timing belt. Refer to Engine. Initial Inspection and Diagnostic Overview Dimmer Switch: Initial Inspection and Diagnostic Overview INSPECT LIGHT CONTROL RHEOSTAT STEP TYPE: w/o Tachometer (DLX Grade M/T Vehicle) Gradually turn the rheostat knob from the bright side to dark side, check that the resistance between terminals increases from approximately 0 to 9.0 Ohms. If operation is not as specified, replace the rheostat. NON-STEP TYPE: w/Tachometer (DLX Grade M/T Vehicle) 1. Turn the rheostat knob OFF and check that there is no continuity between terminals. (Rheostat knob turned to fully counterclockwise) 2. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 Ohms. (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. ELECTRICAL TYPE: w/ All A/T Vehicle and SR5 Grade M/T Vehicle 1. Connect terminals 1 and 3 through a 3.4 W test bulb. 2. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. 3. Turn the rheostat knob to fully counterclockwise and check that the test bulb goes out. 4. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 3587 Components For Removal And Installation Part 2 Of 2 Page 3739 P 1 PARK/NEUTRAL POSITION SW 4-Ground: Approx. 12 Volts with ignition SW ON position O 4-B, S 4-A O/D MAIN SW A-5-A-10, B-1-B-3: Open with O/D main SW at ON position Open with O/D main SW at OFF position S 5-A, B STOP LIGHT SW A-1-A-2, B-1-B-2: Closed with Brake Pedal Depressed E 5-A, E 6-D, E 7-C, E 8-B ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) IDL-E2: 0-3 Volts with Throttle Valve fully closed 9-14 Volts with Throttle Valve open VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with shift lever at expect 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at expect L position L4-E1: 10-14 Volts with Transfer Shift at H2 or H4 position 0 Volts with Transfer shift at L4 position OIL-W-E1: 0.1-4.9 Volts +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Page 136 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2657 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 3269 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Standard Values Of ECM Terminals Chart 1 Of 2 Page 4427 c. While pushing the 3 shifting keys, install the clutch hub No.1 to the reverse gear, as shown. 3. Install 3rd gear and hub sleeve No.2 on output shaft. a. Apply gear oil to the shaft and needle roller bearing. b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. c. Install the needle roller bearing in the 3rd gear. d. Using a press, install the 3rd gear and hub sleeve No.2. 4. Install snap ring. a. Select a snap ring that will allow minimum axial play. Mark A: 1.80-1.85 mm (0.0709-0.0728 inch) Mark B: 1.85-1.90 mm (0.0728-0.0748 inch) Mark C: 1.90-1.95 mm (0.0748-0.0768 inch) Mark D: 1.95-2.00 mm (0.0768-0.0787 inch) Mark E: 2.00-2.05 mm (0.0787-0.0807 inch) Mark F: 2.05-2.10 mm (0.0807-0.0827 inch) Mark G: 2.10-2.15 mm (0.0827-0.0846 inch) b. Using a snap ring expander, install the snap ring. 5. Inspect 3rd gear thrust clearance. 6. Install 2nd gear and reverse gear. a. Apply gear oil to the shaft and needle roller bearing. b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. c. Align the projection of the synchronizer inner ring with the slots of the clutch hub No.1. d. Install the needle roller bearing in the 2nd gear. Page 1757 Catalytic Converter: Service and Repair CATALYTIC CONVERTER REPLACEMENT Installation is in the reverse order of removal. REMOVE CENTER EXHAUST PIPE Remove the 4 bolts, TWC joint retainer. center exhaust pipe and 2 gasket. Torque: 62 N.m (632 kgf.cm. 40 ft.lbf) INSTALLATION HINT: Place 2 new gaskets on the front exhaust and tail pipes. and temporarily install the center exhaust pipe. Testing and Inspection Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) Connect a voltmeter to terminals PTNK and E2 of the ECM and measure the output voltage under ambient atmospheric pressure. - Apply vacuum (2.0 kPa, 15 mm Hg. 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V - Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V - Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 1058 Page 379 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 586 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2968 Page 1173 Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration with SAE 5W-30 being the preferred engine oil. Oil capacity: Drain and refill w/o Oil filter change: 4.9 liters (5.2 US qts.) w/ Oil filter change: 5.2 liters (5.5 US qts.) Dry fill: 5.9 Liters (6.2 US qts.) (c) Reinstall the oil filler cap. 4. Start engine and check for oil leaks. 5. Check engine oil level. Page 3095 Glossary Of Term And Symbols (Part 1 Of 2) Page 2648 Engine Bank Identification Page 1419 Drive Belt: Tools and Equipment Belt Tension Gauge: Nippondenso BTG-20 (95506-00020) or Borroughs No.BT-33-73F Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 662 CHART 22 Page 3270 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4747 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Page 1591 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS (a) Assemble the holder and grommet. (b) Align the spline of the ignition coil with the spline of the holder and push in the cord. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration. (c) Check that the lock claw of the holder is engaged by lightly pulling the holder. 6. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS 7. REINSTALL AIR CLEANER HOSE Page 2806 Page 3106 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Electrical Specifications EGR Temperature Sensor: Electrical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) Resistance 64 - 97 K ohms at 122 deg F 11 - 16 K ohms at 212 deg F 2 - 4 K ohms at 302 deg F Page 1829 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4138 Washer thickness: 2.00 - 2.02 mm (0.0787 - 0.0795 inch) 2.03 - 2.05 mm (0.0799 - 0.0807 inch) 2.06 - 2.08 mm (0.0811 - 0.0819 inch) 2.09 - 2.11 mm (0.0823 - 0.0831 inch) 2.12 - 2.14 mm (0.0835 - 0.0843 inch) 2.15 - 2.17 mm (0.0846 - 0.0854 inch) 2.18 - 2.20 mm (0.0858 - 0.0866 inch) 2.21 - 2.23 mm (0.0870 - 0.0878 inch) 2.24 - 2.26 mm (0.0882 - 0.0890 inch) 2.27 - 2.29 mm (0.0894 - 0.0902 inch) 2.30 - 2.32 mm (0.0906 - 0.0913 inch) 2.33 - 2.35 mm (0.0917 - 0.0925 inch) 2.36 - 2.38 mm (0.0929 - 0.0937 inch) 2.39 - 2.41 mm (0.0941 - 0.0949 inch) 2.42 - 2.44 mm (0.0953 - 0.0961 inch) 2.45 - 2.47 mm (0.0965 - 0.0972 inch) 2.48 - 2.50 mm (0.0976 - 0.0984 inch) 2.51 - 2.53 mm (0.0988 - 0.0996 inch) 2.54 - 2.56 mm (0.1000 - 0.1008 inch) 2.57 - 2.59 mm (0.1012 - 0.1020 inch) 2.60 - 2.62 mm (0.1024 - 0.1031 inch) 2.63 - 2.65 mm (0.1035 - 0.1043 inch) 2.66 - 2.68 mm (0.1047 - 0.1055 inch) 2.69 - 2.71 mm (0.1059 - 0.1067 inch) 2.72 - 2.74 mm (0.1071 - 0.1079 inch) 2.75 - 2.77 mm (0.1083 - 0.1091 inch) 2.78 - 2.80 mm (0.1094 - 0.1102 inch) 12. Measure total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) 13. Inspect tooth contact between ring gear and drive pinion. a. Remove the side bearing retainer and differential case. b. Coat 3 or 4 teeth at three different positions on the ring gear with red lead. c. Install the differential case and side bearing retainer. Torque to 69 Nm (51 ft. lbs.) d. Hold the companion flange firmly and rotate the ring gear in both directions. e. Remove the side bearing retainer and differential case. Page 1396 ADJUSTING SHIM SELECTION CHART (EXHAUST) Page 3271 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2943 CHART 18 CHART 19 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 660 Page 1877 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 885 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Specifications Brake Pedal Assy: Specifications DIMENSIONS Pedal Freeplay .................................................................................................................................... ......................................... 3-6 mm (0.12-0.24 inch) Pedal Height .............................................................................................................................................................. 159.1-169.1 mm (6.262-6.657 inch) Reserve Distance [1] .................................................................. ........................................................................................................... 72 mm (2.83 inch) Switch To Pedal Clearance ............................................................................................................................................... 0.5-2.4 mm (0.020-0.094 inch) TIGHTENING SPECIFICATIONS Push rod lock nut torque: ..................................................................................................................... ................................................. 25 Nm (19 ft. lbs.) [1] From asphalt sheet @ 490 N (110 lbs.) Page 4015 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1455 Engine Oil: Technician Safety Information WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. Page 3636 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3892 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 25) Specifications Band: Specifications SECOND COAST BRAKE Piston Stroke ....................................................................................................................................... .............................. 1.5 - 3.0 mm (0.059 - 0.118 inch) Piston Rod Length ........................................... .................................................................................................................................... 72.9 mm (2.870 inch) .............................................................................................................................................................. ...................................... 71.4 mm (2.811 inch) Specifications Water Pump: Specifications TIGHTENING SPECIFICATIONS Water Pump To Cylinder Block ..................................................................................................................................................... 20 Nm (14 ft. lbs.) Water Inlet To Water Pump ............................................................................................................................................................ 20 Nm (14 ft. lbs.) Page 3234 Fillpipe Restrictor: Testing and Inspection Remove the fuel filler cap and check the fillpipe restrictor for tampering. On models with more that one fuel tank, check each tank filler tube. Page 2021 Page 2387 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 161 Step 7 INSPECTION PROCEDURE Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1539 10. w/ A/C: Disconnect A/C compressor from engine. 11. w/ A/C: Remove A/C compressor bracket. Remove the 5 bolts and A/C compressor bracket. 12. Remove oil dipstick and guide. Remove the bolt, oil dipstick, guide and O-ring. 13. Remove No. 2 timing belt cover. (a) Disconnect the camshaft position sensor connector, 3 high-tension cord clamps and PS pump hose from the No. 2 timing belt cover. (b) Remove the 6 bolts and No. 2 timing belt cover. 14. Remove fan bracket. (a) Remove the nut and PS pump adjusting strut. (b) Remove the bolt, nut, and fan bracket. 15. Remove crankshaft pulley. (a) Using Special Service Tool (SST) Crankshaft Pulley Holding Tool # 09213 - 54015 (Bolt 90119 08216) and Companion Flange Holding Tool # 09330 - 00021 or equivalents, loosen the pulley bolt. (b) Remove the SST, pulley bolt and pulley. NOTE: If necessary, remove the pulley with SST Puller C Set # 09950 - 50010 (Hanger 150 # 09551 - 05010, Slide Arm # 09552 - 05010, Center Bolt 150 # 09553 - 05020, Claw No. 3 # 09554 05030) or equivalents and service bolt. Page 4262 5. Disconnect brake line and parking brake cable. Using SST 09751-36011, disconnect the brake line from the wheel cylinder. Installation Hint: Torque to 15 Nm (11 ft. lbs.) 6. Remove rear axle shaft assembly. a. Remove the 4 backing plate mounting nuts. Installation Hint: Torque to 68 Nm (50 ft. lbs.) b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 7. Remove o-ring from rear axle housing. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed brake system and check ABS speed sensor signal. Inspection and Repair INSPECTION AND REPAIR 1. w/ ABS: Remove bearing retainer (differential side) and ABS speed sensor rotor. a. Attach 4 nuts to the serration bolts and remove the serration bolts from the backing plate using a hammer. NOTICE: Do not reuse the nuts previously removed from the vehicle. b. Grind the retainer and sensor rotor surfaces using grinder, then chisel them out with a chisel. c. Attach washers and nut to the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove the 4 nuts from the serration:ion bolts. 2. Remove snap ring from axle. shaft Using a snap ring expander, remove the snap ring. Page 134 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1073 Torque: 5.4 Nm (48 inch lbs.) 21. Install No. 2 fan shroud. 22. Install and adjust drive belt for generator. 23. w/ A/C: install and adjust drive belt for A/C compressor. 24. Install and adjust drive belt for PS pump. 25. Connect upper radiator hose. 26. Fill engine with coolant. 27. Start engine check for leaks. 28. Install engine under cover. 29. Perform road test. Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 30. Recheck engine coolant level. Page 3386 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4540 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 22) Parts Location Parts Location Page 3260 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2972 Glossary Of Term And Symbols (Part 1 Of 2) A/C - Liquid Tube Improvement Hose/Line HVAC: Technical Service Bulletins A/C - Liquid Tube Improvement AC007-97 HEATING & AIR CONDITIONING December 5, 1997 Title: A/C LIQUID TUBE IMPROVEMENT Models: '95 - '97 Tacoma Introduction The air conditioning Liquid Tube on Tacoma has been changed: ^ The shape and length of Liquid Tube # 1 has been changed to reduce vibrations transmitted by condenser movement. ^ Additional condenser brackets with horizontal braces have replaced the previous supply parts to reduce condenser movement. Affected Vehicles 1995 - 1997 model year Tacomas. Parts Information APPLICATION PART NUMBER PART NAME '95 - '96 L4 & V6 88840-35080 Liquid Tube Repair Kit 1997 L4 & V6 88840-35090 Liquid Tube Repair Kit Contents of Parts Kits Page 4660 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Junction Block and Wire Harness Connector Page 299 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Bolt Inspection Connecting Rod: Testing and Inspection Bolt Inspection 1. Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. 2. If the cap nut cannot be turned easily, measure the outside diameter of the compressed thread with a vernier caliper. Standard outside diameter: 7.860 - 8.000 mm (0.3094 - 0.3150 inch) Minimum outside diameter: 7.600 mm (0.2992 inch) NOTE: If the location of minimum diameter cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration. If the outside diameter is less than minimum, replace the connecting rod and rod cap nut as a set. Page 943 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 678 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Improvement ENGINE EG006-99 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma June 18, 1999 Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed 10 reduce the possibility of moisture contacting the ceramic element. Affected Vehicles ^ 1996-1999 model year Tacomas built before the VINs listed below. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Electrical Specifications EGR Temperature Sensor: Electrical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) Resistance 64 - 97 K ohms at 122 deg F 11 - 16 K ohms at 212 deg F 2 - 4 K ohms at 302 deg F Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 676 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Modified ENGINE EG011-99 October 15, 1999 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed to reduce the possibility of moisture contacting the ceramic element. Applicable Vehicles ^ 1996-1999 model year Tacomas built before the VIN listed. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. Page 2293 Knock Sensor: Oscilloscope Patterns and Waveforms Page 2658 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Door Unlock Detection Switch Power Door Lock Switch: Testing and Inspection Door Unlock Detection Switch INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1188 Refrigerant: Service Precautions PRECAUTION 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION 3. BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: a. Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. b. Apply clean petroleum jelly to the skin. c. Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system. oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILST COMPRESSOR IS OPERATING If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the low pressure valve only. Page 135 Glossary Of Term And Symbols (Part 1 Of 2) With Automatic Disconnecting Differential Output Shaft: Service and Repair With Automatic Disconnecting Differential NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY Page 2517 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 3096 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1853 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2832 Page 1499 Intake Manifold: Pressure, Vacuum and Temperature Specifications INTAKE MANIFOLD VACUUM At Idle Speed ....................................................................................................................................... .............................. 60 kPa (17.7 inch Hg) or more Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 4413 Input Shaft: Service and Repair NOTE: For removal and installation procedures refer to "Manual Transmission/Transaxle, Service and Repair." If necessary, replace input shaft bearing. a. Using a snap ring expander, remove the snap ring. b. Using a press, remove the bearing. c. Using SST 09506-35010 and a press, install a new bearing. d. Select a snap ring that will allow minimum axial play. Mark A: 2.10-2.15 mm (0.0827-0.0846 inch) Mark B: 2.15-2.20 mm (0.0846-0.0866 inch) Mark C: 2.20-2.25 mm (0.0866-0.0886 inch) Mark D: 2.25-2.30 mm (0.0886-0.0906 inch) Mark E: 2.30-2.35 mm (0.0906-0.0925 inch) Mark F: 2.35-2.40 mm (0.0925-0.0945 inch) Mark G: 2.40-2.45 mm (0.0945-0.0965 inch) e. Using a snap ring expander, install the snap ring. Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2858 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 973 Power Window Switch: Testing and Inspection Power Window Switch INSPECT POWER WINDOW SWITCH CONTINUITY If operation is not as specified, replace the switch. Page 1142 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .................................. DEXRON II or DEXRON III Page 76 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2104 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 837 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Output Shaft: Specifications Rear Output Shaft Assembly Drive Sprocket Thrust Clearance Standard .............................................................................................................................................................. 0.10-0.25 mm (0.0039-0.0098 inch) Maximum .................................................................................... ............................................................................................ 0.25 mm (0.0098 inch) Rear Output Shaft Journal Surface (Minimum) Part A ................................................................................................................................................... .................................. 27.98 mm (1.1016 inch) Part B ......................................................................... ............................................................................................................ 36.98 mm (1.4561 inch) Drive Sprocket Radial Clearance Standard .......................................................................................................................................................... 0.010-0.055 mm (0.0004-0.0022 inch) Maximum ................................................................................ ............................................................................................... 0.055 mm (0.0022 inch) Front Drive Shift Fork To Clutch Sleeve Clearance: Maximum ............................................................................................................................................. ........................................ 1.0 mm (0.039 inch) High and Low Shift Fork To Sleeve Clearance: Maximum ............................................................................................................................................. ........................................ 1.0 mm (0.039 inch) Page 3075 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2960 CHART 30 Page 892 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4485 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Front Wheel Speed Sensor: Service and Repair Front Front Speed Sensor Components REMOVAL 1. Remove speed sensor. Disconnect Speed Sensor Connector (a) Disconnect the speed sensor connector. (b) Remove the 2 clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Remove Clamp Bolts (c) Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kg.cm 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. CAUTION: Make sure that: Page 3911 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Testing and Inspection Hazard Warning Switch: Testing and Inspection HAZARD WARNING SWITCH INSPECTION INSPECT SWITCH CONTINUITY Reference If continuity is not as specified, replace the switch. Page 352 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2188 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Service and Repair Solenoid: Service and Repair 1. Remove A.D.D. switch. 2. Remove sleeve fork pin. a. Using a hexagon wrench, remove the screw plug. b. Using a pin punch and a hammer, remove the pin through the hole of clutch case cover. 3. Separate actuator from clutch case cover and remove sleeve fork. Using a hexagon wrench, remove the screw plug. b. Remove the spring seat, spring and steel ball. c. Remove the 2 bolts and actuator from the clutch case cover. d. Separate the actuator from the clutch case cover and remove the sleeve fork. e. Remove the O-ring from the actuator. 4. Install sleeve fork and actuator into clutch case cover. a. Install a new O-ring to the actuator. b. Coat the O-ring with MP grease. c. Place the sleeve fork and install the actuator to the clutch case cover. d. Torque the 2 bolts. Torque to 21 Nm (15 ft. lbs.) e. Install the steel ball, spring and spring seat. f. Coat the threads of screw plug with FIPG. FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. g. Using a hexagon wrench, install the screw plug. Torque to 13 Nm (9 ft. lbs.) 5. Install sleeve fork pin. a. Using a pin punch and a hammer, install the pin through the hole of clutch case cover. b. Coat the threads of screw plug with FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. c. Using a hexagon wrench, install the screw plug. Torque to 20 Nm (14 ft. lbs.) 6. Install A.D.D. switch. Install a new gasket and indicator switch. Torque to 40 Nm (30 ft. lbs.) Brakes - Pad Clicking Noise Brake Pad: All Technical Service Bulletins Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to Drive/Forward). This is a normal noise caused by the required brake pad-to-caliper clearances. When the direction of travel is changed, the brake pads may "shift" towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard. To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under normal usage conditions this grease should be effective for a period of 6 months to 1 year. Applicable Vehicles ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly. 1. Floating Type Brake Caliper A. Lift up or remove the brake caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the brake caliper. B. If equipped with anti-squeal spring: Remove the anti-squeal springs. C. Remove the brake pads with anti-squeal shims. D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads. Page 3860 Overdrive Direct Clutch Page 2897 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1067 05010, Center Bolt 150 # 09553 - 05020, Claw No. 1 # 09554 - 05010) or equivalents and service bolt to remove the crankshaft timing pulley. Page 4490 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 886 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2220 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1904 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2678 CHART 21 Page 708 Glossary Of Term And Symbols (Part 1 Of 2) Page 2039 CHART 2 CHART 3 CHART 4 Page 873 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 2227 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1755 Catalytic Converter: Description and Operation View: Typical Catalytic Converter View: Typical Catalytic Converter Catalytic converters are used to convert carbon monoxide (CO), hydrocarbon (HC) and oxides of nitrogen (NOx) into water vapor (H2O), carbon dioxide (CO2) and nitrogen (N2). The catalysts used to create these conversions are platinum, palladium and rhodium (depending on type of converter). During engine operation, all of the exhaust gases flow through the converter where a chemical change takes place. This change causes the temperature inside the converter to be higher than the temperature of the exhaust gases when they leave the engine. Due to this increase in heat the converter is insulated so that its outside temperature is about the same temperature as the muffler. However, due to its solid mass, the converter remains hot much longer than the muffler. The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle. Catalytic converters maybe of the monolith or pellet type. Although all vehicles with a catalytic converter must use unleaded fuel, small amounts of leaded fuel can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has a built-in restrictor. The conventional Oxidizing Catalytic (OC) converter, uses platinum and palladium, included as a fine coating on the substrate, to reduce harmful exhaust fumes. The Three-Way Catalytic (TWC) converter, contains platinum and palladium as conventional oxidizing agents in addition to rhodium. The Warm-Up (WU) converter, is installed in the exhaust system ahead of the main converter. This converter operates on the same principle as the main converter, but it reacts more rapidly to incoming gases. It is especially effective in converting gases immediately after start up. Page 514 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4602 Page 526 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 1270 - Right Side Cylinder Head Intake Camshaft - Right Side Cylinder Head Exhaust Camshaft - Left Side Cylinder Head Intake Camshaft - Left Side Cylinder Head Exhaust Camshaft Page 1610 Adjusting Shim Selection Chart (Intake) Page 2753 Step 7 INSPECTION PROCEDURE Page 4828 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ Type "B": Has a flat upper and lower edge on the brake pad backing plate. Type "A" Brake Pad A. Remove the anti-squeal spring, clip and pad guide pin. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 2101 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1841 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4001 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2080 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1542 05010, Center Bolt 150 # 09553 - 05020, Claw No. 1 # 09554 - 05010) or equivalents and service bolt to remove the crankshaft timing pulley. Page 2410 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3303 (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Description and Operation Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in Anti-Lock Brake System (ABS) control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2008 Page 1280 Using a vernier caliper, measure the free distance between the spring end. Free distance: 18.2 18.8 mm (0.712 - 0.740 inch) If the free distance is not as specified, replace the gear spring. 5. Inspect camshaft journal oil clearance. (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. Torque: 16 Nm (12 ft. lbs.) CAUTION: Do not turn the camshaft. (e) Remove the bearing caps. (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.035 - 0.072 mm (0.0014 0.0028 inch) Maximum oil clearance: 0.10 mm (0.0039 inch) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. 6. Inspect camshaft thrust clearance. (a) Install the camshafts. (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.033 - 0.080 mm (0.0013 - 0.0031 inch) Maximum thrust clearance: 0.12 mm (0.0047 inch) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 7. Inspect camshaft gear backlash. (a) Install the camshafts without installing the exhaust camshaft sub-gear. Page 3349 Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics Component Inspection IAC VALVE INSPECTION INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is closed. (b) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is open. If operation is not as specified, replace the IAC valve. On-Vehicle Inspection IDLE AIR CONTROL (IAC) VALVE ON-VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION (a) Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed is kept at approx. 1000 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST from the DLC1. SST 09843-18020 2. INSPECT IAC VALVE RESISTANCE NOTICE: Cold and Hot in the following sentences express the temperature of the coils themselves. Cold is from - 10°C (14°F) to 50°C (122°F) Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY 1. Check that there is no continuity between terminal and the switch body in the ON position (switch pin released/opened door). 2. Check that there is continuity between terminal and the switch body in the OFF position (switch pin pushed in/closed door). If operation is not as specified, replace the switch. Page 221 B. Inspect relay operation a. Apply battery voltage across terminals 1 and 2. b. Check that there is continuity between terminals 3 and 5. If operation is not as described, replace the relay. 3. REINSTALL STARTER RELAY Page 634 Applicable Vehicles Page 4403 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Page 1377 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 1740 Thermostat: Testing and Inspection NOTE: The thermostat is numbered according to the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature and valve lift. Valve opening temperature: 80° - 84° C (176° -183° F) Valve lift: At 95° C (203° F): 8.5 mm (0.335 inch) or more. If the valve opening temperature and valve lift are not within specifications, replace the thermostat. (c) Check that the valve is fully closed when the thermostat is at low temperatures (below 40° C (104° F)). If not tight, replace the thermostat. Page 556 Page 2359 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 3006 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3047 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 3248 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 2024 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 333 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 857 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Locations Headlamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 355 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1517 5. Select a new guide bushing (STD size or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 11.027 mm (0.4341 inch), machine the bushing bore to these dimensions: 11.050 - 11.077 mm (0.4350 - 0.4361 inch) If the bushing bore diameter of the cylinder head is greater than 11.077 mm (0.4361 inch), replace the cylinder head. 6. Gradually heat the cylinder head to 80° - 100° C (176° - 212° F). 7. Using SST Valve Guide Bushing Remover & Replacer Set # 09201 - 10000 (Valve Guide Bushing Remover & Replacer 6 # 09201 - 01060), Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head. 8. Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. Page 4461 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1905 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 872 Page 310 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3016 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1974 Glossary Of Term And Symbols (Part 1 Of 2) Page 4271 The design of the rear axle seal has been changed from a flat face to an angled face for part number 90310-50006 and part number 90310-56002. Installation Procedure Sequoia To properly install Rear Axle Oil Seal part number 90310-56002, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00730-01) - Replacer 73 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Tacoma & Tundra To properly install Rear Axle Oil Seal part number 90310-56006, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00710) - Replacer 71 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Page 4717 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2891 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2057 CHART 24 Page 2123 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 512 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2824 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 4197 Fluid - Differential: Fluid Type Specifications Front Differential TYPE.................................................................................................................................................... ........................................................................ GL-5* CAPACITY Front .............................................. .............................................................................................................................................................. .. 1.1L (2.3 pints) With A.D.D [1] .......................................................................................................... .................................................................................... 1.2L (2.4 pints) VISCOSITY Below -18° C (0° F) ......................................................................................................................................................... ............................... 80W, 80W-90 Above -18° C (0° F) ...................................................................... ..................................................................................................................................... 90 With A.D.D .............................................................................................................................................................. ................................................. 75W-90 [1] Automatic Disconnecting Differential Oil Type and Viscosity Differential Type ..................................................................................................................................................... ......................................................... Hypoid gear oil Grade ................................................................ ...................................................................................................................................................... API GL-5 Viscosity: Front (w/ADD) ...................................................................................................................................... ........................................................... SAE 75W-90 Front (without ADD) Above 0° F (-18° C) ............................................................................................ ....................................................................................................... SAE 90 Below 0° F (18° C) ......... .............................................................................................................................................................. ....... SAE 80W or 80W-90 Rear Above 0° F (-18° C) .................................................................................................................... ............................................................................... SAE 90 Below 0° F (18° C) ................................. ............................................................................................................................................. SAE 80W or 80W-90 Special Service Materials w/ Differential Lock: Shaft Retainer X Differential Carrier .................................................................... ............................................................................................................. [1] Actuator x Differential Carrier .................................................................................................................................................. ........................................ [1] Shift Fork Shaft Set Bolt ........................................................................ ........................................................................................................................... [2] Pinion Shaft Pin .. .............................................................................................................................................................. ................................................. [2] Shaft Retainer Bolt ....................................................................... ..................................................................................................................................... [3] Screw Plug .............................................................................................................................................................. ........................................................... [3] w/o Differential Lock: Ring Gear Set Bolts ......................... .............................................................................................................................................................. .................... [4] [1]: Part No. 08826-00090; Seal Packing 1281, THREE BOND 1281 FIPG, or equivalent. [2]: Part No. 08833-00070; Adhesive 1324, THREE BOND 1324, or equivalent. [3]: Part No. 08833-00080; Adhesive 1344, THREE BOND 1344, LOCTITE 242, or equivalent [4]: Part No. 08833-00100: THREE BOND 1360K, or equivalent Page 4852 (b) Press in the pistons with a monkey wrench handle or equivalent. NOTE: Tape the monkey wrench handle before use. - Always change the pad on one wheel at a time as there is a possibility of the opposite piston flying out. - If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the 4 anti-squeal shims to new pads. NOTE: Apply disc brake grease to both sides of the inner anti-squeal shims, see EXPLODED VIEW of system. (d) Install the 2 pads. CAUTION: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 5. Install anti-rattle spring and 2 pins. 6. Install clip. 7. Install front wheel. 8. Check that fluid level is at max line. Page 332 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1959 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3869 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .................................. DEXRON II or DEXRON III Page 2507 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3741 operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 3964 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 3345 Idle Speed/Throttle Actuator - Electronic: Description and Operation CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed and a VSV for idle up control is also added (for air conditioning). Page 3709 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 3536 Page 3019 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2620 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 65 Inspection Procedure / ECU Power Source Circuit (1 Of 3) Inspection Procedure / ECU Power Source Circuit (2 Of 3) Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 816 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 2732 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2672 CHART 14 Page 4348 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 22) Parts Location Parts Location Service and Repair Oil Filter: Service and Repair WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. Drain engine oil. (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. Replace oil filter. (a) Using Special Service Tool (SST) Oil Filter Wrench # 09228 - 07501 or equivalent, remove the oil filter. (b) Clean the oil filter contact surface on the oil filter mounting. (c) Lubricate the filter rubber gasket with clean engine oil. (d) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. (e) Then using SST Oil Filter Wrench # 09228 - 07501 or equivalent, tighten it an additional 3/4 turn to seat the filter. 3. Fill with engine oil. (a) Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (29 ft. lbs.) (b) Fill with new engine oil. Page 294 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check A/T - Chatter When Shifted From R to P/N Valve Body: Customer Interest A/T - Chatter When Shifted From R to P/N TRANSMISSION & CLUTCH TC001-98 FEBRUARY 13, 1998 TITLE: A340E, A343F "R" TO "P/N" CHATTER MODELS: '97-'98 TACOMA, 4RUNNER, T-100 & LAND CRUISER Introduction Some Tacoma, 4Runner, T-100 and Land Cruisers with A340E, A340F or A343F automatic transmissions may produce a chatter noise when shifted out of Reverse into either Neutral or Park. To prevent this noise, a check ball has been added to the valve body as indicated in the illustration. Affected Vehicles 1997-98 model year Tacoma, 4Runner, T-100 and Land Cruiser with A340E, A340F or A343F automatic transmissions with serial numbers from 97H*-00001 through 97K*-99999. Parts Information OLD PART NUMBER NEW PART NUMBER PART NAME 35495-22020 Same Ball, Check, No. 1 35433-30064 Same Valve Body Gasket No. 1 35434-30076 Same Valve Body Gasket No. 2 Warranty Information Applicable Warranty: This repair Is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Repair Procedure 1. Disassembly: A. Remove valve body as described in the Repair Manual for the vehicle being serviced. B. Turn over and remove 25 bolts. Page 2944 CHART 20 Page 3037 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Vehicle - Towing Guide. Towing Information: Technical Service Bulletins Vehicle - Towing Guide. BULLETIN NUMBER: AX001-00 DATE: March 17, 2000 TITLE: TOYOTA "DINGHY" TOWING GUIDE MODELS: All Models INTRODUCTION The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer/Service Outlet for recommended towing equipment. Warranty Information WARRANTY INFORMATION APPLICABLE VEHICLES Page 3579 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 905 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 3103 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Service and Repair Solenoid: Service and Repair 1. Remove A.D.D. switch. 2. Remove sleeve fork pin. a. Using a hexagon wrench, remove the screw plug. b. Using a pin punch and a hammer, remove the pin through the hole of clutch case cover. 3. Separate actuator from clutch case cover and remove sleeve fork. Using a hexagon wrench, remove the screw plug. b. Remove the spring seat, spring and steel ball. c. Remove the 2 bolts and actuator from the clutch case cover. d. Separate the actuator from the clutch case cover and remove the sleeve fork. e. Remove the O-ring from the actuator. 4. Install sleeve fork and actuator into clutch case cover. a. Install a new O-ring to the actuator. b. Coat the O-ring with MP grease. c. Place the sleeve fork and install the actuator to the clutch case cover. d. Torque the 2 bolts. Torque to 21 Nm (15 ft. lbs.) e. Install the steel ball, spring and spring seat. f. Coat the threads of screw plug with FIPG. FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. g. Using a hexagon wrench, install the screw plug. Torque to 13 Nm (9 ft. lbs.) 5. Install sleeve fork pin. a. Using a pin punch and a hammer, install the pin through the hole of clutch case cover. b. Coat the threads of screw plug with FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. c. Using a hexagon wrench, install the screw plug. Torque to 20 Nm (14 ft. lbs.) 6. Install A.D.D. switch. Install a new gasket and indicator switch. Torque to 40 Nm (30 ft. lbs.) Page 3203 Idle Speed: Adjustments 1. Initial conditions. (a) Engine coolant at normal operating temperature. (b) Air cleaner installed. (c) All pipes and hoses of air induction system connected. (d) All accessories switched OFF. (e) All vacuum lines properly connected. NOTE: All vacuum hoses for Exhaust Gas Recirculation (EGR) systems, etc. should be properly connected. (f) Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged. (g) Ignition timing set correctly. (h) Transmission in neutral position. (i) A/C switch is OFF. 2. Connect TOYOTA hand-held tester or OBD II scan tool or equivalent. 3. Inspect idle speed. (a) Race the engine speed at 2,500 rpm for approximately 90 seconds. (b) Check the idle speed. Idle speed: 700 +/- 50 rpm NOTE: If the idle speed is not as specified, check the Idle Air Control (IAC) valve and air intake system. 4. Disconnect TOYOTA hand-held tester or OBD II scan tool or equivalent. Page 436 Glossary Of Term And Symbols (Part 1 Of 2) Page 2440 Page 1720 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2783 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Page 4002 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Drain Plug: Specifications Drain Plug ............................................................................................................................................ .................................................... 37 N.m (27 ft. lbs.) Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 1939 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Page 2879 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Diagrams Combination Switch Page 1220 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4818 2. Remove pistons from cylinder. (a) Prepare the wooden plate to hold the pistons. (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. WARNING: Do not place your fingers in front of the piston when using compressed air. 3. Remove piston seals. Using a screwdriver, remove the 4 piston seals from the cylinder. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTE: Apply lithium soap base glycol grease to the parts indicated by arrows in EXPLODED VIEW. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 3559 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1850 Glossary Of Term And Symbols (Part 1 Of 2) Page 1356 Piston Ring: Testing and Inspection 1. Insert the piston ring into the cylinder bore. 2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 115 mm (4.53 inch) from the top of the cylinder block. 3. Using a feeler gauge, measure the end gap. Ring end gap: STD: No. 1: 0.300 - 0.500 mm (0.0118 - 0.0197 inch) No. 2: 0.400 - 0.600 mm (0.0157 - 0.0236 inch) Oil (side rail): 0.150 - 0.550 mm (0.0059 - 0.0217 inch) Maximum: No. 1: 1.100 mm (0.0433 inch) No. 2: 1.200 mm (0.0472 inch) Oil (side rail): 1.150 mm (0.0453 inch) 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, rebore all the 6 cylinders or replace the cylinder block. Page 4266 HUB BOLT REPLACEMENT 1. Remove wheel and brake drum. 2. Remove hub bolt. Using SST, 09650-17011 3. Install hub bolt. Install a washer and nut to a new hub bolt as shown and install the hub bolt with torquing the nut. 4. Install brake drum and wheel. Torque to 110 Nm (83 ft. lbs.) Page 846 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 209 Air Bag Control Module: Service and Repair NOTICE: ^ Do not open the cover or the case of the ECU and various computers unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) ^ Never use SRS parts from another vehicle. When replacing parts, replace with new parts. ^ Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. ^ Never repair a sensor in order to reuse it. Wire Harness 1. REMOVE THESE PARTS: a. Lower center cover b. ABS ECU 2. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTICE: Removal of the connector is done with the sensor assembly installed. b. Using a torx wrench, remove the 3 screws and the airbag sensor assembly. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) 3. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 21 N.m (210 kgf cm, 15 ft.lbf) b. Connect the connector. NOTICE: ^ Installation of the connector is done with the sensor assembly installed. ^ Make sure the sensor assembly is installed to the specified torque. ^ If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. ^ When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. ^ After installation, shake the sensor assembly to check that there is no looseness, 4. INSTALL THE REMOVED PARTS Page 3025 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 248 Power Door Lock Switch: Testing and Inspection Door Lock Control Switch DRIVER'S DOOR LOCK CONTROL SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. PASSENGER'S DOOR LOCK CONTROL SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 568 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1940 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Locations One Touch 2-4 Selector System Page 2583 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3744 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1209 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4905 2. Install Load Sensing Proportioning Valve (LSPV) gauge, Special Service Tool (SST) # 09709 29017, and bleed air. 3. Raise front brake pressure to 7,845 kPa (1,138 psi) and check rear brake fluid pressure. Rear brake fluid pressure: 5,325 ± 490 kPa (772 ± 71 psi). NOTE: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. If necessary, adjust fluid pressure. (a) Adjust the length of the No.2 shackle. Low pressure: Lengthen A. High pressure: Shorten A. Initial set: 120 mm (4.72 inch) Adjustment range: 114 - 126 mm (4.49 - 4.96 inch) NOTE: One turn of the nut changes the fluid pressure as shown in the following specification. 52 kPa (7.5 psi) (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 Nm (9 ft. lbs.) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 3933 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Supercharger - Squeak/Rattle Noises From Idler Pulley Idler Pulley: Customer Interest Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 2875 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1701 Radiator Cap: Testing and Inspection 1. Remove radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. Inspect radiator cap. NOTE: If the radiator cap contaminations, always rinse it with water. Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard opening pressure: 74 - 103 kPa (10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (8.5 psi) NOTE: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. Reinstall radiator cap. Page 2797 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2480 Cranking Signal: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4679 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Page 3491 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3945 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Capacity Specifications Coolant: Capacity Specifications A/T Engine Coolant .................................................................................................................................... ............................................. 9.5 liters (10.0 US qts.) M/T Engine Coolant .................................................................................................................................... .............................................. 9.7 liters (10.3 US qts.) Specifications Clutch Disc: Specifications Disc Rivet Head Depth: Minimum .............................................................................................................................................. ............................................. 0.3 mm (0.012 inch) Disc Runout: Maximum ............................................................................................................................................. .............................................. 0.8 mm (0.031 inch) Page 1096 Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration with SAE 5W-30 being the preferred engine oil. Oil capacity: Drain and refill w/ Oil filter change: 5.2 liters (5.5 US qts.) (c) Reinstall the oil filler cap. 4. Start engine and check for oil leaks. 5. Check engine oil level. Page 1936 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2918 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 196 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Specifications Coolant Drain Plug: Specifications TIGHTENING SPECIFICATIONS Drain Plug To Cylinder Block ............................................................................................................... ................................................ 39 Nm (29 ft. lbs.) Page 372 Glossary Of Term And Symbols (Part 1 Of 2) Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 664 CHART 23 Page 2015 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 185 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Speedometer Gear: Specifications Speedometer Driven Gear Set Bolt ................................................................................................................................................... 11.5 N.m (96 inch lbs.) Page 2033 Page 869 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 4131 Differential Carrier INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. If the runout is greater Page 4906 5. If necessary, check valve body. (a) Assemble the valve body in the uppermost position. NOTE: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. - With the front pressure @ 1,960 kPa (285 psi) the rear pressure should be 1,960 kPa (285 psi). - With the front pressure @ 3,920 kPa (570 psi) the rear pressure should be 2,352 kPa ± 196 (342 ± 28.5 psi). - With the front pressure @ 6,860 kPa (997.5 psi) the rear pressure should be 2,940 kPa ± 343 (427.5 ± 50 psi). NOTE: If the measured value is not within standard, replace the valve body. Page 2807 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 4552 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4554 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2534 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1627 Coolant: Testing and Inspection COOLANT CHECK 1. Check engine coolant level at radiator reservoir. The engine coolant level should be between the "LOW" and "FULL" lines, when the engine is cold. If low, check for leaks and add engine coolant up to the "FULL" line. 2. Check engine coolant quality. (a) Remove the radiator cap from the water outlet. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. (c) Reinstall the radiator cap. Specifications Compression Check: Specifications Compression Pressure: Minimum [1] ......................................................................................................................................... ........................................ 1,000 kPa (145 psi) Standard [1] ................................................................ ..................................................................................................... 1,200 kPa (174 psi) or more Pressure Difference: Between Each Cylinder .......................................................................................................................................................... 100 kPa (15 psi) or less [1] @ 250 rpm Page 2178 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2758 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3003 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1823 Engine Control Module: Testing and Inspection Related Diagnostic Procedures ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to the terminal +B of the ECM. WIRING DIAGRAM Step 1 Step 2 Page 142 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 618 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 855 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2511 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Specifications Idle Speed/Throttle Actuator - Mechanical: Specifications Setting Specifications Setting Specifications Actuator Setting Speed 900 - 1,950 rpm Page 3696 Components For Removal And Installation Part 2 Of 2 Page 3011 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1406 4. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. Page 2246 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 683 Page 1977 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 808 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2120 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2825 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Specifications Clutch Fluid: Specifications Fluid Type FMVSS No. 116 DOT 3 Brake Fluid Page 119 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 593 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4608 If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve. ASSEMBLY 1. Install front drive clutch sleeve onto drive sprocket. a. Install the front drive clutch sleeve onto the drive sprocket. HINT: Make sure to install the clutch sleeve in the correct direction. b. Install the 3 shifting keys and 2 springs. NOTICE: Install the key springs positioned so that their end gaps are not in line. 2. Install drive sprocket with front drive clutch sleeve assembly, spacer and bearing. a. Apply gear oil to the shaft and needle roller bearing. b. Place the synchronizer ring on the spline and align the ring slots with the shifting keys. Install the needle roller bearing in the drive sprocket. d. Install the drive sprocket with the front drive clutch sleeve assembly. 3. Inspect drive sprocket thrust clearance. Using a feeler gauge, measure the drive sprocket thrust clearance. Standard Clearances. 0.10-0.25 mm (0.0039-0.0098 inch) Page 492 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1068 Timing Belt: Service and Repair Timing Belt Installation 1. Install crankshaft timing pulley. (a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. 2. Install No. 1 idler pulley. (a) Using a 10 mm hexagon wrench, install the No. 1 idler pulley with the plate washer and bolt. Torque: 35 Nm (26 ft. lbs.) (b) Check that the pulley bracket moves smoothly. 3. Install No. 2 idler pulley. (a) Install the No. 2 idler pulley with the bolt. Torque: 40 Nm (30 ft. lbs.) (b) Check that the No. 2 idler pulley moves smoothly. 4. Install LH camshaft timing pulley. (a) Face the flange side of the timing pulley outward. (b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. (c) Using Special Service Tool (SST) Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, install the pulley bolt. Torque: 110 Nm (81 ft. lbs.) 5. Install RH camshaft timing pulley. (a) Face the flange side of the timing pulley outward. (b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. Page 3273 Fuel Injector: Exploded Views Components For Removal And Installtion Part 1 Of 2 Page 4664 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 24) Page 2248 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2145 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4151 c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050), remove the companion flange. 2. Remove front oil seal. Using SST 09308-10010, remove the oil seal from the differential carrier. 3. Remove front bearing and bearing spacer. a. Using SST 09556-22010, remove the bearing from the drive pinion. b. Remove the 2 washers and bearing spacer. 4. Remove differential case. a. Place matchmarks on the bearing cap and differential carrier. b. Remove the 4 bolts and bearing cap. c. Using SST 09504-22011 and a hammer, remove the 2 side bearing plate washers. HINT: Measure the plate washer and note the thickness. Page 314 Brake Switch (Cruise Control): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2796 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 937 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4857 Brake Rotor/Disc: Adjustments DISC RUNOUT 1. Remove the hub nuts and disc. Reinstall the disc 1/6 of a turn round from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. 2. Repeat (1) until the disc has been installed on the 4 remaining hub positions. 3. If the minimum runout recorded in (1) and (2) is less than the maximum disc runout, install the disc in that position. 4. If the minimum runout recorded in (1) and (2) is greater than the maximum disc runout, replace the disc. Page 614 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 995 c. Turn the left and right rack ends an amount to adjust the toe-in. HINT: Try to adjust the camber and caster to the center value. d. Tighten the rack end lock nuts. Torque to 55 Nm (41 ft. lbs.) e. Place the boot on the seat and clip it. HINT: Ensure that the boots are not twisted. f. Inspect the wheel angle. Turn the steering wheel fully, and measure the turning angle. If wheel angle deviates from the specifications, readjust the toe-in and wheel angle within the specifications. At this time, the left-right error lengths of the tie rod end may be less than 1.5 mm (0.059 inch). Locations Ignition Switch Oil Level Check Engine Oil: Testing and Inspection Oil Level Check 1. The oil level should be between the "L" and "F" marks on the dipstick. 2. If low, check for leakage and add oil up to the "F" mark. Page 3442 Ohmmeter Connection Reference (c) Using an ohmmeter, measure the resistance between each terminal. (d) Reconnect the sensor connector. 3. M/T: INSPECT DASHPOT (DP) (a) Allow the engine to warm up to normal operating temperature. (b) Check idle speed. Idle speed: 700 ± 50 rpm (c) Remove the cap, filter and separator from the DP. (d) Maintain engine speed at 2,500 rpm or more. (e) Plug the VTV hole with your finger. (f) Release the throttle valve. (g) Check the DP is set. DP setting speed: 1,800 - 2,200 rpm (h) If the setting speed is not as specified, adjust it with the DP adjusting screw. (i) Remove your finger from the hole and check that the engine returns to idle speed in approx. 1 second. (j) Reinstall DP separator, filter and cap. Page 2861 Page 391 Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING SWITCH 1. Disconnect the connector from the switch. 2. Check that there is continuity between terminal and ground with the engine stopped. 3. Check that there is no continuity between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2586 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1309 Connecting Rod: Testing and Inspection Oil Clearance 1. Remove connecting rod caps and check oil clearance. (a) Using a punch or numbering stamp, mark the connecting rod and cap to ensure correct reassembly. (b) Remove the connecting rod cap nuts. (c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap. NOTE: Keep the lower bearing inserted with the connecting rod cap. (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing. (f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (g) Lay a strip of Plastigage across the crank pin. (h) Install the connecting rod cap with the 2 nuts. Torque: Page 4726 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2404 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3035 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2555 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 936 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2412 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Tightening Specifications Flex Plate: Specifications Tightening Specifications Sequence TORQUE SPECIFICATIONS Drive Plate To Crankshaft: 83 N.m (61 ft. lbs.) Page 4556 Differential: Electrical Diagrams Rear Differential Lock (Part 1 Of 2) Page 458 Combination Switch: Adjustments After inspecting the Combination Switch, adjust the Spiral Cable. Center the spiral cable and then do the following. 1. Check that the front wheels are facing straight ahead. 2. Turn the cable counterclockwise by hand until it becomes harder to turn the cable. 3. Then rotate the cable clockwise about three turns to align the mark. NOTE: The cable will rotate about three turns to either left or right of the center. A/C Drive Belt: Testing and Inspection A/C DRIVE BELT TENSION INSPECTION 1. INSPECT DRIVE BELTS INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt: 160 ± 25 lb Used belt: 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Page 595 Page 2978 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1820 Standard Values Of ECM Terminals Chart 2 Of 2 Page 797 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Page 343 Clutch Switch: Testing and Inspection CLUTCH SWITCH CIRCUIT CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Park / Neutral Position Switch WIRING DIAGRAM Inspection Procedure / Clutch Switch Circuit (1 Of 4) Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Testing and Inspection Leak Detection Solenoid: Testing and Inspection VACUUM SWITCHING VALVE (VSV) FOR VAPOR PRESSURE SENSOR INSPECTION 1. REMOVE VSV (a) Disconnect the connector and 3 EVAP hoses from the VSV. (b) Remove the bolt and VSV. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20°C (68°F): 37 - 44 ohm If there is no continuity, replace the VSV B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from ports E to P and does not flow from ports E to F. (b) Apply battery voltage across the terminals. Page 3490 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1064 10. w/ A/C: Disconnect A/C compressor from engine. 11. w/ A/C: Remove A/C compressor bracket. Remove the 5 bolts and A/C compressor bracket. 12. Remove oil dipstick and guide. Remove the bolt, oil dipstick, guide and O-ring. 13. Remove No. 2 timing belt cover. (a) Disconnect the camshaft position sensor connector, 3 high-tension cord clamps and PS pump hose from the No. 2 timing belt cover. (b) Remove the 6 bolts and No. 2 timing belt cover. 14. Remove fan bracket. (a) Remove the nut and PS pump adjusting strut. (b) Remove the bolt, nut, and fan bracket. 15. Remove crankshaft pulley. (a) Using Special Service Tool (SST) Crankshaft Pulley Holding Tool # 09213 - 54015 (Bolt 90119 08216) and Companion Flange Holding Tool # 09330 - 00021 or equivalents, loosen the pulley bolt. (b) Remove the SST, pulley bolt and pulley. NOTE: If necessary, remove the pulley with SST Puller C Set # 09950 - 50010 (Hanger 150 # 09551 - 05010, Slide Arm # 09552 - 05010, Center Bolt 150 # 09553 - 05020, Claw No. 3 # 09554 05030) or equivalents and service bolt. Page 3487 Glossary Of Term And Symbols (Part 1 Of 2) Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2148 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit TMC Made Universal Joint: Service and Repair TMC Made REPLACEMENT Page 3672 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 1568 Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 4046 3. TURN OVER ASSEMBLY AND REMOVE 25 BOLTS 4. LIFT OFF UPPER VALVE BODY AND PLATE AS A SINGLE UNIT Hold the valve body plate to the upper valve body. HINT: Be careful that the check balls and strainer do not fall out. VALVE BODY ASSEMBLY 1. POSITION NEW NO.1 GASKET ON UPPER VALVE BODY Align a new No.1 gasket at each bolt hole. 2. POSITION VALVE BODY PLATE ON NO.1 GASKET Align the plate at each bolt hole. 3. POSITION NEW NO.2 GASKET ON PLATE Align a new No.2 gasket at each bolt hole. Electrical Specifications Fuel Injector: Electrical Specifications Resistance Resistance Resistance Between Terminals 13.8 ohms Specifications Catalytic Converter: Specifications TWC to Front Exhaust Pipe 46 ft.lb TWC to Tailpipe 35 ft.lb Page 3803 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3282 (d) Remove the 2 O-rings and 2 grommets from each injector. INJECTORS INSTALLATION 1. TEMPORARILY INSTALL INJECTORS AND DELIVERY PIPES (a) Install 2 new grommets to each injector. (b) Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector. (c) While turning the injector clockwise and counter clockwise. push it to the delivery pipes. Install the 6 injectors. (d) Position the injector connector outward. (e) Place the 4 spacers in position on the intake manifold. (f) Place the delivery pipes with the 6 injectors in position on the intake manifold. (g) Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. (h) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. (i) Position the injector connector outward. 2. CONNECT INJECTOR CONNECTORS Page 4541 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 24) Page 3736 Position Of Parts In Instrument Panel (1 Of 2) (Fig 28) Page 1747 Water Pump: Service and Repair Page 2810 Page 1048 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only those valves indicated in the illustration. 1. Using a thickness gauge, measure the clearance between the valve lifter and camshaft. Valve Clearance (Cold): 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Page 2396 Page 1889 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Specifications EGR Tube: Specifications Except VZN170 Models. EGR Pipe to LH Exhaust Manifold 14 ft.lb EGR Pipe Stays to Cylinder Head 71 in.lb Page 1812 Engine Control Module: Connector Views Standard Values Of ECM Terminals Chart 1 Of 2 Page 2149 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1049 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using Special Service Tool (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) Page 1650 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4677 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3632 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2917 A/F and 02 Sensor Identification Page 2180 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3890 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 22) Parts Location Parts Location Page 4120 4. Measure drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.) 5. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) If necessary, disassemble and inspect the differential. 6. Check tooth contact between ring gear and drive pinion. Without Differential Lock Page 3079 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3701 Knock Sensor: Oscilloscope Patterns and Waveforms Page 2930 Page 3399 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Page 2405 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Testing and Inspection Shift Interlock Solenoid: Testing and Inspection Inspect shift lock solenoid. a. Disconnect the solenoid connector. b. Using an ohmmeter, measure the resistance at each terminal. Standard Resistance 20-28 ohms. If resistance value is not as specified. Replace the solenoid. c. Apply battery positive voltage at each terminal. At this time, confirm that the solenoid operates. If the solenoid does not operate, replace the solenoid. Page 4309 Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7 and the slip yoke grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5, and 6 grease fittings (double cardan joint). Page 1340 Piston: Testing and Inspection Inspect Oil Clearance NOTE: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top. 1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 26 mm (1.02 inch) from the piston head. Piston diameter: STD: Mark "1": 93.356 - 93.666 mm (3.6754 - 3.6758 inch) Mark "2": 93.367 - 93.376 mm (3.6759 3.6762 inch) Mark "3": 93.377 - 93.389 mm (3.6763 - 3.6766 inch) O/S 0.50: 93.856 - 93.886 mm (3.6951 - 3.6963 inch) 2. Measure the cylinder bore diameter in the thrust directions. 3. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.134 - 0.154 mm (0.0053 - 0.0060 inch) Maximum oil clearance: 0.174 mm (0.0069 inch) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, rebore all the 6 cylinders or replace the cylinder block. NOTE: (Use new cylinder block): Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block. Page 1986 Page 337 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2117 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 666 CHART 24 Page 3999 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1097 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Locations Fusible Link: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Electrical Specifications Oxygen Sensor: Electrical Specifications Bank 1: Sensor 1, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1: Sensor 2, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1 Sensor 1 Bank 1 Sensor 2 Page 4043 Upper Valve Body Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid A340F Dry capacity ......................................................................................................................................... ........................................................................ 8.0 Qt Drain and Refill ................................................ ................................................................................................................................................. 2.0L (2.1 Qt) Specifications Engine Accessory Bracket: Specifications TIGHTENING SPECIFICATIONS Generator Bracket To LH Cylinder Head .......................................................................................................................................... 18.5 Nm (14 ft. lbs.) Generator Adjusting Bar To Cylinder Block ..................................................................................................................................... 42.0 Nm (31 ft. lbs.) Power Steering Pump Bracket To RH Cylinder Head..........................................................................................................................18.5 Nm (14 ft. lbs.) Engine Rear Mount Bracket To Engine Rear Mount Insulator ................................................................................................................................................. 18.0 Nm (13 ft. lbs.) To Frame Crossmember .............................................................................................................................................................. 58.0 Nm (43 ft. lbs.) Engine Mount Bracket To Cylinder Block ........................................................................................................................................ 44.0 Nm (32 ft. lbs.) No. 2 Idler Pulley Bracket To Cylinder Block .................................................................................................................................. 38.0 Nm (28 ft. lbs.) Page 1859 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3654 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Testing and Inspection Brake Warning Indicator: Testing and Inspection INSPECT BRAKE WARNING LIGHT 1. Disconnect the connectors from the level warning switch and parking brake switch. 2. Connect terminals on the wire harness side connector of the level warning switch connector. 3. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 4533 Differential: Capacity Specifications For capacity and fluid type information relating to the Transfer Case assembly, please refer to Transfer Case Fluid; Specifications. Oil Level Check Engine Oil: Testing and Inspection Oil Level Check 1. The oil level should be between the "L" and "F" marks on the dipstick. 2. If low, check for leakage and add oil up to the "F" mark. Page 3340 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4127 a. Using a chisel and a hammer, unstake the nut. b. Using SST 09330-00021 to hold the flange, remove the nut. c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange. 7. Remove oil seal and oil slinger. a. Using SST 09308-10010, remove the oil seal. b. Remove the oil slinger. 8. Remove rear bearing and bearing spacer. a. Using SST 09556-22010, remove the rear bearing from the drive pinion. b. Remove the bearing spacer. 9. Remove side bearing retainer. Remove the 10 bolts and tap out the retainer with a plastic hammer. 10. Remove differential case assembly. 11. Remove drive pinion from differential carrier. Page 2199 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2258 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 834 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2000 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2486 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4159 d. Install the shift fork in the groove of the sleeve holding it by hand and install the case in the carrier. HINT: Make sure that there is backlash between the ring gear and drive pinion. 9. Install bearing caps. Align the matchmarks on the cap and carrier. Screw in the 2 bearing cap bolts 2 or 3 turns and press down the bearing cap by hand. HINT: If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary. 10. Adjust side bearing preload. a. Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by hand. Torque to 78 Nm (58 ft. lbs.) b. Fully tighten the 4 bearing cap bolts by hand. c. Using the SST 09616-30020, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 inch). d. While turning the ring gear, use the SST 09616-30020 to fully tighten the adjusting nut on the drive pinion side. after the bearings are settled, loosen the adjusting nut on the drive pinion side. Page 4411 Input Shaft: Application and ID Input Shaft Snap Ring Thickness Mark A ................................................................................................................................................. ............... 2.10-2.15 mm (0.0827-0.0846 inch) Mark B ........................................................................ ........................................................................................ 2.15-2.20 mm (0.0846-0.0866 inch) Mark C .............................................................................................................................................................. .. 2.20-2.25 mm (0.0866-0.0886 inch) Mark D ..................................................................................... ........................................................................... 2.25-2.30 mm (0.0886-0.0906 inch) Mark E ............ .................................................................................................................................................... 2.30-2.35 mm (0.0906-0.0925 inch) Mark F ........................................................................................ ......................................................................... 2.35-2.40 mm (0.0925-0.0945 inch) Mark G ............. ................................................................................................................................................... 2.40-2.45 mm (0.0945-0.0965 inch) Page 3797 Page 384 Vehicle Speed Sensor Circuit Page 824 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 3688 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 545 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 237 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4000 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2189 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 585 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4428 e. Using a press, install the 2nd gear assembly and reverse gear assembly. 7. Install snap ring. a. Select a snap ring that will allow minimum axial clay. Mark A: 2.30-2.35 mm (0.0906-0.0925 inch) Mark B: 2.35-2.40 mm (0.0925-0.0945 inch) Mark C: 2.40-2.45 mm (0.0945-0.0965 inch) Mark D: 2.45-2.50 mm (0.0965-0.0984 inch) Mark E: 2.50-2.55 mm (0.0984-0.1004 inch) Mark F: 2.55-2.60 mm (0.1004-0.1024 inch) Mark G: 2.60-2.65 mm (0.1024-0.1043 inch) b. Using a screwdriver and hammer, install the snap ring. 8. Install spacer and 1st gear assembly. a. Install the spacer on the output shaft. b. Apply gear oil to the needle roller bearing. c. Assemble the 1st gear, synchronizer ring and needle roller bearing. d. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys. 9. Install straight pin and 1st gear thrust washer. Install the 1st gear thrust washer onto the output-shaft with the straight pin aligned with the 1st gear-thrust washer. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 443 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4503 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 2799 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2439 Specifications Lifter / Lash Adjuster: Specifications DIMENSIONS Diameter: Bore ......................................................................................................................................................... 31.000 - 31.018 mm (1.2205 - 1.2212 inch) Lifter ....................................................................................................................................................... 30.966 - 30.976 mm (1.2191 - 1.2195 inch) Oil Clearance: Maximum ............................................................................................................................................. .................................... 0.08 mm (0.0031 inch) Standard ...................................................................................................................................................... 0.024 - 0.052 mm (0.0009 - 0.0020 inch) Page 2745 Engine Control-Connectors Page 4816 Remove the 2 mounting bolts and remove the caliper. Torque: 123 Nm (90 ft. lbs.) 4. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 pads. - 4 anti-squeal shims. INSTALLATION Installation is in the reverse order of removal. NOTE: After installation: Fill brake reservoir with brake fluid, bleed brake system. See: Brake Bleeding/Service and Repair - Check for leaks. Page 1347 Piston: Service and Repair Assembly 1. Assemble piston and connecting rod. (a) Using a small screwdriver, install a new snap ring on one side of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. (b) Gradually heat the piston to 60° C (140° F). (c) Coat the piston pin with engine oil. (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. 2. Install piston rings. (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code Mark: No. 1: "1R" or "T" No. 2: "2R" or "T" Page 4234 Front Axle Hub / 4WD Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 791 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2819 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4468 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Specifications Compression Check: Specifications Compression Pressure: Minimum [1] ......................................................................................................................................... ........................................ 1,000 kPa (145 psi) Standard [1] ................................................................ ..................................................................................................... 1,200 kPa (174 psi) or more Pressure Difference: Between Each Cylinder .......................................................................................................................................................... 100 kPa (15 psi) or less [1] @ 250 rpm Page 2769 Glossary Of Term And Symbols (Part 1 Of 2) Page 3943 Glossary Of Term And Symbols (Part 1 Of 2) Page 2195 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4621 Planetary Gears: Testing and Inspection NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." INSPECTION 1. Inspect pinion gear thrust clearance using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard Clearance: 0.11-0.84 mm (0.0043-0.0331 inch) Maximum Clearance: 0.84 mm (0.0331 inch) If the clearance exceeds the Maximum, replace the planetary gear assembly. 2. Inspect planetary pinion gear radial clearance. Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard Clearance: 0.009-0.038 mm (0.0004-0.0015 inch) Maximum Clearance: 0.038 mm (0.0015 inch) If the clearance exceeds the Maximum, replace the planetary gear assembly. Page 4462 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Capacity Specifications Lubricant Page 1987 Intake Air Temperature Sensor: Description and Operation Figure 1 Reference CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value and the higher the intake air temperature, the lower the thermistor resistance value (See Fig.1.). The intake air temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 2959 CHART 29 Page 1909 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 360 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 47 Glossary Of Term And Symbols (Part 1 Of 2) Page 2545 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3151 EGR Temperature Sensor: Mechanical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) EGR Sensor to EGR Valve 14 ft.lb Page 3505 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 2173 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2139 Glossary Of Term And Symbols (Part 1 Of 2) Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1871 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 2474 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4534 Differential: Fluid Type Specifications For capacity and fluid type information relating to the Transfer Case assembly, please refer to Transfer Case Fluid; Specifications. Page 2077 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3526 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4920 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Actuator Components REMOVAL 1. Disconnect brake lines. Disconnect Brake Lines Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TIGHTENING SPECIFICATIONS Attaching Nuts ..................................................................................................................................... ................................................. 19 Nm (14 ft. lbs.) Bracket Attaching Nuts ........................................ ............................................................................................................................. 5.4 Nm (48 inch lbs.) Brake Line Union ......................................................................................................................... ......................................................... 15 Nm (11 ft.lbs.) Page 4903 Load Sensing Proportioning And By-Pass Valve Components Page 4781 Depress MOTOR Switch And Brake Pedal (h) Push and hold in the MOTOR switch for a few seconds. (i) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (j) Release the brake pedal. 7. Push MOTOR switch. Depress MOTOR Switch (a) Push and hold in the MOTOR switch for a few seconds. (b) Stop the engine. 8. Disconnect actuator checker (SST) from actuator. Disconnect the actuator checker (SST) and sub-wire harnesses (SST) from the actuator, control relay and body side wire harness. SST 09990-00150, 09990-00200, 09990-00210, 09990 - 00370 9. Connect connectors. (a) Connect the 2 connectors to the control relay. (b) Connect the connector to the actuator. 10. Clear the Diagnostic Trouble Code (DTC). Component Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection 1. REMOVE GLOVE COMPARTMENT DOOR 2. DISCONNECT CONNECTOR OF THERMISTOR 3. CHECK RESISTANCE OF THERMISTOR Measure resistance between 1 and 2 terminals. Standard resistance: 1,500 Ohms at 25° C (77° F) If resistance is not as specified, replace the thermistor. Page 4169 b. Heat the ring gear to about 100 C (212° F) in boiling water. c. Carefully remove the ring gear from the water. d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the ring gear and differential case. e. After the ring gear cools down enough, torque the set bolts to which thread lock has been applied. Thread lock: Part No. 08833 - 00100, THREE BOND 1360K, or equivalent. Torque to 125 Nm (92 ft. lbs.) 4. Inspect ring gear runout. a. Install the differential case into the carrier and install the plate washers to where there is no play in the bearing. b. Install the bearing cap. c. Using a dial indicator, measure the runout of ring gear. Maximum runout: 0.05 mm (0.0020 inch) 5. Install drive pinion bearing outer races and adjusting washer. a. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) and a press, install a new front bearing outer race to the carrier. b. Using SST 09950-60020 (09951-00910), 09950-70010 (09951-07150) and a press, install a new adjusting washer and a new rear bearing outer race to the carrier. Page 2407 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2084 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 66 Inspection Procedure / ECU Power Source Circuit (3 Of 3) INSPECTION PROCEDURE Electronically Controlled Transmission Communication Circuit ELECTRONICALLY CONTROLLED TRANSMISSION (ECT) COMMUNICATION CIRCUIT SOLENOID # 2 CIRCUIT DESCRIPTION When driving uphill under cruise control, in order to reduce shifting due to ON-OFF overdrive operation and to provide smooth driving, when down shifting in the electronically controlled transmission occurs, a signal to prevent upshift until the end of the up hill slope is sent from the cruise control ECU to the electronically controlled transmission. Terminal ECT of the cruise control ECU detects the shift change signal (output to electronically controlled transmission No.2 solenoid) from the electronically controlled transmission. If vehicle speed down, also when terminal electronically controlled transmission of the cruise control ECU receives down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. ECT Communication Circuit - Solenoid #2 Page 2748 Standard Values Of ECM Terminals Chart 2 Of 2 Page 1858 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4379 Counter Gear: Testing and Inspection 1. Inspect 5th gear radial clearance. a. Install the spacer, counter 5th gear and needle roller bearings. b. Using a dial indicator, measure the counter 5th gear radial clearance. Standard Clearance: 0.015-0.068 mm (0.0006-0.0027 inch) Maximum Clearance: 0.160 mm (0.0063 inch) If the clearance exceeds the Maximum, replace the gear bearing or shaft. 2. Inspect counter gear. Using a micrometer, measure the outer diameter of the counter gear journal. Minimum Diameter: 27.860 mm (1.0968 inch) If the outer diameter is less than the minimum, replace the counter gear. 3. Inspect 5th synchronizer ring. a. Check for wear or damage. Page 3222 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2618 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 668 Page 75 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2331 Ignition Cable: Testing and Inspection HIGH-TENSION CORDS INSPECTION 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS Disconnect the high - tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS (a) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (b) Disconnect the high-tension cord at the grommet. DO NOT pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high-tension cord is disconnected. 4. INSPECT HIGH-TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 K ohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. Page 316 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 865 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1776 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4150 Differential Carrier (3RZ-FE, 5VZ-FE w/o Differential Lock) DISASSEMBLY 1. Remove companion flange. a. Using a chisel and hammer, unstake the staked part of the nut. b. Using SST 09330-00021 to hold the flange, remove the nut. Page 1842 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 4217 a. Coat a new oil seal lip with MP grease. b. 2RZ-FE: Using SST and a hammer, install the oil seal. SST 09554-30011 Oil seal drive in depth: 1.5 mm (0.059 inch) c. 3RZ-FE, 5VZ-FE w/o Diff. lock: Using SST and a plastic hammer, install the oil seal until its surface is flush with the differential carrier end. SST 09316-12010, 09649-17010 Oil seal drive in depth: 0.5 mm (0.020 inch) HINT: Connect SST with vinyl tape. d. 3RZ-FE, 5VZ-FE w/ Diff. lock: Using SST and a hammer, install the oil seal. SST 09214-76011 Oil seal drive in depth: 1.0 mm (0.039 inch) 13. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Specifications Pressure Plate: Specifications SERVICE SPECIFICATIONS Diaphragm Spring Finger Wear: Maximum Width ................................................................................................................................... ....................................... 5.0 mm (0.197 inch) Maximum Depth ......................................................... ................................................................................................................. 0.6 mm (0.024 inch) Diaphragm Spring Tip Non-Alignment: Maximum ............................................................................................................................................. ........................................ 0.5 mm (0.020 inch) TORQUE SPECIFICATIONS Clutch Cover To Flywheel ................................................................................................................... ................................................ 19 N.m (14 ft. lbs.) Page 2548 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4261 Rear Axle Shaft (2 Of 2) REMOVAL 1. Remove rear wheel and brake drum. Installation Hint: ^ Torque to 110 Nm (83 ft. lbs.) ^ After installation, bleed the brake system and check for leaks. 2. Check bearing backlash and axle shaft deviation. a. Using a dial indicator, check the backlash in the bearing shaft direction. If it is greater than the maximum, replace the bearing. Maximum: 0.7 mm (0.027 inch) b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. If it is greater than the maximum, replace the axle shaft. Maximum: 0.1 mm (0.0039 inch) 3. w/ ABS: Remove ABS speed sensor from rear axle housing. Installation Hint: Torque to 8.0 Nm (71 inch lbs.) 4. Remove rear brake assembly. Page 646 O2S Application Table O2S Failure Threshold Charts Page 3341 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2789 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 2041 CHART 7 Page 4248 1. Remove free wheel hub cover. a. Set the control handle to FREE. b. Remove the 6 cover mounting bolts and pull off the cover. Torque to 10 Nm (7 ft. lbs.) Installation Hint: Before install the hub cover, apply MP grease to the clutch splines. c. Remove the gasket. 2. Remove free wheel hub body. a. Remove the 6 mounting nuts and washers. Torque to 31 Nm (23 ft. lbs.) b. Using a brass bar and a hammer, tap on the bolts head and remove the cone washers. c. Pull off the free wheel hub body. d. Remove the gasket. INSPECTION 1. Inspect cover, handle and seal. Check the handle moves smoothly. 2. Inspect inner hub. Place the cover in the body and check that the inner hub turns smoothly. INSTALLATION Installation is in the reverse order of removal. Removal and Installation Page 921 Ignition Switch: Testing and Inspection IGNITION SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Fluid Level Check Power Steering Fluid: Testing and Inspection Fluid Level Check 1. Keep vehicle level. 2. Check fluid level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II. HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. 3. Boost fluid temperature. Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80° C (176° F) 4. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. 5. Check fluid level rise. a. With the engine idling, measure the fluid level in the oil reservoir. b. Stop the engine. c. Wait a few minutes and remeasure the fluid level in the reservoir. If a problem is found, bleed power steering system. Maximum fluid level rise: 5.0 mm (02inch) 6. Check fluid level. Page 34 ABS Control (Motor) Relay Circuit Inspection Procedure (Part 1 Of 2) Page 726 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3627 Glossary Of Term And Symbols (Part 1 Of 2) Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Specifications Brake Drum: Specifications Standard Inside Diameter 11.614 in Maximum Inside Diameter 11.693 in Page 2674 CHART 16 CHART 17 Front Wheel Speed Sensor: Specifications Mounting bolt 71 in.lb Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 691 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 623 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 3515 Glossary Of Term And Symbols (Part 1 Of 2) Page 736 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4380 b. Install the synchronizer pull ring, cone ring and outer ring to the gear spline piece No.5. c. Check the braking effect of the synchronizer ring. turn the synchronizer ring in one direction while pushing it to the gear cone. check that the ring locks. If it does not lock, replace the synchronizer ring. 4. Inspect shift fork and hub sleeve clearance. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or hub sleeve. 5. Inspect reverse idler gear radial clearance. Using a dial indicator, measure the reverse idler gear radial clearance. Standard Clearance: 0.040-0.082 mm (0.0016-0.0032 inch) Maximum Clearance: 0.130 mm (0.0051 inch) If the clearance exceeds the Maximum, replace the reverse idler gear or reverse idler gear shaft. Page 4358 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Compression Check: Specifications Compression Pressure: Minimum [1] ......................................................................................................................................... ........................................ 1,000 kPa (145 psi) Standard [1] ................................................................ ..................................................................................................... 1,200 kPa (174 psi) or more Pressure Difference: Between Each Cylinder .......................................................................................................................................................... 100 kPa (15 psi) or less [1] @ 250 rpm Specifications Brake Master Cylinder: Specifications TIGHTENING SPECIFICATIONS Brake Lines........................................................................................................................................... ................................................. 15 Nm (11 ft. lbs.) Mounting Nuts....................................................... .................................................................................................................................. 13 Nm (9 ft. lbs.) Reservoir Set Screw............................................................................................................................. ............................................. 1.5 Nm (13 inch lbs.) Piston Stopper Bolt............................................... ............................................................................................................................ 8.0 Nm (69 inch lbs.) Page 2686 CHART 26 Page 1575 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 2665 CHART 2 CHART 3 CHART 4 Page 4128 12. Remove drive pinion front bearing. Using SST 09950-00020 and a press, remove the bearing and washer from the drive pinion. HINT: If the drive pinion or ring gear are damaged replace them as a set. 13. Remove drive pinion bearing outer races. a. Using a brass bar and a hammer, remove the front bearing outer race. b. Using SST 09502-12010, 09612-65014 (09612-01020, 09612-01050), remove the rear bearing outer race. 14. Remove side bearing outer races. HINT: ^ Measure the plate washer and note the thickness. ^ Tag the bearing outer races to show the location for reassembly. a. Using SST 09950-60010 (09951-00540), 09550-70010 (09951-01500) and a press, remove the plate washer and outer race from the bearing retainer. Page 3257 Fuel Injector: Capacity Specifications Injector Volume Injector Volume Resistance Per Injector Approx. 13.8 ohms Injection Volume 3.4 - 4.2 cu in. Per 15 seconds Difference Between Injectors 0.31 or less Leakage Rate Per Injector 1 drop or less per Minute Fuel - Idle Speed Increased by Replacement ECM Engine Control Module: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 4069 Clutch Master Cylinder: Service and Repair Overhaul DISASSEMBLY 1. Remove reservoir tank. a. Using a pin punch and hammer, drive out the slotted spring pin. b. Remove the reservoir tank and grommet. 2. Remove push rod. Pull back the boot, and using snap ring pliers, remove the snap ring. 3. Remove piston. ASSEMBLY 1. Coat parts with lithium soap base glycol grease, as shown. 2. Insert piston into cylinder. 3. Install push rod assembly with snap ring. 4. Install reservoir tank. a. Install the reservoir tank and a new grommet. b. Using a pin punch and hammer, drive in the slotted spring pin. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4555 Rear Differential Lock-Connector Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2921 Engine Bank Identification Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness And Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Page 4155 c. Install the side gear to the RH case. d. Install the 4 pinion gears and pinion gear thrust washers to the spider. e. Install the pinion gear with spider to the RH case. f. Using a dial indicator, measure the side gear backlash with holding the side gear and spider. Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch) If the backlash is not within the specification, install a thrust washer of a different thickness. Thrust washer thickness: 0.9 mm (0.035 inch) 1.0 mm (0.039 inch) 1.1 mm (0.043 inch) 1.2 mm (0.047 inch) 1.3 mm (0.051 inch) HINT: ^ Measure at all 4 locations. ^ Measure the backlash at the RH case at the LH case. g. Install the side gear and side gear thrust washer to the RH case. h. Install the pinion gears and spider to the RH case. i. Install the side gear and side gear thrust washer to the RH case. j. Align the matchmarks on the LH and RH cases. k. Torque the 8 bolts uniformly, a little at a time. Torque to 47 Nm (35 ft. lbs.) Page 3745 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2004 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2870 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2856 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Locations ABS Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 650 CHART 7 Page 3216 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 621 Knock Sensor: Oscilloscope Patterns and Waveforms Page 835 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2941 CHART 15 Page 1628 Coolant: Service and Repair 1. Drain engine coolant. (a) Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the drain plugs, and drain the engine coolant. (c) Close the drain plugs. 2. Fill engine coolant. (a) Slowly fill the system with engine coolant. ^ Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. ^ Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. CAUTION: Do not use an alcohol type engine coolant. - The engine coolant should be mixed with demineralized water or distilled water. Capacity: A/T: 9.5 liters (10.0 US qts.) M/T: 9.7 liters (10.3 US qts.) (b) Reinstall the radiator cap. (c) Start the engine, and bleed the cooling system. (d) If necessary, refill the radiator reservoir with coolant until it reaches the "FULL" line. 3. Check engine coolant for leaks. Page 2219 Glossary Of Term And Symbols (Part 1 Of 2) Page 3087 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 1938 Page 2971 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Locations Back-Up Light Switches / Park Neutral Position Switch Page 1609 HINT: 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. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size according to these Formula or Charts: Page 3753 Electronically Controlled Transmission And A/T Indicator (Part 3 Of 3) Page 3650 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 361 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2153 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2613 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 191 Ignition Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Specifications Input Shaft: Specifications Input Shaft Input Shaft Journal Outer Diameter: Minimum .............................................................................................................................................. ................................. 47.59 mm (1.8736 inch) Input Shaft Bushing Diameter: Maximum ............................................................................................................................................. .................................. 39.14 mm (1.5409 inch) Synchronizer Ring To Sprocket Clearance: Standard .............................................................................................................................................................. 1.05-1.85 mm (0.0413-0.0728 inch) Minimum ..................................................................................... ............................................................................................ 0.80 mm (0.0315 inch) Page 510 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Specifications Valve Clearance: Specifications Intake 0.13 - 0.23 mm Exhaust 0.27 - 0.37 mm Page 1359 Piston Ring: Service and Repair Installation 1. Install the oil ring expander and 2 side rails by hand. 2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code Mark: No. 1: "1R" or "T" No. 2: "2R" or "T" 3. Position the piston rings so that the ring ends are as shown. CAUTION: Do not align the end gaps. Page 3001 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 3793 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2570 Engine Control Module: Testing and Inspection Related Diagnostic Procedures ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to the terminal +B of the ECM. WIRING DIAGRAM Step 1 Step 2 Page 4212 8. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 9. ADJUST DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the drive pinion using the backlash between the drive pinion and ring gear. Preload (at starting): 0.6 - 1.0 Nm (6 - 10 kgf-cm, 5.2 - 8.7 inch lbs.) If the preload is greater than the specified value, replace the bearing spacer. If the preload is less than the specified value, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) a little at a time until the specified preload is reached. Torque: 223 Nm (2,275 kgf-cm, 165 ft. lbs.) or less If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not back off the pinion nut to reduce the preload. 10. STAKE DRIVE PINION NUT 11. INSTALL FRONT PROPELLER SHAFT 12. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) w/o A.D.D.: Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: Above -18°C (0 °F) SAE 90 Below -18°C (O°F) SAE 80W or 8OW-90 Capacity: 1.10 liters (1.16 US qts., 0.97 Imp. qts.) w/A.D.D.: Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: SAE 75W-90 Page 63 Cruise Control Module: Component Tests and General Diagnostics Diagnosis Circuit DIAGNOSIS CIRCUIT CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DTC output is required. Diagnosis Circuit WIRING DIAGRAM Inspection Procedure / Diagnosis Circuit (1 Of 2) Page 538 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 592 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3298 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the 6 bolts and disconnect the No.2 timing belt cover. (d) Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. (e) Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (f) Wipe off any splattered gasoline. (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Reconnect the negative (-) terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high. replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections - Fuel pump - Fuel filter - Fuel pressure regulator (k) Disconnect the TOYOTA hand-held tester from the DLC3. Page 2868 Glossary Of Term And Symbols (Part 1 Of 2) Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 2560 Standard Values Of ECM Terminals Chart 2 Of 2 Page 2726 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2460 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid A340F Dry capacity ......................................................................................................................................... ........................................................................ 8.0 Qt Drain and Refill ................................................ ................................................................................................................................................. 2.0L (2.1 Qt) Page 2932 CHART 1 Page 2303 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the 6 bolts and disconnect the No.2 timing belt cover. (d) Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. (e) Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (f) Wipe off any splattered gasoline. (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Reconnect the negative (-) terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high. replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections - Fuel pump - Fuel filter - Fuel pressure regulator (k) Disconnect the TOYOTA hand-held tester from the DLC3. Page 1009 Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 4344 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Ground Points Ground Points Page 1697 Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 108 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01) 6. When using the radiator cap tester, tilt it more than 30 degrees. Page 2369 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3580 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2469 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 1330 Crankshaft: Testing and Inspection Main Journals and Crank Pins Inspection 1. Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD: 63.985 - 64.000 mm (2.5191 -2.5197 inch) U/S 0.25: 63.745 - 63.755 mm (2.5096 - 2.5100 inch) Crank pin diameter: STD: 54.987 - 55.000 mm (2.1648 - 2.1654 inch) U/S 0.25: 54.745 - 54.755 mm (2.1553 - 2.1557 inch) If the diameter is not as specified, check the oil clearance. 2. Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.002 mm (0.0008 inch) If the taper and out-of-round is greater than maximum, replace the crankshaft. Page 1713 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3519 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2496 Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Locations One Touch 2-4 Selector System Page 2854 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1717 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2036 Page 657 CHART 16 CHART 17 Page 728 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 792 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3886 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Ground Points Ground Points Page 1091 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 3412 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3159 Page 2729 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3952 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Replacement Clutch Slave Cylinder: Service and Repair Replacement REMOVAL 1. Disconnect clutch line. Using Special Service Tool (SST) 09023-00100, disconnect the line. use a container to catch the fluid. Torque: 15 N.m (11 ft. lbs.) 2. Remove 2 bolts and pull out release cylinder. Torque: 13 N.m (108 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed clutch system. Page 2603 Idle Speed/Throttle Actuator - Mechanical: Testing and Inspection THROTTLE OPENER INSPECTION INSPECT THROTTLE OPENER (a) Allow the engine to warm up to normal operating temperature. (b) Check idle speed. Idle speed: 700 ± 50 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop the engine. (f) Reconnect the vacuum hose to the throttle opener. (g) Start the engine and check that the idle speed returns to the correct speed. Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 4595 Input Shaft: Service and Repair Manual Transmission NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY Remove oil seal rings remove the 2 oil seal rings. INSPECTION 1. Inspect input shaft. a. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum Diameter: 47.59 mm (1.8736 inch) b. Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum Inside Diameter: 39.14 mm (1.5409 inch) If the inside diameter exceeds the Maximum, replace the input shaft. 2. Inspect synchronizer ring. Page 817 Page 3697 Page 3664 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3395 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (174 ft.lb) Page 4073 Page 4568 Fluid Pump: Service and Repair NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY 1. Check oil pump operation install the oil pump drive gear to the drive rotor, check that the drive rotor turns smoothly. 2. Remove relief valve and O-ring. a. Mount the oil pump plate in a vise. b. Remove the relief valve and O-ring from the oil pump body. Torque: 29.4 N.m (21 ft. lbs.) INSTALLATION HINT: Coat a new O-ring with gear oil and install it to the oil pump body. Page 1804 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3789 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2392 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4889 Remove the 2 mounting bolts and remove the caliper. Torque: 123 Nm (90 ft. lbs.) 4. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 pads. - 4 anti-squeal shims. INSTALLATION Installation is in the reverse order of removal. NOTE: After installation: Fill brake reservoir with brake fluid, bleed brake system. See: Brake Bleeding/Service and Repair - Check for leaks. Page 1561 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 94 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1806 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 24 If circuit is as specified, inspect the door lock signal and key-off power window signal. 2. INSPECT DOOR LOCK SIGNAL HINT: When the relay circuit is as specified, inspect the door lock signal. a. Connect the connector to the relay. b. Connect the positive (+) lead from the voltmeter to terminal 1 and the negative (-) lead to terminal c. Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. d. Reverse the polarity of the voltmeter leads. e. Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. Page 4767 ABS Main Relay: Description and Operation ABS Control (Solenoid) Relay CIRCUIT DESCRIPTION This relay supplies power to each Anti-Lock Brake System (ABS) solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. FAIL SAFE FUNCTION If trouble in the ABS control (solenoid) relay circuit, the Electronic Control Unit (ECU) cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Page 525 Page 1782 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3082 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Stop Light System Page 4283 Center Support: Testing and Inspection 1. Inspect center support bearing for wear or damage. ^ Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. 2. Inspect with double cardan joint propeller shaft. HINT: Double cardan joint is used on 4WD rear propeller shafts. a. Inspect the shaft for wear or damage. b. Inspect the double cardan joint for wear or damage. If any problem is found, replace the propeller shaft assembly. Page 2081 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2696 Warranty Information Applicable warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 2612 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Service and Repair Seals and Gaskets: Service and Repair If necessary, replace extension housing oil seal. a. Using a screwdriver, pry out the oil seal. b. Using SST 09950-60010 (09951-00570), 09950-70010 (09951-07150) and a hammer, drive in a new oil seal. Drive in depth: 45.6 ±0.5 mm (1.795 ±0.020 inch) Page 3078 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3483 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 1057 Timing Belt: Diagrams Page 2257 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 546 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3500 Page 4362 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1646 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Specifications Oil Pan: Specifications TIGHTENING SPECIFICATIONS Oil Pan To Cylinder Block ......................................................................................................................................................... 5.9 Nm (52 inch lbs.) Page 2417 Brake Signal: Testing and Inspection DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed. (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.) DETECTING CONDITION WIRING DIAGRAM Step 1 Page 2502 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3415 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 441 Brake Light Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1953 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1085 Drive Belt: Tools and Equipment Belt Tension Gauge: Nippondenso BTG-20 (95506-00020) or Borroughs No.BT-33-73F Diagrams Standard Value Of ECU Terminals Page 577 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 2803 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Specifications Firing Order: Specifications Firing Order: 1-2-3-4-5-6 Page 62 Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (2 Of 3) Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (3 Of 3) INSPECTION PROCEDURE Page 1619 REMOVAL 1. Remove timing belt. Refer to Engine. 2. Remove water inlet and thermostat. 3. Disconnect No. 2 oil cooler hose from water pump. 4. Remove water pump. INSTALLATION 1. Install water pump. (a) Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. ^ Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the water pump groove as shown in the illustration. Seal packing: Part No. 08826 - 00100 or equivalent. ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. Page 603 Glossary Of Term And Symbols (Part 1 Of 2) Specifications Shifter M/T: Specifications Shift Lever Housing Set Bolt ................................................................................................................ ................................................... 38 N.m (28 ft. lbs.) Control Shift Lever Retainer To: Transfer Adaptor .................................................................................................................................. ............................................... 18 N.m (13 ft. lbs.) Page 4354 P 1 PARK/NEUTRAL POSITION SW 4-Ground: Approx. 12 Volts with ignition SW ON position O 4-B, S 4-A O/D MAIN SW A-5-A-10, B-1-B-3: Open with O/D main SW at ON position Open with O/D main SW at OFF position S 5-A, B STOP LIGHT SW A-1-A-2, B-1-B-2: Closed with Brake Pedal Depressed E 5-A, E 6-D, E 7-C, E 8-B ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) IDL-E2: 0-3 Volts with Throttle Valve fully closed 9-14 Volts with Throttle Valve open VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with shift lever at expect 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at expect L position L4-E1: 10-14 Volts with Transfer Shift at H2 or H4 position 0 Volts with Transfer shift at L4 position OIL-W-E1: 0.1-4.9 Volts +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Locations Page 1295 Lifter / Lash Adjuster: Testing and Inspection INSPECT VALVE LIFTERS AND LIFTER BORES 1. Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.018 mm (1.2205 - 1.2212 inch). 2. Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 inch). 3. Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 - 0.052 mm (0.0009 - 0.0020 inch) Maximum oil clearance: 0.08 mm (0.0031 inch). If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 3224 Page 1906 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Fuel - Idle Speed Increased by Replacement ECM Idle Speed: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 3889 Locations-J/B No.1 Left Kick Panel (Fig 20) Specifications Ignition Cable: Specifications Maximum Resistance per Cord 25 K ohms Page 3635 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3123 (a) Install the VSV with the screw. (b) Connect the connector and 2 EVAP hoses to the VSV. Locations Blower Motor Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2007 Components For Removal And Installation Part 2 Of 2 Page 4384 d. Turn the reverse synchronizer pull ring, separate the pull ring and cone ring. e. Push the shifting key and spring, and remove the 3 shifting keys and springs to the reverse synchronizer ring. Page 4351 Position Of Parts In Instrument Panel (1 Of 2) (Fig 28) Page 3866 Fluid - A/T: Technical Service Bulletins A/T - Fluid Type T-IV Replaces Type T-II TRANSMISSION & CLUTCH TC003-98 June 19, 1998 Title: AUTOMATIC TRANSMISSION FLUID TYPE T-IV Models: ALL MODELS Introduction The introduction of Automatic Transmission Fluid type T-IV makes type T-II obsolete. Use type T-IV for all applications that specify ATF type T-II. Affected Vehicles ^ All vehicles with Automatic Transmissions specified to use ATF Types T-II or T-IV. Parts Information Warranty Information Page 2999 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 2675 CHART 18 CHART 19 Page 3005 Page 3510 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 2718 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSORS INSPECTION (Bank 1, Sensor 1, Bank 1 Sensor 2) INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connector. Bank 1 Sensor 1 Bank 1 Sensor 2 (b) Using an ohmmeter. measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F): 11 - 16 ohms If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Reconnect the oxygen sensor connector. Page 3317 a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Page 952 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 3077 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 783 Glossary Of Term And Symbols (Part 1 Of 2) Page 137 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3951 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4238 Front Drive Shaft Page 3443 HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER (a) Allow the engine to warm up to normal operating temperature. (b) Check idle speed. Idle speed: 700 ± 50 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop the engine. (f) Reconnect the vacuum hose to the throttle opener. (g) Start the engine and check that the idle speed returns to the correct speed. Page 2411 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3573 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 499 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 1533 Page 810 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 864 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2181 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3528 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 2623 Components For Removal And Installation Part 2 Of 2 Page 1933 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2801 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 883 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Page 2444 Page 1741 Thermostat: Service and Repair REMOVAL 1. Drain engine coolant. 2. Disconnect lower radiator hose. 3. Remove thermostat. (a) Remove the 3 nuts, water inlet and thermostat with gasket from the water pump. (b) Remove the gasket from the thermostat. INSTALLATION 1. Install thermostat. (a) Place a new gasket to the thermostat. Page 3311 a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Page 1259 Towing Information: Technical Service Bulletins Vehicle - Towing Guide ACCESSORIES AX004-99 March 19, 1999 Title: TOYOTA "DINGHY" TOWING GUIDE Models: All Models Introduction: The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome. CAUTION: Dinghy towing 6 vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer / Service Outlet for recommended towing equipment. Affected Vehicles - All Models Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Warranty Information Testing and Inspection Clutch Release Bearing: Testing and Inspection Inspect release bearing. Turn the bearing by hand while applying force in the axial direction. HINT: the bearing is permanently lubricated and re-quires no cleaning or lubrication. If necessary, replace the release bearing. Page 3641 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 511 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1405 Valve: Service and Repair Installation 1. Using Special Service Tool (SST) Valve Stem Oil Seal Replacer # 09201 - 41020 or equivalent, push in a new oil seal. NOTE: The intake valve oil seal is sliver and the exhaust valve oil seal is black. 2. Install these parts: (1) Valve. (2) Spring seat. (3) Valve spring. (4) Spring retainer. 3. Using SST Valve Spring Compressor # 09202 - 70020 (Attachment # 09202 - 00010) or equivalents, compress the valve spring and place the 2 keepers around the valve stem. Page 2579 Glossary Of Term And Symbols (Part 1 Of 2) Page 3375 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 1809 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3061 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4134 2. Assemble differential case. a. Install the proper thrust washers on the side gears. Washer thickness: 0.96 - 1.04 mm (0.0378 - 0.0409 inch) 1.06 - 1.14 mm (0.0417 - 0.0449 inch) 1.16 - 1.24 mm (0.0457 - 0.0488 inch) 1.26 - 1.34 mm (0.0496 - 0.0528 inch) HINT: Select thrust washers which will ensure that the backlash is within the specifications. b. Install the side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case. HINT: Align the holes of the differential case and pinion shaft. c. Measure the side gear backlash with holding one pinion gear toward the differential case. If the backlash is not within the specification, install side gear thrust washers with different thicknesses. Backlash: 0 - 0.20 mm (0 - 0.0079 inch) 3. Install straight pin and stake differential case. a. Using a pin punch and a hammer, install the straight pin through the differential case and hole of the pinion shaft b. Stake the differential case. 4. Install ring gear on differential case. a. Clean the contact surfaces of the differential case and ring gear. Page 2687 Page 2100 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 293 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2393 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 249 Power Door Lock Switch: Testing and Inspection Door Key Lock and Unlock Switch DOOR KEY LOCK AND UNLOCK SWITCH INSPECTION INSPECT SWITCH CONTINUITY LH: If continuity is not as specified, replace the switch. RH: Page 1030 Page 3796 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3554 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 35 ABS Control (Motor) Relay Circuit Inspection Procedure (Part 2 Of 2) CIRCUIT DESCRIPTION The Anti-Lock Brake System (ABS) control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the Electronic Control Unit (ECU) switches the ABS control (motor) relay ON and operates the ABS pump motor. FAIL SAFE FUNCTION If trouble occurs in the ABS control (motor) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Page 3626 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Supercharger - Squeak/Rattle Noises From Idler Pulley Supercharger: All Technical Service Bulletins Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 485 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 3567 Page 3905 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2528 Data Link Connector: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2053 CHART 22 Page 832 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Fuel Filler Cap: Testing and Inspection FUEL FILLER CAP INSPECTION 1. VISUALLY INSPECT FUEL TANK CAP Check if the cap and/or gasket are deformed or damaged. If necessary. repair or replace the cap. Page 3562 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2946 CHART 21 Page 2770 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2268 Ignition Switch: Testing and Inspection IGNITION SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1854 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4295 Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7 and the slip yoke grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5, and 6 grease fittings (double cardan joint). Specifications Clutch Release Fork: Specifications Release Fork Support .......................................................................................................................... ..................................................... 47 N.m (35 ft. lbs.) Page 760 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1032 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS (a) Assemble the holder and grommet. (b) Align the spline of the ignition coil with the spline of the holder and push in the cord. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration. (c) Check that the lock claw of the holder is engaged by lightly pulling the holder. 6. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS 7. REINSTALL AIR CLEANER HOSE Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 3013 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3225 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 513 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1954 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 521 Page 1659 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Diagram Information and Instructions Vehicle Speed Sensor/Transducer - Cruise Control: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2046 CHART 14 Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY 1. Check that there is no continuity between terminals with the switch OFF (float up). 2. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 3685 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4365 Electronically Controlled Transmission And A/T Indicator-Connectors Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 3056 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2889 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4130 18. W/ A.D.D.: Remove bearing. Using a brass bar and a hammer, remove the 2 bearings. Inspection Page 2397 Intake Air Temperature Sensor: Description and Operation Figure 1 Reference CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value and the higher the intake air temperature, the lower the thermistor resistance value (See Fig.1.). The intake air temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 964 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Page 1105 E. Install the new condenser brackets onto the condenser. Tightening Torque: 6x30 mm: 4.0 ft/lbf (5.4 N.m, 55 Kgf/cm) 6x16 mm: 7.2 ft/lbf (9.8 N.m, 100 Kgf/cm) 6x18 mm: 9.2 ft/lbf (12.6 N.m, 127 Kgf/cm) CAUTION: To prevent damage to the condenser's plastic supports please Install the 6 x 16 mm bolts first, the 6 x 18 mm bolts second, and the 6 x 30 mm bolts last. 2. Replace Liquid Tube # 1: A. Remove original liquid tube # 1. B. Install the new plastic clamp eight rows down and 110 mm in from the left as illustrated and then install new liquid tube, retaining the Page 1799 Glossary Of Term And Symbols (Part 1 Of 2) Page 3880 Page 2954 CHART 26 Page 3794 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3904 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check A/C Belt Drive Belt: Specifications A/C Belt DRIVE BELT New belt ............................................................................................................................................... ............................................................... 160 ± 25 lb. Used belt ............................................................................................................................................. ................................................................ 100 ± 20 lb. Page 2205 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Supercharger - Squeak/Rattle Noises From Idler Pulley Supercharger: Customer Interest Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Testing and Inspection Fuel Pump Relay: Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION CIRCUIT OPENING RELAY INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals ST and E1 If there no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there no continuity, replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals ST and E1. Page 3588 Page 838 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2713 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2135 Page 2064 CHART 28 Page 3859 Overdrive Brake Page 655 CHART 14 Page 2588 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4789 Wheel Speed Sensor: Specifications Mounting Bolt 71 in.lb Page 166 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4317 7: 2.400-2.450 mm (0.0945-0.0965 inch) 8: 2.450-2.500 mm (0.0965-0.0984 inch) b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 7. Check spider bearing. ^ Check that the spider baring moves smoothly. ^ Check the spider bearing axial play. Bearing axial play: Maximum 0.05 mm (0.0020 inch) HINT: Install new spider bearings on the shaft side in the procedure described above. Page 1982 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4149 6. Check drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.6 - 0.9 Nm (5.7 - 8.3 inch lbs.) 7. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) If necessary, disassemble and inspect the differential. Disassembly Page 2126 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2744 Engine Control-Connectors Page 3109 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. With ABS Brake Master Cylinder: Service and Repair With ABS Master Cylinder Components REMOVAL 1. Disconnect level warning switch connector. 2. Take out fluid with syringe. CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. Disconnect brake lines. Using Special Service Tool (SST) # 09023-00100, disconnect the 5 brake lines. Page 4543 Position Of Parts In Instrument Panel (1 Of 2) (Fig 28) Page 2933 CHART 2 CHART 3 CHART 4 Page 807 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3993 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3029 Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ...................................................... 1.1 mm (0.043 in.) Page 2481 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4045 Valve Body: Service and Repair VALVE BODY COMPONENTS VALVE BODY DISASSEMBLY 1. UNBOLT AND REMOVE DETENT SPRING 2. REMOVE MANUAL VALVE Page 396 Air Conditioning Switch: Service and Repair REMOVAL OF A/C SWITCH Using a screw driver, pry loose the clip and remove the A/C switch. REMOVAL HINT: Tape the screwdriver tip before use. A/C SWITCH INSTALLATION Installation is in the reverse order of removal. Page 1275 Camshaft Gear/Sprocket: Specifications Tightening Specifications Camshaft Timing Pulley Torque ................................................................................................................................................. ......................... 110 N-m (1,100 kgf-cm, 91 ft-lbf) Page 9 Antenna Relay: Testing and Inspection INSPECT ANTENNA MOTOR CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart. If circuit is as specified, replace the relay. Page 3695 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 1718 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4868 Brake Shoe: Testing and Inspection Fig. 4 Measuring Brake Shoe Lining Thickness LINING THICKNESS 1. Using a ruler, measure the shoe lining thickness. - Standard thickness: 6.0 mm (0.236 inch) - Minimum thickness: 1.0 mm (0.039 inch) 2. If the shoe lining is less than the minimum, or shows signs of uneven wear, replace the brake shoes. NOTE: If any of the brake shoes have to be replaced, replace all of the rear brake shoes in order to maintain even braking. 3. Inspect brake lining and drum for proper contact. NOTE: If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. Page 1279 Camshaft: Testing and Inspection INSPECT CAMSHAFTS 1. Inspect camshaft for runout. (a) Place the camshaft on V-blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 inch) If the circle runout is greater than the maximum, replace the camshaft. 2. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake: 42.31 - 42.41 mm (1.6657 - 1.6697 inch) Exhaust: 41.96 - 42.06 mm (1.6520 - 1.6559 inch) Minimum cam lobe height: Intake: 42.16 mm (1.6598 inch) Exhaust: 41.81 mm (1.6461 inch) If the cam lobe height is greater than the maximum, replace the camshaft. 3. Inspect camshaft journals. Using a micrometer, measure the journal diameter. Journal diameter: 26.949 - 26.965 mm (1.0610 - 1.0616 inch) If the journal diameter is not as specified, check the oil clearance. 4. Inspect camshaft gear spring. Page 207 Airbag Sensor Assembly Page 809 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3997 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 446 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Removal Valve: Service and Repair Removal 1. Using Special Service Tool (SST) Valve Spring Compressor # 09202 - 70020 (Attachment # 09202 - 00010) or equivalents, compress the valve spring and remove the 2 keepers. 2. Remove these parts: - Spring retainer. - Valve spring. - Valve. 3. Using needle-nose pliers, remove the oil seal. 4. Using compressed air and a magnetic finger, remove the spring seat by blowing air. NOTE: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. Page 828 Glossary Of Term And Symbols (Part 1 Of 2) Specifications Evaporative Emission Control Canister: Specifications Evaporative Canister Bracket to Body 23 ft.lb Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3291 (c) Remove the 2 bolts. and pull out the pressure regulator. (d) Remove the O-ring from the pressure regulator. FUEL PRESSURE REGULATOR INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new O-ring and install it to the pressure regulator. (b) Attach the pressure regulator to the LH delivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If it does not rotate smoothly, the O-ring may be pinched, so remove the pressure regulator and repeat steps (a) to (c) above. (d) Install the pressure regulator with the 2 bolts. Torque: 8 N.m (80 kgf.cm. 71 in.lbf) (e) Install the engine wire with the bolt. 2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR NOTICE: Be sure to insert the hose up to the stopper and clip it. 3. INSTALL INTAKE AIR CONNECTOR 4. INSTALL AIR CLEANER HOSE 5. CHECK FOR FUEL LEAKS Page 3651 Page 2948 Page 4245 NOTICE: Do not scratch the serration of the speed sensor rotor. 5. w/ Free wheel hub: Install new lock nut. a. Using SST 09318 - 12010, install and torque a new nut to the axle hub. Torque to 274 Nm (203 ft. lbs.) b. Using a chisel and hammer, stake the nut. 6. w/o Free wheel hub: Install bearing spacer. Using SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) and a press, install the bearing spacer. 7. Install new oil seal (Inside). a. Using SST 09527-17011 and a plastic hammer, install a new oil seal (inside). HINT: Strike the SST on its circumference evenly. b. Coat MP grease to the oil seal lip. Front Wheel Hub Bolt Page 896 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 2275 Glossary Of Term And Symbols (Part 1 Of 2) Page 2069 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Improvement ENGINE EG006-99 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma June 18, 1999 Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed 10 reduce the possibility of moisture contacting the ceramic element. Affected Vehicles ^ 1996-1999 model year Tacomas built before the VINs listed below. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Page 1973 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. How to Read Adjustment Chart Alignment: Service and Repair How to Read Adjustment Chart Adjustment Chart HOW TO READ ADJUSTMENT CHART a. Find the wheel alignment standard value applicable for the particular model. b. Mark the selected standard value on the adjustment chart. Electrical Specifications EGR Temperature Sensor: Electrical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) Resistance 64 - 97 K ohms at 122 deg F 11 - 16 K ohms at 212 deg F 2 - 4 K ohms at 302 deg F Page 298 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Page 297 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Page 3804 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 4728 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2040 CHART 5 CHART 6 Page 1855 Ignition Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 68 Inspection Procedure / ECT Communication Circuit - Solenoid #2 (3 Of 5) Inspection Procedure / ECT Communication Circuit - Solenoid #2 (4 Of 5) Inspection Procedure / ECT Communication Circuit - Solenoid #2 (5 Of 5) INSPECTION PROCEDURE Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) A/C Belt Drive Belt: Specifications A/C Belt DRIVE BELT New belt ............................................................................................................................................... ............................................................... 160 ± 25 lb. Used belt ............................................................................................................................................. ................................................................ 100 ± 20 lb. Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 4842 Type "B" Brake Pad A. Remove the clip, pins and anti-rattle spring/pad retainer clip. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 2296 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 1548 Torque: 5.4 Nm (48 inch lbs.) 21. Install No. 2 fan shroud. 22. Install and adjust drive belt for generator. 23. w/ A/C: install and adjust drive belt for A/C compressor. 24. Install and adjust drive belt for PS pump. 25. Connect upper radiator hose. 26. Fill engine with coolant. 27. Start engine check for leaks. 28. Install engine under cover. 29. Perform road test. Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 30. Recheck engine coolant level. Page 1961 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Page 1611 Adjusting Shim Selection Chart (Exhaust) Page 2202 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2668 CHART 8 CHART 9 Page 520 Page 1930 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Page 712 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 761 Vehicle Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 3342 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ...................................................... 1.1 mm (0.043 in.) Page 4249 Front Drive Shaft REMOVAL 1. Remove front wheel. Torque to 1 10 Nm (83 ft. lbs.) 2. Drain differential oil. 3. w/o Free wheel hub: remove drive shaft lock nut. a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. c. While apply the brakes, remove the lock nut. Torque to 235 Nm (174 ft. lbs.) 4. w/ Free wheel hub: remove free wheel hub. Page 4345 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Junction Block and Wire Harness Connector Page 3055 Glossary Of Term And Symbols (Part 1 Of 2) Page 1654 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1671 ** Warranty application is limited to correction of a problem based upon a customer's specific complaint Parts Information Repair Procedure Replace the Cowl Top Louver and the Heater Unit. Page 2564 Engine Control-Connectors Page 2995 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2624 Page 686 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Locations Fuse Block: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 4205 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4347 Locations-J/B No.1 Left Kick Panel (Fig 20) Page 713 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2552 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4612 1. Inspect drive sprocket thrust clearance. Using a feeler gauge, measure the drive sprocket thrust clearance. Standard Clearance: 0.10-0.25 mm (0.0039-0.0098 inch) Maximum Clearance: 0.25 mm (0.0098 inch) f the clearance exceeds the Maximum, replace the drive sprocket. 2. Remove high and low clutch sleeve assembly. a. Using a snap ring expander, remove the snap ring. b. Remove the clutch sleeve and 3 shifting keys. c. Using a press, remove the clutch hub, 2 key springs and key retainer. 3. Remove bearing, spacer and drive sprocket with front drive clutch sleeve. a. Using SST 09555-55010 and a press, remove the bearing. b. Remove these parts. ^ Spacer and ball. ^ Drive sprocket with front drive clutch sleeve. ^ Needle roller bearing. c. Remove the front drive clutch sleeve from the drive. INSPECTION Page 3384 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4547 Location Of Splice Points (Fig 38) System Outline This system frees or locks the Rear Differential according to the position of the Diff. Lock Control SW. The differential will lock only when the Rear Diff. Lock Detection SW is ON and the vehicle speed is at 8 kph (5 mph) or less. When the Rear Diff. Lock SW is switched from OFF position to ON position. The current flows to TERMINAL 4 of the 4WD control ECU. If the limit SW on the lock side inside the Rear Diff. Lock Motor is ON at this time, until the limit SW is turned OFF, the current flows from the 4WD fuse to TERMINAL 5 of the 4WD Control ECU --> TERMINAL 3 --> TERMINAL 3 of the Rear Diff. Lock Motor TERMINAL 2 TERMINAL --> 2 of the 4WD Control ECU --> TERMINAL 7 --> GROUND. This drives the Rear Diff. Lock Motor and locks the rear differential. When the rear differential locks. the rear diff. lock detection SW turns ON, lighting up the rear diff. lock indicator light in the combination meter. When the rear diff. lock SW is switched from ON position to OFF position, current to TERMINAL 4 of the 4WD control ECU is cut OFF. If the limit SW ON the free side inside the rear diff. lock motor is ON, until the limit SW is turned OFF the current flows from the 4WD fuse to TERMINAL 5 of the 4WD control ECU --> TERMINAL 2 --> TERMINAL 2 of the rear diff. lock motor --> TERMINAL 3 --> TERMINAL 3 of the 4WD control ECU --> TERMINAL 7 --> GROUND. This drives the rear diff. lock motor and frees the rear differential. When the rear differential is free, the rear diff. lock detection SW and the rear diff. lock indicator light in the combination meter are turned OFF. The diff. lock indicator light flashes when: ^ The rear diff. lock SW is switched to ON position during differential lock prohibition conditions (vehicle speed above 8 kph (5 mph)). ^ The rear diff. lock detection SW is turned OFF during operation of the rear diff. lock motor. Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Brake Components (4WD) REMOVAL 1. Remove front wheel. 2. Disconnect flexible hose. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (22 ft. lbs.) CAUTION: Install the flexible hose lock securely in the lock hole in the caliper. 3. Remove caliper. Page 3018 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1937 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2302 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 1964 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Replacement Drive/Propeller Shaft: Service and Repair Replacement REMOVAL 1. Remove front propeller shaft. a. Place matchmarks on the propeller shaft and differential flanges. b. Remove the 4 nuts, bolts and washers. Torque: 74 N.m (54 ft. lbs.) c. Suspend the front side of the propeller shaft. d. Place matchmarks on the propeller shaft and transfer flanges. e. Remove the 4 nuts and washers. Torque: 74 N.m (54 ft. lbs.) f. Remove the front propeller shaft. 2. Remove rear propeller shaft. a. Place matchmarks on the propeller shaft and transfer flanges. b. Remove the 4 nuts and washers. Torque: 74 N.m (54 ft. lbs.) c. Place matchmarks on the propeller shaft and differential flanges. d. Remove the 4 nuts, bolts and washers. Torque: 74 N.m (54 ft. lbs.) e. 3-joint type: Remove the 2 bolts and center support bearing from the frame crossmember. Torque: 36 N.m (27 ft. lbs.) f. Remove the rear propeller shaft. Page 4316 Yoke: Bearing With drill mark: With color mark (Red) No drill mark: No color mark 5. Install spider bearings. a. Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. d. Using SST 09332-25010, install new bearings on the spider. e. Using SST, adjust both bearings so that the snap ring grooves are at Maximum and equal widths. TMC 6. Install snap rings. a. Install 2 new snap rings of equal thickness which will allow 0-0.05 mm (0-0.0020 inch) axial play. HINT: Do not reuse the snap rings. Mark: Thickness 1: 2.100-2.150 mm (0.0827-0.0846 inch) 2: 2.150-2.200 mm (0.0846-0.0866 inch) 3: 2.200-2.250 mm (0.0866-0.0886 inch) Brown: 2.250-2.300 mm (0.0886-0.0906 inch) Blue: 2.300-2.350 mm (0.0906-0.0925 inch) 6: 2.350-2.400 mm (0.0925-0.0945 inch) Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 519 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3493 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2636 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3947 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 159 Engine Control Module: Testing and Inspection Related Diagnostic Procedures ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to the terminal +B of the ECM. WIRING DIAGRAM Step 1 Step 2 Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 4243 NOTICE: Be careful not to damage the oil seal and drive shaft boot. HINT: When it is difficult to disconnect the drive shaft, tap the drive shaft with a plastic hammer. INSTALLATION ^ Installation is in the reverse order of removal. HINT: After installation, bleed brake system, check ABS speed sensor signal and front wheel alignment. Disassembly / Assembly DISASSEMBLY 1. Remove oil seal (inside). a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. w/ Free wheel hub: Remove lock nut and ABS speed sensor rotor/spacer. a. Using a hammer and a chisel, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using SST 09318-12010, remove the lock nut. c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 3. Remove axle hub from steering knuckle. a. Remove the 4 bolts and shift the brake dust cover towards the hub side (outside). b. Using SST 09710-30021 (09710-03051), 09950-40010 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04030, 09957-04010, 09958-04010), remove the axle hub from the steering knuckle. c. w/o Free wheel hub: Remove the bearing spacer and ABS speed sensor rotor/spacer. 4. Remove oil seal (Outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 5. Remove bearing from steering knuckle. a. Using snap ring pliers, remove the snap ring. Page 231 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 734 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Specifications Engine Mount: Specifications TIGHTENING SPECIFICATIONS Engine Rear Mounting Bracket To Front Crossmember ....................................................................................................................... ............................................. 58 Nm (43 ft. lbs.) To Engine Rear Mounting Insulator ................................................................................................................................................ 18 Nm (13 ft. lbs.) Engine Front Mounting Insulator To Frame .......................................................................................................................................... 38 Nm (28 ft. lbs.) Engine Hanger No. 2 To RH Cylinder Head ......................................................................................................................................... 40 Nm (30 ft. lbs.) Engine Mounting Bracket To Cylinder Block ....................................................................................................................................... 44 Nm (32 ft. lbs.) Page 2772 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1836 (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 2980 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2820 Glossary Of Term And Symbols (Part 1 Of 2) Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 560 Glossary Of Term And Symbols (Part 1 Of 2) Page 3400 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 4296 Drive/Propeller Shaft: Specifications SERVICE SPECIFICATIONS Propeller Shaft Runout: Maximum ............................................................................................................................................. ........................................ 0.8 mm (0.031 inch) TORQUE SPECIFICATIONS Front Differential To Propeller Shaft ................................................................................................................................................... 74 N.m (54 ft. lbs.) Propeller Shaft To Transfer ........................................................................................ ......................................................................... 74 N.m (54 ft. lbs.) Rear Differential To Propeller Shaft .................................................................................................................................................... 74 N.m (54 ft. lbs.) Specifications Valve: Specifications VALVE CLEARANCE (COLD) Intake ................................................................................................................................................... ................ 0.13 - 0.23 mm (0.006 - 0.009 inch) Exhaust ..................................................................... ........................................................................................... 0.27 - 0.37 mm (0.011 - 0.014 inch) ADJUSTING SHIM (FOR REPAIR PART) Mark 2.500 ........................................................................................................................................... ................................. 2.500 mm (0.0984 inch) Mark 2.550 .................................................................. .......................................................................................................... 2.550 mm (0.1004 inch) Mark 2.600 .................................................................................................................................................... ........................ 2.600 mm (0.1024 inch) Mark 2.650 ........................................................................... ................................................................................................. 2.650 mm (0.1043 inch) Mark 2.700 .. .............................................................................................................................................................. ............ 2.700 mm (0.1063 inch) Mark 2.750 ....................................................................................... ..................................................................................... 2.750 mm (0.1083 inch) Mark 2.800 .............. .............................................................................................................................................................. 2.800 mm (0.1102 inch) Mark 2.850 .................................................................................................... ........................................................................ 2.850 mm (0.1122 inch) Mark 2.900 ........................... ................................................................................................................................................. 2.900 mm (0.1142 inch) Mark 2.950 .............................................................................................................. .............................................................. 2.950 mm (0.1161 inch) Mark 3.000 ..................................... ....................................................................................................................................... 3.000 mm (0.1181 inch) Mark 3.050 ..................................................................................................................... ....................................................... 3.050 mm (0.1201 inch) Mark 3.100 ............................................ ................................................................................................................................ 3.100 mm (0.1220 inch) Mark 3.150 ..................................................................................................................... ....................................................... 3.150 mm (0.1240 inch) Mark 3.200 ............................................ ................................................................................................................................ 3.200 mm (0.1260 inch) Mark 3.250 ..................................................................................................................... ....................................................... 3.250 mm (0.1280 inch) Mark 3.300 ............................................ ................................................................................................................................ 3.300 mm (0.1299 inch) VALVE OVERALL LENGTH STD: Intake ................................................................................................................................................... ............................ 95.15 mm (3.7461 inch) Exhaust ............................................................................ ................................................................................................ 94.90 mm (3.7362 inch) Minimum: Intake ................................................................................................................................................... ............................ 94.60 mm (3.7244 inch) Exhaust ............................................................................ ................................................................................................ 94.40 mm (3.7165 inch) VALVE FACE ANGLE ......................................................................................................................... ..................................................................... 44.5° STEM DIAMETER Intake ........................................................................................................................................................... 5.970 - 5.985 mm (0.2350 - 0.2356 inch) Exhaust ........................................................................................................................................................ 5.965 - 5.980 mm (0.2348 - 0.2354 inch) STEM OIL CLEARANCE STD: Intake ..................................................................................................................................................... 0.025 - 0.060 mm (0.0010 - 0.0024 inch) Exhaust .................................................................................................................................................. 0.030 - 0.065 mm (0.0012 - 0.0026 inch) Maximum: Intake ................................................................................................................................................... .............................. 0.08 mm (0.0031 inch) Exhaust ............................................................................ .................................................................................................. 0.10 mm (0.0039 inch) MARGIN THICKNESS STD ..................................................................................................................................................... ........................................ 1.0 mm (0.039 inch) Maximum ................................................................... .................................................................................................................. 0.5 mm (0.020 inch) Page 4715 Glossary Of Term And Symbols (Part 1 Of 2) Page 4549 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2629 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 2070 Warranty Information Applicable warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 1608 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using Special Service Tool (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) Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3887 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Junction Block and Wire Harness Connector Page 4247 Front Axle Hub / 4WD REMOVAL Page 758 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2981 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Crankshaft: Specifications DIMENSIONS Thrust Clearance STD ............................................................................................................................................................. 0.020 - 0.220 mm (0.0008 - 0.0087 inch) Maximum ............................................................................ ................................................................................................... 0.300 mm (0.0118 inch) Thrust Washer Thickness STD ............................................................................................................................................................. 2.440 - 2.490 mm (0.0961 - 0.0980 inch) Main Journal Oil Clearance No. 1 STD ....................................................................................................................................................... 0.020 - 0.038 mm (0.0008 - 0.0015 inch) U/S 0.25 ................................................................................................................................................ 0.019 0.059 mm (0.0007 - 0.0023 inch) Others STD ....................................................................................................................................................... 0.024 - 0.042 mm (0.0009 - 0.0017 inch) U/S 0.25 ................................................................................................................................................ 0.023 0.063 mm (0.0009 - 0.0025 inch) Maximum ............................................................................................................................................. .................................... 0.08 mm (0.0031 inch) Main Journal Diameter STD ................................................................................................................................................... 63.985 - 64.000 mm (2.5191 - 2.5197 inch) U/S 0.25 ............................................................................................................................................ 63.745 63.755 mm (2.5096 - 2.5100 inch) Main Bearing Center Wall Thickness No. 1: Mark 1 ................................................................................................................................................... 1.991 - 1.994 mm (0.0784 - 0.0785 inch) Mark 2 ................................................................................................................................................... 1.994 - 1.997 mm (0.0785 - 0.0786 inch) Mark 3 ................................................................................................................................................... 1.997 - 2.000 mm (0.0786 - 0.0787 inch) Mark 4 ................................................................................................................................................... 2.000 - 2.003 mm (0.0787 - 0.0789 inch) Mark 5 ................................................................................................................................................... 2.003 - 2.006 mm (0.0789 - 0.0790 inch) Others: Mark 1 ................................................................................................................................................... 1.989 - 1.992 mm (0.0783 - 0.0784 inch) Mark 2 ................................................................................................................................................... 1.992 - 1.995 mm (0.0784 - 0.0785 inch) Mark 3 ................................................................................................................................................... 1.995 - 1.998 mm (0.0785 - 0.0787 inch) Mark 4 ................................................................................................................................................... 1.998 - 2.001 mm (0.0787 - 0.0788 inch) Mark 5 ................................................................................................................................................... 2.001 - 2.004 mm (0.0788 - 0.0789 inch) Crank Pin Diameter STD ......................................................................................................................................................... 54.987 - 55.000 mm (2.1648 - 2.1654 inch) U/S 0.25 .................................................................................................................................................. 54.745 - 54.755 mm (2.1553 - 2.1557 inch) Circle Runout Maximum ............................................................................................................................................. .................................... 0.06 mm (0.0024 inch) Main Journal Taper And Out-Of-Round Maximum ............................................................................................................................................. .................................... 0.02 mm (0.0008 inch) Crank Pin Taper And Out-Of-Round Maximum ............................................................................................................................................. .................................... 0.02 mm (0.0008 inch) Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1225 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2215 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 4160 e. Place a dial indicator on the top of the adjusting nut on the ring gear side. f. Adjust the side bearing for zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move. g. Torque the adjusting nut 1 - 1.5 notches from the zero preload position. h. Using a dial indicator, adjust the ring gear backlash until it is within specification. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) HINT: The backlash is adjusted by turning the left and right adjusting nuts equal amounts. For example, loosen the nut on the left side one notch and torque the nut on the right side one notch. i. Torque the bearing cap bolts. Torque to 78 Nm (58 ft. lbs.) j. Recheck the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) k. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) Page 4229 Axle Shaft: Capacity Specifications Joint Grease Capacity: Outboard (Color = Black) ................................................................................................................................... 215 - 235 grams (7.58 - 8.29 ounce) Inboard (Color = Yellow) ................................................................................................................................... 230 - 250 grams (8.11 - 8.82 ounce) Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3381 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 856 Glossary Of Term And Symbols (Part 1 Of 2) Page 1563 (l) Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) (m)Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator. and plug the hose end. (o) Measure the fuel pressure at idle. Fuel pressure 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm. 21 psi) or more If pressure is not as specified. check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (s) Remove the other union bolt. 3 gaskets and fuel pipe from the delivery pipes. (t) Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 782 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 694 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 535 Glossary Of Term And Symbols (Part 1 Of 2) Page 1369 HINT: 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. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size according to these Formula or Charts: Page 887 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Page 3264 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2282 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2454 Glossary Of Term And Symbols (Part 1 Of 2) Page 208 Air Bag Control Module: Description and Operation Airbag Sensor Assembly The airbag sensor assembly is mounted on the floor inside the console box. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit and ignition control, drive circuit, etc. It receives signals from the airbag sensors and judges whether the SRS must be activated or not. Page 667 CHART 25 Page 2185 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 140 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4369 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Testing and Inspection Shift Interlock Solenoid: Testing and Inspection Inspect shift lock solenoid. a. Disconnect the solenoid connector. b. Using an ohmmeter, measure the resistance at each terminal. Standard Resistance 20-28 ohms. If resistance value is not as specified. Replace the solenoid. c. Apply battery positive voltage at each terminal. At this time, confirm that the solenoid operates. If the solenoid does not operate, replace the solenoid. Page 2558 Page 3266 Fuel Injector: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 30 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Specifications Reverse Idler Gear: Specifications Reverse Idler Gear Radial Clearance Standard Clearance ......................................................................................................................................... 0.040-0.082 mm (0.0016-0.0032 inch) Maximum Clearance .............................................................................................................................................................. 0.130 mm (0.0051 inch) Reverse Idler Gear And Shift Arm Clearance Standard .............................................................................................................................................................. 0.05-0.35 mm (0.0020-0.0138 inch) Maximum .................................................................................... ............................................................................................. 0.50 mm (0.0197 inch) Page 4875 Wheel Cylinder: Service and Repair Rear Brake Components (4WD) REPLACEMENT 1. Remove wheel and tire. 2. Remove brake drum, brake shoes, and hardware. 3. Disconnect the brake line. Use a container to catch the brake fluid. 4. Install in reverse order of removal, noting the following: - Brake line torque 15 Nm (11 ft. lbs.) - Mounting bolts 10 Nm (7 ft. lbs.) - Bleed brake system. See: Brake Bleeding/Service and Repair OVERHAUL Remove these parts from the wheel cylinder. 1. 2 boots. 2. 2 pistons. 3. 2 piston cups. 4. Spring. NOTE: Assemble in the reverse order. Page 2060 CHART 26 Page 1908 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2005 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1941 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 1882 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Testing and Inspection Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) Connect a voltmeter to terminals PTNK and E2 of the ECM and measure the output voltage under ambient atmospheric pressure. - Apply vacuum (2.0 kPa, 15 mm Hg. 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V - Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V - Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 2367 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 757 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3683 Glossary Of Term And Symbols (Part 1 Of 2) Page 2083 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3972 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4558 Differential: Description and Operation This system frees or locks the Rear Differential according to the position of the Diff. Lock Control SW. The differential will lock only when the Rear Diff. Lock Detection SW is ON and the vehicle speed is at 8 kph (5 mph) or less. When the Rear Diff. Lock SW is switched from OFF position to ON position. The current flows to TERMINAL 4 of the 4WD control ECU. If the limit SW on the lock side inside the Rear Diff. Lock Motor is ON at this time, until the limit SW is turned OFF, the current flows from the 4WD fuse to TERMINAL 5 of the 4WD Control ECU --> TERMINAL 3 --> TERMINAL 3 of the Rear Diff. Lock Motor TERMINAL 2 TERMINAL --> 2 of the 4WD Control ECU --> TERMINAL 7 --> GROUND. This drives the Rear Diff. Lock Motor and locks the rear differential. When the rear differential locks. the rear diff. lock detection SW turns ON, lighting up the rear diff. lock indicator light in the combination meter. When the rear diff. lock SW is switched from ON position to OFF position, current to TERMINAL 4 of the 4WD control ECU is cut OFF. If the limit SW ON the free side inside the rear diff. lock motor is ON, until the limit SW is turned OFF the current flows from the 4WD fuse to TERMINAL 5 of the 4WD control ECU --> TERMINAL 2 --> TERMINAL 2 of the rear diff. lock motor --> TERMINAL 3 --> TERMINAL 3 of the 4WD control ECU --> TERMINAL 7 --> GROUND. This drives the rear diff. lock motor and frees the rear differential. When the rear differential is free, the rear diff. lock detection SW and the rear diff. lock indicator light in the combination meter are turned OFF. The diff. lock indicator light flashes when: ^ The rear diff. lock SW is switched to ON position during differential lock prohibition conditions (vehicle speed above 8 kph (5 mph)). ^ The rear diff. lock detection SW is turned OFF during operation of the rear diff. lock motor. Page 2457 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1382 Valve Cover: Specifications Uniformly tighten. 6 N.m (53 inch lbs) Electrical Specifications Ignition Coil: Electrical Specifications Cold Resistance Hot Resistance Primary Coil 0.67 - 1.05 ohms at 14 - 122 deg F 0.85 - 1.23 ohms at 122 - 212 deg F Secondary Coil 9.3 - 16.0 K ohms at 14 - 122 deg F 11.7 - 18.8 K ohms at 122 - 212 deg F Page 3676 Ignition Switch: Testing and Inspection IGNITION SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 69 Cruise Control Module: Pinout Values and Diagnostic Parameters Standard Values Of ECU Terminals (1 Of 2) 5VZ-FE Page 2663 O2S Application Table O2S Failure Threshold Charts Page 1082 Drive Belt: Testing and Inspection Alternator GENERATOR DRIVE BELT INSPECT DRIVE BELT 1. Visually check the belt for excessive wear, frayed cords etc. HINT: Cracks on the ribbed side of the belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. 2. Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG 20 (95506-00020) or Borroughs No. BT-33-73F Drive belt tension: New belt: 160 ± 25 lb Used belt: 100 ± 20 lb If necessary, adjust the drive belt tension. HINT: New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After 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. - After installing a new belt, run the engine for approx. 5 minutes and then recheck the tension. Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL WARNING SWITCH 1. Check that there is no continuity between terminals with the switch OFF (float up). 2. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 2907 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Specifications Oil Cooler: Specifications TIGHTENING SPECIFICATIONS Oil Cooler Union To Cylinder Block ............................................................................................................................................. 30 Nm (22 ft. lbs.) Oil Cooler To Relief Valve ............................................................................................................................................................ 59 Nm (43 ft. lbs.) Oil Cooler Union Bolt To Cylinder Block ...................................................................................................................................... 59 Nm (43 ft. lbs.) Page 3310 Fuel Return Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened parts. INSPECTION INSPECT FUEL TANK AND LINE Page 2475 Glossary Of Term And Symbols (Part 1 Of 2) Page 4388 e. Select a snap ring that will allow minimum axial play. Mark A: 2.00-2.05 mm (0.0787-0.0807 inch) Mark B: 2.05-2.10 mm (0.0807-0.0827 inch) Mark C: 2.10-2.15 mm (0.0827-0.0846 inch) Mark D: 2.15-2.20 mm (0.0846-0.0866 inch) Mark E: 2.20-2.25 mm (0.0866-0.0886 inch) Mark F: 2.25-2.30 mm (0.0886-0.0906 inch) f. Using a snap ring expander, install the snap ring. Specifications Output Shaft: Specifications Gear Thrust Clearance Standard 1st gear .......................................................................................................................................................... 0.15-0.45 mm (0.0059-0.0177 inch) 2nd and 3rd gears .......................................................................................................................................... 0.10-0.25 mm (0.0039-0.0098 inch) Maximum 1st gear ................................................................................................................................................ ............................... 0.50 mm (0.0197 inch) 2nd and 3rd gears .......................................................... ..................................................................................................... 0.30 mm (0.0118 inch) Gear Radial Clearance Standard: 1st Gear ..................................................................................................................................................... 0.020-0.073 mm (0.0008-0.0029 inch) 2nd and 3rd Gears ..................................................................................................................................... 0.015-0.068 mm (0.0006-0.0027 inch) Maximum: 1st Gear ............................................................................................................................................... ............................. 0.160 mm (0.0063 inch) 2nd and 3rd Gears ............................................................................................................................................................ 0.160 mm (0.0063 inch) Output Shaft Journal Minimum Diameter: 1st gear ................................................................................................................................................ ........................... 38.860 mm (1.5299 inch) 2nd gear ......................................................................... ................................................................................................ 46.860 mm (1.8449 inch) 3rd gear ..... .............................................................................................................................................................. ....... 37.860 mm (1.4905 inch) Shaft Runout. Maximum ............................................................................................................................................. .................................... 0.06 mm (0.0024 inch) Clearance Between The Synchronizer Ring Back And Gear Spline End. Minimum .............................................................................................................................................. ....................................... 0.8 mm (0.031 inch) Flange Thickness ................................................................................................................................ ........................................... 4.70 mm (0.1850 inch) Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3337 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3894 Position Of Parts In Instrument Panel (2 Of 2) (Fig 29) Relay Blocks Relay Blocks Page 2580 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3355 Idle Speed/Throttle Actuator - Mechanical: Testing and Inspection THROTTLE OPENER INSPECTION INSPECT THROTTLE OPENER (a) Allow the engine to warm up to normal operating temperature. (b) Check idle speed. Idle speed: 700 ± 50 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop the engine. (f) Reconnect the vacuum hose to the throttle opener. (g) Start the engine and check that the idle speed returns to the correct speed. Page 1370 Adjusting Shim Selection Chart (Intake) Page 1927 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3488 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4233 Axle Shaft: Locations Axle Shaft Assembly, Constant Velocity Type Front Drive Shaft Page 845 Page 3457 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 953 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 4727 Page 2750 Standard Values Of ECM Terminals Chart 2 Of 2 Page 4215 a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 4. REMOVE OIL SEAL Using SST, remove the oil seal. SST 09350-32014 (09308-10010) 5. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: REMOVE OIL SLINGER 6. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 Locations Fuse: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 149 Standard Values Of ECM Terminals Chart 2 Of 2 Page 1890 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 2531 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 570 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2878 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 549 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Page 457 Combination Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY Reference If continuity is not as specified, replace the switch. Page 2848 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2066 CHART 30 Page 1106 original clamp. Tightening Torque: @Receiver: 4.0 ft/lbf (5.4 N.m, 55 Kgf/cm) @Condenser: 7.2 ft/lbf (9.8 N.m, 100 Kgf/cm) C. Install 40 x 70 mm packing on Liquid Tube No.2 as illustrated. The seam should face forward as shown. 3. Perform Gas Charge and Leak Check procedures as explained in the A/C Installation Manual. Page 1617 Water Pump: Service and Repair Page 4699 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3909 Electronically Controlled Transmission And A/T Indicator (Part 2 Of 3) Specifications Synchronizer Ring: Specifications Synchronizer Ring To Gear Clearance: Minimum .............................................................................................................................................. ............................................. 0.8 mm (0.031 inch) Page 108 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3557 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3520 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4683 Electronically Controlled Transmission And A/T Indicator (Part 3 Of 3) Page 1811 Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 2693 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Modified ENGINE EG011-99 October 15, 1999 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed to reduce the possibility of moisture contacting the ceramic element. Applicable Vehicles ^ 1996-1999 model year Tacomas built before the VIN listed. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. Page 2670 CHART 11 Page 3746 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Mechanical Specifications Differential: Mechanical Specifications Straight Screw Plug For Ring Gear ...................................................................................................................................................... 18.6 N.m (14 ft. lbs.) Page 4662 Locations-J/B No.1 Left Kick Panel (Fig 20) Electrical Specifications Oxygen Sensor: Electrical Specifications Bank 1: Sensor 1, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1: Sensor 2, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1 Sensor 1 Bank 1 Sensor 2 Valve Cover Oil Baffle - Damage Prevention Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention ENGINE EG007-02 Title: GENERAL MAINTENANCE TIP Models: All '93 - '03 Models March 22, 2002 Introduction To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These devices can place stress on the baffle, and bend or break it during the oil fill process. Applicable Vehicles ^ All 1993 - 2003 model year Toyota vehicles. Oil Filling Procedure Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral damage occurs. Warranty Information Page 784 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2850 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3790 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Specifications Clutch: Specifications OVERDRIVE DIRECT CLUTCH Clutch Drum Bushing Inside Diameter, Maximum .......................................................................................................................... 27.11 mm (1.0673 inch) Overdrive Direct Clutch Piston Stroke Tacoma, 4 Runner ................................................................................................................................................. 1.77 2.07 mm (0.0697 - 0.0815 inch) Previa Toyota T100, Land Cruiser ........................................................................................................................ 1.85 - 2.15 mm (0.0728 - 0.0846 inch) Overdrive Planetary Gear Bushing, Maximum ................................................................................................................................ 11.27 mm (0.4437 inch) Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) DIRECT CLUTCH Piston Stroke Tacoma, 4 Runner ................................................................................................................................................. 1.03 1.33 mm (0.0405 - 0.0524 inch) Previa, Toyota T100, Land Cruiser ....................................................................................................................... 1.37 - 1.60 mm (0.0539 - 0.0630 inch) Drum Bushing Inside Diameter ....................................................................................................................................................... 53.99 mm (2.1256 inch) FORWARD CLUTCH Pack Clearance Tacoma, 4 Runner ................................................................................................................................................. 0.40 0.80 mm (0.0157 - 0.0315 inch) Previa, Toyota T100 .............................................................................................................................................. 0.50 0.90 mm (0.0197 - 0.0354 inch) Land Cruiser .......................................................................................................................................................... 0.60 - 1.00 mm (0.0236 - 0.0394 inch) OVERDRIVE BRAKE Piston Stroke Tacoma, 4 Runner ................................................................................................................................................. 1.32 1.62 mm (0.0520 - 0.0638 inch) Previa, Toyota T100 .............................................................................................................................................. 1.40 1.70 mm (0.0551 - 0.0069 inch) Land Cruiser .......................................................................................................................................................... 1.75 - 2.05 mm (0.0689 - 0.0807 inch) SECOND BRAKE Pack Clearance Tacoma, 4 Runner ................................................................................................................................................. 0.50 1.76 mm (0.0197 - 0.0693 inch) Previa, Toyota T100, Land Cruiser ....................................................................................................................... 0.62 - 1.98 mm (0.0244 - 0.0780 inch) FIRST AND REVERSE BRAKE Pack Clearance Tacoma, 4 Runner ................................................................................................................................................. 0.50 1.02 mm (0.0197 - 0.0402 inch) Previa, Toyota T100 .............................................................................................................................................. 0.60 1.12 mm (0.0244 - 0.0441 inch) Land Cruiser .......................................................................................................................................................... 0.70 - 1.22 mm (0.0276 - 0.0480 inch) Page 2105 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 313 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2337 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 904 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 3903 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION 1. Disconnect the connector from the sender gauge. 2. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. 3. Ground terminal on the wire harness side connector through a 3.4 W test bulb. 4. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 362 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2778 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2781 Page 4310 Universal Joint: Specifications Spider Bearing Axial Play .................................................................................................................... ............................................. 0.05 mm (0.0020 inch) Bearing Cup Outer Diameter: Mark None ............................................................................................................................................................ 29.008-29-021 mm (1.1420-1.1426 inch) Red .............................................................................................................................................................. 29.028-29-041 mm (1.1428-1.1433 inch) Bearing Hole Inner Diameter: Mark None ............................................................................................................................................................ 29.000-29.020 mm (1.1417-1.1425 inch) Drill ............................................................................................................................................................. 29.021-29.042 mm (1.1426-1.1434 inch) Page 3410 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4487 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Page 3537 Ignition Cable: Testing and Inspection HIGH-TENSION CORDS INSPECTION 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS Disconnect the high - tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS (a) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (b) Disconnect the high-tension cord at the grommet. DO NOT pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high-tension cord is disconnected. 4. INSPECT HIGH-TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 K ohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. Page 1696 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Front Wheel Speed Sensor: Specifications Mounting bolt 71 in.lb Page 107 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4539 Locations-J/B No.1 Left Kick Panel (Fig 20) Page 1224 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2200 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2823 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 542 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4590 Page 4902 Brake Proportioning/Combination Valve: Pressure, Vacuum and Temperature Specifications - With the front pressure @ 1,960 kPa (285 psi) the rear pressure should be 1,960 kPa (285 psi). - With the front pressure @ 3,920 kPa (570 psi) the rear pressure should be 2,352 kPa ± 196 (342 ± 28.5 psi). - With the front pressure @ 6,860 kPa (997.5 psi) the rear pressure should be 2,940 kPa ± 343 (427.5 ± 50 psi). Page 3656 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3494 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Description and Operation Fillpipe Restrictor: Description and Operation Fillpipe Restrictor The fillpipe restrictor is used to prevent leaded fuel from being added to the fuel tank. The gasoline pump for unleaded fuel has a smaller nozzle. The fillpipe restrictor will only allow the unleaded type nozzle to be inserted into the fuel tank. Symptom Related Diagnostic Procedures One Touch 2-4 Selector System Page 4044 Lower Valve Body Page 2230 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 737 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3102 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1535 (a) Visually check the seal portion of the tensioner for oil leakage. NOTE: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. (b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. CAUTION: Never hold the tensioner push rod facing downward. (c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. Page 2735 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1978 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4827 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plates. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the flow chart. G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illustration. H. Install the brake pads with the anti-squeal shims. I. If equipped with anti-squeal spring: Install the anti-squeal springs. J. Press the piston in firmly and install the brake caliper. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. K. Install the wheel assembly. 2. Fixed Type Brake Caliper There are two types of brake pads: Page 652 CHART 10 Connecting Rod Connecting Rod: Specifications Connecting Rod DIMENSIONS Thrust Clearance Standard ...................................................................................................................................................... 0.150 - 0.330 mm (0.0059 - 0.0130 inch) Maximum ............................................................................ ................................................................................................... 0.380 mm (0.0150 inch) Bearing Center Wall Thickness Mark 1 ......................................................................................................................................................... 1.484 - 1.488 mm (0.0584 - 0.0586 inch) Mark 2 ......................................................................................................................................................... 1.488 - 1.492 mm (0.0586 - 0.0587 inch) Mark 3 ......................................................................................................................................................... 1.492 - 1.496 mm (0.0587 - 0.0589 inch) Oil Clearance Standard ...................................................................................................................................................... 0.024 - 0.053 mm (0.0009 - 0.0021 inch) U/S 0.25 ...................................................................................................................................................... 0.023 - 0.069 mm (0.0009 - 0.0027 inch) Maximum ............................................................................ ..................................................................................................... 0.08 mm (0.0031 inch) Rod Bend Maximum Per 100 mm (3.94 inch) .......................................................................................................................................... 0.05 mm (0.0020 inch) Rod Twist Maximum Per 100 mm (3.94 inch) .......................................................................................................................................... 0.15 mm (0.0059 inch) Bushing Inside Diameter ..............................................................................................................................22.005 - 22.017 mm (0.8663 - 0.8668 inch) Piston Pin Diameter .................................................................................................................................... 21.997 22.009 mm (0.8660 - 0.8665 inch) Bushing Oil Clearance Standard ...................................................................................................................................................... 0.005 - 0.011 mm (0.0002 - 0.0004 inch) Maximum ............................................................................ ..................................................................................................... 0.05 mm (0.0020 inch) Bolt Outer Diameter Standard ...................................................................................................................................................... 7.860 - 8.000 mm (0.3094 - 0.3150 inch) Minimum ............................................................................. .................................................................................................. 7.600 mm (0.2992 inch) TIGHTENING SPECIFICATIONS Connecting Rod Cap To Connecting Rod 1st Pass ............................................................................................................................................... ............................................ 25 Nm (18 ft. lbs.) 2nd Pass ................................................................... .................................................................................................................... Turn Additional 90° Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Page 2034 Page 716 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3578 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3581 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4424 2. Inspect each gear radial clearance. Using a dial indicator, measure the radial clearance of each gear. Standard Clearance: 1st Gear: 0.020-0.073 mm (0.0008-0.0029 inch) 2nd and 3rd Gears: 0.015-0.068 mm (0.0006-0.0027 inch) Maximum Clearance: 1st Gear: 0.160 mm (0.0063 inch) 2nd and 3rd Gears: 0.160 mm (0.0063 inch) If the clearance exceeds the Maximum, replace the gear, needle roller bearing or shaft. 3. Remove 5th gear, output shaft center bearing and 1st gear assembly. a. Using a press, remove the 5th gear, center bearing, thrust washer and 1st gear. b. Remove the synchronizer ring. c. Remove the straight pin and needle roller bearing. d. Remove the spacer. 4. Remove reverse gear assembly and 1st gear assembly. a. Using 2 screwdrivers and a hammer, tap out the snap ring. b. Using a press, remove the reverse gear assembly and 2nd gear assembly. c. Remove the needle roller bearing. 5. Remove reverse gear, shifting key and spring from clutch hub No.1 a. Remove the reverse gear from the clutch hub No.1. b. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs. Page 160 Step 3 Step 4 Step 5 Step 6 Page 4765 ABS Control (Motor) Relay Circuit Inspection Procedure (Part 1 Of 2) Page 4615 4. Insert high and low clutch hub onto clutch sleeve. a. Install the clutch hub and 3 shifting keys onto the clutch sleeve. b. Install the-2-shifting key springs under the shifting keys. NOTICE: Install the key springs positioned so that their end gaps are not in line. 5. Install high and low clutch hub assembly. Using SST 09316-60011 (09316-00011) and a hammer, drive in a new key retainer. NOTICE: Be careful not to deform or damage the key retainer. b. Using a press, install the high and low clutch hub assembly. 6. Install snap ring. Select a snap ring that will allow minimum axial play and install it to the shaft. Mark: Thickness A: 2.10-2.15 mm (0.0827-0.0846 inch) B: 2.15-2.20 mm (0.0846-0.0866 inch) C: 2.20-2.25 mm (0.0866-0.0886 inch) D: 2.25-2.30 mm (0.0886-0.0906 inch) E: 2.30-2.35 mm (0.0906-0.0925 inch) F: 2.35-2.40 mm (0.0925-0.0945 inch) G: 2.40-2.45 mm (0.0945-0.0965 inch) H: 2.45-2.50 mm (0.0965-0.0984 inch) Page 3667 Page 858 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4440 Reverse Idler Gear: Service and Repair Assembly Install synchronizer ring assembly to hub sleeve No.3. a. Put the key spring to the hole of the shifting key. b. Push the 3 shifting keys with the 3 key springs to the reverse synchronizer ring. c. Install the synchronizer cone ring to synchronizer pull ring and turn the pull ring. d. Install the 5th synchronizer ring. e. Install the reverse synchronizer ring. Page 4557 Rear Differential Lock (Part 2 Of 2) Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1648 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1956 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1284 (a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (b) Remove the 5 bearing caps, oil seal and intake camshaft. 2. Remove camshafts of LH cylinder head. CAUTION: 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, 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, these steps should be carried out. A. Exhaust: (a) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub-gear to the main gear with a service bolt (See step (c) in step A in step 25). (c) Uniformly loosen and remove the 8 bearing cap bolts, in several passes, in the sequence shown. (d) Remove the 4 bearing caps and exhaust camshaft. B. Intake: (a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (b) Remove the 5 bearing caps, oil seal and intake camshaft. NOTE: Page 536 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3330 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1471 Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration with SAE 5W-30 being the preferred engine oil. Oil capacity: Drain and refill w/ Oil filter change: 5.2 liters (5.5 US qts.) (c) Reinstall the oil filler cap. 4. Start engine and check for oil leaks. 5. Check engine oil level. Page 3497 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 648 CHART 2 CHART 3 CHART 4 Page 3501 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 1649 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3021 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3595 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 3586 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 3348 Step 2 Step 3 Step 4 INSPECTION PROCEDURE Page 3692 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3057 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 341 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3127 Evaporative Emission Control Canister: Testing and Inspection CHARCOAL CANISTER INSPECTION 1. REMOVE CHARCOAL CANISTER 2. REMOVE VSV 3. VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. 4. CHECK FOR CLOGGED FILTER. AND STUCK CHECK VALVE AND DIAPHRAGM (a) Install the plugs to ports A and B. (b) While holding port C closed, blow air (1.47 kPa, 15gf/sq.cm. 0.21 psi) into port D and check that air flows from port E. (c) While holding port C and port E closed, blow air (1.47 kPa. 15 gf/sq.cm, 0.21 psi) into port D and check that air does not flow from port F. (d) Apply vacuum (2.94 kPa, 22 mmHg, 0.87 in.Hg) to port C. check that the vacuum does not decrease when port F is closed and check that the vacuum decreases when port F is released. Page 695 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3748 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 322 Brake Switch (Cruise Control): Testing and Inspection STOP LIGHT SWITCH CIRCUIT CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Stop Light Switch Circuit WIRING DIAGRAM Inspection Procedure / Stop Light Switch Circuit (1 Of 4) Page 329 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2340 6. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) 7. REINSTALL SPARK PLUGS Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 8. REINSTALL IGNITION COILS 9. RECONNECT HIGH-TENSION CORDS Removal Piston: Service and Repair Removal 1. Remove piston and connecting rod assemblies. (a) Using a ridge reamer, remove the all carbon from the top of the cylinder. (b) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: ^ Keep the bearings, connecting rod and cap together. ^ Arrange the piston and connecting rod assemblies in correct order. Page 4152 d. Remove the differential case and bearing outer race from the carrier. HINT: Tag the bearing outer races to show the location for reassembly. 5. Remove drive pinion. 6. Remove drive pinion rear bearing. Using SST 09950-00020 and a press, remove the bearing from the drive pinion. HINT: If the drive pinion or ring gear are damaged, replace them as a set. 7. Remove front and rear bearing outer races. Using a brass bar and a hammer, remove the outer races and adjusting washer from the carrier. NOTICE: Do not remove the outer races except when replacing the bearings. HINT: Measure the adjusting washer and note the thickness. 8. Remove ring gear. a. Place matchmarks on the ring gear and differential case. b. Remove the 12 ring gear set bolts. c. Using a plastic hammer, tap on the ring gear to separate it from the differential case. 9. Check differential case runout. a. Install the differential case in the differential carrier. Page 3086 Page 1700 Radiator Cap: Specifications RELIEF VALVE OPENING PRESSURE Standard .............................................................................................................................................. .......................... 74 - 103 kPa (10.7 - 14.9 psi) Minimum ................................................................... .......................................................................................................................... 59 kPa (8.5 psi) Page 2794 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2798 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4167 Differential Carrier (3RZ-FE, 5VZ-FE w/o Differential Lock) 1. Assemble differential case. a. Install the proper thrust washer to the side gears. Washer thickness: Page 605 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential TYPE.................................................................................................................................................... ........................................................................ GL-5* CAPACITY Front .............................................. .............................................................................................................................................................. .. 1.10L (1.16 Qt) With A.D.D [1] .......................................................................................................... ................................................................................... 1.15L (1.22 Qt) VISCOSITY Below -18° C (0° F) ......................................................................................................................................................... ............................... 80W, 80W-90 Above -18° C (0° F) ...................................................................... ..................................................................................................................................... 90 With A.D.D .............................................................................................................................................................. ................................................. 75W-90 [1] Automatic Disconnecting Differential Rear Differential Rear Differential Fluid Capacity* 4WD Extra Long Model: 2.05L (2.17 Qt) w/ Differential Lock Short Model: 2.65L (2.80 Qt) w/ Differential Lock Extra Long Model: 2.95L (3.18 Qt) w/o Differential Lock: 2.55L (2.69 Qt) Fluid level should be less than 0.20 in (5mm) below the fill plug. *Capacities are approximate Page 1860 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3267 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1149 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Page 2445 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 2243 Page 3871 Fluid - A/T: Service and Repair 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 4434 Reverse Idler Gear: Testing and Inspection 1. Inspect 5th gear radial clearance. a. Install the spacer, counter 5th gear and needle roller bearings. b. Using a dial indicator, measure the counter 5th gear radial clearance. Standard Clearance: 0.015-0.068 mm (0.0006-0.0027 inch) Maximum Clearance: 0.160 mm (0.0063 inch) If the clearance exceeds the Maximum, replace the gear bearing or shaft. 2. Inspect counter gear. Using a micrometer, measure the outer diameter of the counter gear journal. Minimum Diameter: 27.860 mm (1.0968 inch) If the outer diameter is less than the minimum, replace the counter gear. 3. Inspect 5th synchronizer ring. a. Check for wear or damage. Page 2895 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3407 Glossary Of Term And Symbols (Part 1 Of 2) Page 435 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness And Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator to Fuel Rail 71 in.lb Page 4076 Clutch Slave Cylinder: Service and Repair Overhaul DISASSEMBLY 1. Pull out boot with push rod. 2. Remove piston. Using compressed air, remove the piston with the spring from the cylinder. ASSEMBLY 1. Coat piston with lithium soap base glycol grease, as shown. 2. Install piston with spring into cylinder. 3. Install boot with push rod to cylinder. Page 2945 Page 147 Page 3924 Rear Planetary Gear Page 564 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2711 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 548 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Page 1522 Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING SWITCH 1. Disconnect the connector from the switch. 2. Check that there is continuity between terminal and ground with the engine stopped. 3. Check that there is no continuity between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2737 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Fuel Pump Relay: Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION CIRCUIT OPENING RELAY INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals ST and E1 If there no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there no continuity, replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals ST and E1. Page 3628 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 172 (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Specifications Intake Air Plenum: Specifications DIMENSIONS Air Intake Chamber: Warpage (Maximum) ......................................................................................................................................................... 0.10 mm (0.0039 inch) Intake Air Connector: Warpage (Maximum) ......................................................................................................................................................... 0.10 mm (0.0039 inch) TIGHTENING SPECIFICATIONS Air Intake Chamber To Intake Air Connector ................................................................................................................................ 18 Nm (13 ft. lbs.) Air Intake Chamber Stay To LH Cylinder Head .............................................................................................................................. 40 Nm (30 ft. lbs.) Intake Air Connector To Intake Manifold ...................................................................................................................................... 18 Nm (13 ft. lbs.) Page 2597 Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics Component Inspection IAC VALVE INSPECTION INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is closed. (b) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is open. If operation is not as specified, replace the IAC valve. On-Vehicle Inspection IDLE AIR CONTROL (IAC) VALVE ON-VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION (a) Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed is kept at approx. 1000 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST from the DLC1. SST 09843-18020 2. INSPECT IAC VALVE RESISTANCE NOTICE: Cold and Hot in the following sentences express the temperature of the coils themselves. Cold is from - 10°C (14°F) to 50°C (122°F) Page 4800 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 2110 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3272 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Specifications Engine Oil Pressure: Specifications OIL PRESSURE (NORMAL OPERATING TEMPERATURE) At Idle Speed ....................................................................................................................................... ........................................ 29 kPa (4.3 psi) or more At 3,000 rpm ....................................................... .................................................................................................................... 245 - 520 kPa (36 - 75 psi) Page 2477 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Environmental Impact Information Engine Oil: Environmental Impact Information CAUTION: - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. Page 1814 Standard Values Of ECM Terminals Chart 1 Of 2 Page 4934 Brake Master Cylinder: Service and Repair Without ABS NOTE: For cars with ABS see ABS Master Cylinder. See: Master Cylinder Components REMOVAL 1. Disconnect level warning switch connector. 2. Take out fluid with syringe. CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. Disconnect brake lines. Page 4066 Page 4098 Pilot Bearing: Service and Repair If necessary, replace pilot bearing. a. Remove the 2 bolts at diametrically opposite points. b. Using SST 09303-35011, remove the pilot bearing. c. Using SST 09304-30012 and hammer, install the pilot bearing. HINT: After assembling the pilot bearing to the hub, install sure that it rotates smoothly. d. Install 2 new bolts. Torque: 85 N.m (63 ft. lbs.) Page 1907 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2926 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY 1. Check that there is continuity between terminals with the switch ON (switch pin released). 2. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 148 Engine Control Module: Connector Views Standard Values Of ECM Terminals Chart 1 Of 2 Page 3280 Fuel Injector: Service and Repair Components For Removal And Installtion Part 1 Of 2 Page 141 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3856 Clutch: Diagrams Direct Clutch Page 2413 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1199 Loosen/Tighten Bleeder Plug Insert other end of the tube in a half-full container of brake fluid. NOTE: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. Bleed brake line. (a) Slowly depress the brake pedal several times. (b) While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning (LSP) & By-Pass Valve (BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 Page 3763 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3110 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 321 Stop Light Switch Circuit Page 841 Page 4136 b. Using SST 09950-60020 (09951-007903, 09950-70010 (09951-07150) and a press, install the bearing outer race. c. Install a new plate washer to the differential carrier. d. Using SST 09950-60020 (09951-00790), 09950-70010 (09951-07150) and a press, install the bearing outer race. 7. Install drive pinion front and rear bearing outer races. Using SST 09570-22011, install the outer races. 8. Install drive pinion front bearing. a. Install the washer on the drive pinion. HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary. b. Using SST 09506-30012 and a press, install the front bearing onto the drive pinion. 9. Temporarily adjust drive pinion preload. a. Install the drive pinion and oil slinger. HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern. Page 2950 Capacity Specifications Coolant: Capacity Specifications A/T Engine Coolant .................................................................................................................................... ............................................. 9.5 liters (10.0 US qts.) M/T Engine Coolant .................................................................................................................................... .............................................. 9.7 liters (10.3 US qts.) Page 3058 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2438 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 487 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3634 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2344 Compression Check: Testing and Inspection NOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature. 2. Remove ignition coils. 3. Remove spark plugs. Using a 16 mm plug wrench, remove the 6 spark plugs. 4. Check cylinder compression pressure. (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (174 psi) or more. Minimum pressure: 1,000 kPa (145 psi) Difference between each cylinder: 100 kPa (15 psi) or less. (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. Reinstall spark plugs. Torque: 20 Nm (14 ft. lbs.) 6. Reinstall ignition coils. Page 2795 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3191 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the 6 bolts and disconnect the No.2 timing belt cover. (d) Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. (e) Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (f) Wipe off any splattered gasoline. (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Reconnect the negative (-) terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high. replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections - Fuel pump - Fuel filter - Fuel pressure regulator (k) Disconnect the TOYOTA hand-held tester from the DLC3. Page 4126 b. Using a hammer handle, remove the actuator. 2. Remove differential tube. W/ A.D.D.: a. Remove the 4 torx bolts. Torx socket E14 (Part No. 09044-00010 or locally manufactured tool) b. Using a plastic hammer, tap on the differential tube to remove it. c. Remove the sleeve. d. Remove the O-ring from the differential tube. W/O A.D.D.: a. Remove the 4 bolts. b. Using a plastic hammer, tap on the differential tube to remove it. 3. W/ A.D.D.: Remove clutch case. a. Remove the 2 torx bolts. Torx socket E14 (Part No.09044 - 00010 or locally manufactured tool) b. Using a plastic hammer, tap on the clutch case to remove it. 4. Remove side oil seal. Using SST 09308-00010, remove the side oil seal. 5. W/ A.D.D.: Remove intermediate shaft No. 1. Using SST 09350-20015, 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04010, 09957-04010, 09958-04010), remove the intermediate shaft No. 1. 6. Remove companion flange. Page 1590 Ignition Cable: Testing and Inspection HIGH-TENSION CORDS INSPECTION 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS Disconnect the high - tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS (a) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (b) Disconnect the high-tension cord at the grommet. DO NOT pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high-tension cord is disconnected. 4. INSPECT HIGH-TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 K ohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. Page 484 Glossary Of Term And Symbols (Part 1 Of 2) Page 861 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Specifications Case: Specifications Transmission Case To: Transfer Adaptor .................................................................................................................................. ............................................... 37 N.m (27 ft. lbs.) Front Bearing Adapter ........................................... .............................................................................................................................. 17 N.m (12 ft. lbs.) Extension Housing ............................................................................................................................... ................................................ 37 N.m (27 ft. lbs.) Straight Screw Plug ............................................. ................................................................................................................................ 19 N.m (14 ft. lbs.) Clutch Housing ............................................................................................................................ ........................................................ 36 N.m (27 ft. lbs.) Page 2834 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Page 3461 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2664 CHART 1 Page 4323 HINT: When replacing the rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration. Page 3048 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 4385 Counter Gear: Service and Repair Assembly Install synchronizer ring assembly to hub sleeve No.3. a. Put the key spring to the hole of the shifting key. b. Push the 3 shifting keys with the 3 key springs to the reverse synchronizer ring. c. Install the synchronizer cone ring to synchronizer pull ring and turn the pull ring. d. Install the 5th synchronizer ring. e. Install the reverse synchronizer ring. Page 4107 ^ If there are 2 alignment pins present the transmissionltransaxle assembly may be installed following the applicable Repair Manual procedure. NOTE: A missing alignment pin may result in failure of the transmissionltransaxle assembly. 2. Install the missing alignment pin(s). ^ Refer to the applicable Repair Manual procedure for location of the cylinder block rear side alignment pins. NOTE In the Repair Manual, the alignment pin is referred to as a "straight pin." Page 1331 Crankshaft: Testing and Inspection Thrust Clearance INSPECTION Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 inch) Maximum thrust clearance: 0.300 mm (0.0118 inch) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 inch) Page 2030 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4165 24. Measure distance between sleeve and differential case end side. Measure distance between the sleeve and tip of the differential case when differential is free and locked. Standard distance: LOCK: 17.44 - 18.86 mm (0.6866 - 0.7425 inch) FREE: 32.40 - 33.90 mm (1.2756 - 1.3346 inch) 25. Install indicator switch. Install the indicator switch with a new gasket. Torque to 40 Nm (30 ft. lbs.) 26. Install actuator. a. Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole. Page 2225 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4678 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1816 Engine Control-Connectors Page 4594 HINT: ^ Apply gear oil to the oil seal ring. ^ hang securely to eliminate clearance. Page 1010 Idle Speed: Adjustments 1. Initial conditions. (a) Engine coolant at normal operating temperature. (b) Air cleaner installed. (c) All pipes and hoses of air induction system connected. (d) All accessories switched OFF. (e) All vacuum lines properly connected. NOTE: All vacuum hoses for Exhaust Gas Recirculation (EGR) systems, etc. should be properly connected. (f) Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged. (g) Ignition timing set correctly. (h) Transmission in neutral position. (i) A/C switch is OFF. 2. Connect TOYOTA hand-held tester or OBD II scan tool or equivalent. 3. Inspect idle speed. (a) Race the engine speed at 2,500 rpm for approximately 90 seconds. (b) Check the idle speed. Idle speed: 700 +/- 50 rpm NOTE: If the idle speed is not as specified, check the Idle Air Control (IAC) valve and air intake system. 4. Disconnect TOYOTA hand-held tester or OBD II scan tool or equivalent. Page 656 CHART 15 Page 3805 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Symptom Related Diagnostic Procedures One Touch 2-4 Selector System Page 4882 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 1346 Piston: Service and Repair Cleaning 1. Using a gasket scraper, remove the carbon from the piston top. 2. Using a groove cleaning tool or broken ring, clean the piston ring grooves. 3. Using solvent and a brush, thoroughly clean the piston. CAUTION: Do not use a wire brush. Page 1903 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1597 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Page 1800 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3516 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Specifications Clutch Pedal Assembly: Specifications Pedal Height From Floor Panel ........................................................................................................................................................ 70.0-180.0 mm (6.692-7.086 inch) From Asphalt Sheet ................................................................................................................................................... 167.0-177.0 mm (6.574-6.968 inch) Pedal Freeplay .................................................................................................................................... ................................. 5.0-15.0 mm (0.197-0.591 inch) Push Rod Play At Pedal Top .................................................................................................................................................. 1.0-5.0 mm (0.039-0.197 inch) Clutch Release Point From: Pedal Full Stroke End Position ............................................................................................................................................ 25 mm (0.098 inch) Or More Page 1874 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1726 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Specifications Brake Caliper: Specifications Line Union 22 ft.lb Mounting Bolt 90 ft.lb Testing and Inspection General Module: Testing and Inspection INTEGRATION RELAY INSPECTION Integration Relay Inspection 1. INSPECT KEY UNLOCK WARNING OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 2. (b) Connect the negative (-) lead from the battery to terminals 5, 7 and 1 0. (c) Check the chime sounds. Integration Relay Inspection (d) Disconnect the negative (-) lead from the battery to terminal 10. (e) Check that the chime stops sounding. Integration Relay Inspection (f) Connect the negative (-) lead from the battery to terminal 10. (g) Connect the positive (+) lead from the battery to terminal 6. (h) Check that the chime stops sounding. If operation is not as specified, replace the relay. Page 4439 d. Turn the reverse synchronizer pull ring, separate the pull ring and cone ring. e. Push the shifting key and spring, and remove the 3 shifting keys and springs to the reverse synchronizer ring. Page 630 Page 3963 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 3817 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Check Fit Between Piston and Piston Pin Piston: Testing and Inspection Check Fit Between Piston and Piston Pin Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Testing and Inspection Fuel Pump Relay: Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION CIRCUIT OPENING RELAY INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals ST and E1 If there no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there no continuity, replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals ST and E1. Locations Ignition Switch Page 1984 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1878 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately. NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. Fill Brake Reservoir BRAKE FLUID BLEEDING 1. Fill brake reservoir with brake fluid. Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAEJ17O3 or FMVSS No.116 DOT 3 2. Bleed master cylinder. NOTE: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plugs with your fingers, and release the Brake Pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Page 3589 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 2196 Glossary Of Term And Symbols (Part 1 Of 2) Page 3906 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Page 2740 Engine Control Module: Connector Views Standard Values Of ECM Terminals Chart 1 Of 2 Page 4722 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3278 (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. NOTICE: Do not start the engine. (i) Select the active test mode on the TOYOTA hand- held tester. (j) Please refer to the TOYOTA hand - held tester operator's manual for further details. (k) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (i) Connect SST (wire) to the injector and battery for 15 seconds. and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 - 69 ohms (3.4 - 4.2 cu in.) per 15 sec. Difference between each injector: 6 cu.cm (0.4 cu in.) or less If the ignition volume is not as specified, replace the injector. 3. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per minute (b) Turn the ignition switch to LOCK. (c) Disconnect the negative (-) terminal cable from the battery. (d) Remove SST. SST 09268-41045 (e) Disconnect the TOYOTA hand-held tester from the DLC3. Page 2106 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 613 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4917 Depress MOTOR Switch (b) Turn the selector switch of the actuator checker to "FRONT" position. (c) Push and hold in the MOTOR switch for a few seconds. (d) Depress the brake pedal and hold it until the step (g) is completed. Depress POWER Switch (e) Push the POWER switch, and check that the brake pedal does not go down. CAUTION: Do not keep the POWER switch pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. Depress MOTOR Switch (g) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. (h) Release the brake pedal. Depress MOTOR Switch And Brake Pedal (i) Push and hold in the MOTOR switch for a few seconds. Page 4778 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection ABS ACTUATOR INSPECTION 1. Inspect battery positive voltage. Battery positive voltage: 10-14 Volts. 2. Disconnect connectors. Disconnect Connector (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3. Connect actuator checker Special Service Tool (SST) to actuator. Sub-Wire Harness C And Sub-Wire Harness E (a) Connect the actuator checker (SST) to the actuator, control relay and body side wire harnesses through the sub - wire harnesses C and E (SST), as shown. SST 09990-00150, 09990-00200,09990-00210 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (-) terminal. Connect the black cable of the sub-wire harnesses to the battery negative (-) terminal or body ground. (c) Place the "SHEET L" (SST) on the actuator checker. SST 09990 - 00370 4. Inspect brake actuator operation. (a) Start the engine, and run it at idle. Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION 1. Disconnect the connector from the sender gauge. 2. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. 3. Ground terminal on the wire harness side connector through a 3.4 W test bulb. 4. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 2874 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2056 Page 3336 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 344 Inspection Procedure / Clutch Switch Circuit (2 Of 4) Inspection Procedure / Clutch Switch Circuit (3 Of 4) Inspection Procedure / Clutch Switch Circuit (4 Of 4) Page 644 Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 1114 Hose/Line HVAC: Service and Repair Refrigerant Lines REFRIGERANT LINES REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torqued. Receiver x Liquid tube Torque: 6.0 N.m (61 kg.cm, 53 in.lb) Condenser x Discharge tube Torque: 10 N.m (100 kg.cm, 7 ft.lb) Condenser x Liquid tube Torque: 14 N.m (140 kg.cm, 10 ft.lb) Compressor x Discharge tube Torque: 10 N.m (100 kg.cm, 7 ft.lb) Compressor x Suction tube Torque: 10 N.m (100 kg.cm, 7 ft.lb) Cooling unit x Liquid tube Torque: 14 N.m (140 kg.cm, 10 ft.lb) Cooling unit x Suction tube Torque: 32 N.m (330 kg.cm, 24 ft.lb) Expansion valve x Evaporator Torque: 5.4 N.m (55 kg.cm, 48 in.lb) Suction line Torque: 32 N.m (330 kg.cm, 24 ft.lb) Liquid line Torque: 14 N.m (140 kg.cm, 10 ft.lb) Page 1300 Connecting Rod Bearing: Service and Repair 1. Using Special Service Tool (SST) Connecting Rod Bushing Remover & Replacer # 09222 30010 or equivalent and a press, press out the bushing. 2. Align the oil holes of a new bushing and the connecting rod. 3. Using SST Connecting Rod Bushing Remover & Replacer # 09222 - 30010 or equivalent and a press, press in the bushing. 4. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. 5. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 2751 Engine Control Module: Testing and Inspection Related Diagnostic Procedures ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to the terminal +B of the ECM. WIRING DIAGRAM Step 1 Step 2 Page 1946 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: Customer Interest Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 2902 Page 3749 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Page 2044 CHART 11 Page 2880 Page 377 Vehicle Speed Sensor/Transducer - Cruise Control: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Valve Body Assembly Valve Body Assembly Page 2666 CHART 5 CHART 6 Page 863 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 339 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3698 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2176 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Front Differential Carrier Differential Carrier: Testing and Inspection Front Differential Carrier Differential Carrier Page 932 Glossary Of Term And Symbols (Part 1 Of 2) Page 2028 A/F and 02 Sensor Identification Page 2677 Testing and Inspection EGR Backpressure Transducer: Testing and Inspection EGR VACUUM MODULATOR INSPECTION 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR Disconnect these vacuum hoses: (1) Vacuum hose from R port (2) Vacuum hose from Q port (3) Vacuum hose from P port 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q and check that the air passes through to the air filter side freely. (c) Start the engine and maintain speed at 3,500 RPM. (d) Repeat the above test. Check that there is a strong resistance to air flow. 3. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the vacuum hoses: (1) Vacuum hose to R port (2) Vacuum hose to Q port (3) Vacuum hose to P port Page 2020 Applicable Vehicles Page 273 Wheel Speed Sensor: Service and Repair Rear Rear Speed Sensor Components REMOVAL 1. Remove speed sensor. Disconnect Speed Sensor Connector (a) Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. (b) Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Remove Clamp Bolts (c) Remove the 2 mountings bolt and speed sensor. Torque: 8.0 Nm (71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. CAUTION: Make sure that: There are no foreign objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. Page 51 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4297 Drive/Propeller Shaft: Testing and Inspection Inspect propeller shaft and intermediate shafts for damage or runout. Using a dial indicator, check the runout of shafts. Maximum Runout: 0.8 mm (0.031 inch) If shaft runout is greater than Maximum, replace the shaft. Page 4293 Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Propeller Shaft Joint Grease/Fittings DRIVELINE & DIFFERENTIAL DL001-99 Title: PROPELLER SHAFT JOINT GREASE Models: '96-'99 4Runner 4WD, '95-'99 Tacoma 4WD, '98-'99 PreRunner, & '00 Tundra 4WD August 27, 1999 Introduction This Service Bulletin provides the location of the grease fittings for the propeller shaft joints as well as the type of grease to use with each fitting location. See the Scheduled Maintenance Guide of each vehicle for recommended lubrication intervals. Applicable Vehicles ^ 1996-1999 4Runner 4WD, 1995-1999 Tacoma 4WD, 1998-1999 PreRunnner, & 2000 Tundra 4WD Warranty Information Procedure for 4Runner Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7 and 8 grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5 and 6 grease fittings (double cardan joint). Locations Ignition Switch Page 2963 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Improvement ENGINE EG006-99 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma June 18, 1999 Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed 10 reduce the possibility of moisture contacting the ceramic element. Affected Vehicles ^ 1996-1999 model year Tacomas built before the VINs listed below. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Disassembly Reverse Idler Gear: Service and Repair Disassembly Remove hub sleeve No.3, shifting key and spring from synchronizer ring. a. Remove the synchronizer ring assembly from the hub sleeve No.3. b. Turn the reverse synchronizer pull ring. c. Remove the reverse synchronizer ring and 5th synchronizer ring from the synchronizer pull ring and cone ring. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Refill ..................................................................................................................................................... ........................................................................ 2.2 Pt Page 1719 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2175 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 236 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 1660 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1171 Engine Oil: Testing and Inspection Oil Quality Check 1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the oil quality is visibly poor, replace it. 2. Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration. SAE 5W-30 being the preferred engine oil. Page 1115 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Page 3492 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 672 Page 1310 1st pass: 25 Nm (18 ft. lbs.) 2nd pass: Turn additional 90° CAUTION: Do not turn the crankshaft. (i) Remove the 2 nuts and connecting rod cap. (See procedure (b) and (c) above). (j) Measure the Plastigage at its widest point. Standard oil clearance: STD: 0.024 - 0.053 mm (0.0009 - 0.0021 inch) U/S 0.25: 0.023 - 0.069 mm (0.0009 - 0.0027 inch) Maximum oil clearance: 0.08 mm (0.0031 inch) If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft. NOTE: If using a standard bearing, replace with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Reference: Standard bearing center wall thickness: Mark "1": 1.484 - 1.488 mm (0.0584 - 0.0586 inch) Mark "2": 1.488 - 1.492 mm (0.0586 - 0.0587 inch) Mark "3": 1.492 - 1.496 mm (0.0587 - 0.0589 inch) (k) Completely remove the Plastigage. Page 3104 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 717 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2125 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1417 Drive Belt: Testing and Inspection Power Steering TENSION CHECK Using a belt tension gauge, check the tension. Belt tension gauge: Nippondenso BTG-20 (95506-00020) or Borroughs No.BT-33-73F Drive belt tension: New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. NOTICE: After installing the belt, check that it fits properly in the ribbed grooves. HINT: New belt refers to a belt which has been 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. Page 401 Evaporator Temperature Sensor / Switch: Testing and Inspection On Vehicle Inspections ON VEHICLE INSPECTION INSPECT THERMISTOR RESISTANCE 1. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. 2. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 2441 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 2684 CHART 25 Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2012 Knock Sensor: Oscilloscope Patterns and Waveforms Page 4263 3. Remove rear axle shaft from backing plate. a. Position SST 09521-25011 on the backing plate with 4 nuts. b. Using a press, remove the rear axle shaft with the bearing retainer from the backing plate. c. Remove the SST. 4. Inspect axle shaft. If the rear axle shaft or flange are damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft. Maximum shaft runout: 2.0 mm (0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) 5. Remove outer oil seal. Using SST 09308-00010, remove the oil seal. Page 2456 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Specifications Wheel Fastener: Specifications Tightening Torque 83 ft.lb Page 3629 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2660 Page 4483 Glossary Of Term And Symbols (Part 1 Of 2) Page 3558 Ignition Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Initial Inspection and Diagnostic Overview Brake Light Switch: Initial Inspection and Diagnostic Overview INSPECT STOP LIGHT SWITCH CONTINUITY w/o Cruise Control: If continuity is not as specified, replace the switch. w/ Cruise Control: If continuity is not as specified, replace the switch. Page 3617 Specifications Valve Guide: Specifications VALVE GUIDE OIL CLEARANCE STD: Intake ..................................................................................................................................................... 0.025 - 0.060 mm (0.0010 - 0.0024 inch) Exhaust .................................................................................................................................................. 0.030 - 0.065 mm (0.0012 - 0.0026 inch) Maximum: Intake ................................................................................................................................................... .............................. 0.08 mm (0.0031 inch) Exhaust ............................................................................ .................................................................................................. 0.10 mm (0.0039 inch) Page 4012 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 158 Standard Values Of ECM Terminals Chart 2 Of 2 Page 3785 Glossary Of Term And Symbols (Part 1 Of 2) Page 3279 Page 3081 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3042 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3344 Page 3556 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 739 Page 4256 3. Install hub bolt. Install a washer and nut to a new hub bolt as shown and install the hub bolt with torquing the nut. 4. Install brake drum and wheel. Torque to 110 Nm (83 ft. lbs.) Inspection and Repair INSPECTION AND REPAIR 1. w/ ABS: Remove bearing retainer (differential side) and ABS speed sensor rotor. a. Attach 4 nuts to the serration bolts and remove the serration bolts from the backing plate using a hammer. NOTICE: Do not reuse the nuts previously removed from the vehicle. b. Grind the retainer and sensor rotor surfaces using grinder, then chisel them out with a chisel. c. Attach washers and nut to the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove the 4 nuts from the serration:ion bolts. 2. Remove snap ring from axle. shaft Using a snap ring expander, remove the snap ring. 3. Remove rear axle shaft from backing plate. a. Position SST 09521-25011 on the backing plate with 4 nuts. Page 3265 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3283 3. INSTALL FUEL PIPE AND TIGHTENING DELIVERY PIPE HOLDING BOLTS (a) Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (b) Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) 4. CONNECT FUEL INLET PIPE (a) Temporarily install the union and 2 new gaskets. and connect the fuel pipe. (b) Install the clamp bolt. Torque: 8 N.m (80 kgf.cm, 71 in.lbf) (c) Tighten the union bolt. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 5. INSTALL FUEL PRESSURE REGULATOR 6. VISUALLY INSPECT AIR ASSIST LINES AND CONNECTIONS Look for loose connections, sharp bends or damage. 7. INSTALL INTAKE AIR CONNECTOR 8. INSTALL AIR CLEANER HOSE 9. CHECK FOR FUEL LEAKS A/C Drive Belt: Testing and Inspection A/C DRIVE BELT TENSION INSPECTION 1. INSPECT DRIVE BELTS INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt: 160 ± 25 lb Used belt: 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Page 1069 (c) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, install the pulley bolt. Torque: 110 Nm (81 ft. lbs.) 6. Set No. 1 cylinder to Top Dead Center (TDC)/compression. (a) Crankshaft Timing Pulley Position: ^ Temporarily install the crankshaft pulley bolt to the crankshaft. ^ Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. (b) Camshaft Timing Pulley Positions: Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, turn the camshaft pulley, align the timing marks of the timing pulley and No. 3 timing belt cover. 7. Install timing belt. CAUTION: The engine should be cold. (a) Remove any oil or water on the pulleys, and keep them clean. CAUTION: Only wipe the pulleys; do not use any cleansing agent. (b) Face the front mark on the timing belt forward. (c) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. Page 4544 Position Of Parts In Instrument Panel (2 Of 2) (Fig 29) Page 4034 Springs / Lower Valve Body Page 410 Troubleshooting / Meter, Gauges And Illumination Page 3080 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3584 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 7 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2802 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4426 Output Shaft: Service and Repair Assembly HINT: coat all of the sliding and rotating surfaces with gear oil before assembly. 1. Install clutch hub No.2 into hub sleeve No.2 a. Install the clutch hub No.2 and shifting keys to the hub sleeve No.2. b. Install the shifting key springs under the shifting keys. NOTICE: position the key springs so that their end gaps are not in line. 2. Install clutch hub No.1 into reverse gear. a. Install the 3 shifting key springs to the clutch hub No.1. b. While pushing the shifting key spring with a screw-driver, install the 3 shifting keys. Drivetrain - Drive/Axle Shaft Replacement Precautions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement Precautions TRANSMISSION & CLUTCH TC003-07 Title: DRIVESHAFT ASSEMBLY REPLACEMENT Models: '90 - '07 Toyota Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. Applicable Vehicles ^ 1990 - 2007 model year Toyota vehicles. Required Tools & Material Repair Procedure Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 280 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 495 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 286 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4258 b. Using SST 09515-30010, 09950-60020 (09951-00890), install a new bearing. 7. Install new outer oil seal. a. Using SST 09950-60010 (09951-00610), 09950-70010 (09951-07150), install a new oil seal. b. install 4 nuts to the serration bolts. c. Using a hammer, remove the serration bolts and remove the bearing case. d. Position the backing plate on a new bearing case and, using 2 socket wrenches, install the serration bolts. Install a new bearing and oil seal (outer side). 8. Replace bearing case. a. Remove the oil seal (outer side) and bearing. b. Install 4 nuts to the serration bolts. c. using a hammer, remove the serration bolts and the bearing case. d. Position the backing plate on a new bearing case and, using 2 socket wrenches, install the serration bolts. e. Install a new bearing and outer oil seal. 9. Replace oil seal (inner side). a. Using SST 09308-00010, remove the oil seal. Page 2841 Mechanical Specifications Brake Proportioning/Combination Valve: Mechanical Specifications TIGHTENING SPECIFICATIONS Assembly To Shackle No.1 ................................................................................................................. ................................................. 29 Nm (22 ft. lbs.) Bracket to Frame ................................................. ................................................................................................................................. 29 Nm (22 ft. lbs.) Mounting Nut ............................................................................................................................... .......................................................... 13 Nm (9 ft. lbs.) Shackle No.1 To Shackle No.2 ............................................................................................................................................................. 25 Nm (18 ft. lbs.) Shackle No.2 To Shackle Bracket .......................................................................................................................................................... 13 Nm (9 ft. lbs.) Spring Assembly Nut ............................................................................................... ............................................................................. 18 Nm (13 ft. lbs.) Description and Operation Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in Anti-Lock Brake System (ABS) control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. Page 1653 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3043 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4579 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Page 4337 Flywheel: Testing and Inspection Inspect flywheel runout. Using a dial indicator, check the flywheel runout. Maximum Runout: 0.1 mm (0.004 inch) If necessary, replace the flywheel. Page 4918 (j) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down. push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (k) Release the brake pedal. 5. Inspect the other wheels. (a) Change the connection of the actuator checker (SST) to the sub-wire harness E (SST) from the sub-wire harness MAIN connector to the SUB connector, or vice versa. (b) Repeating (c) to (j) of the step 4, check the actuator operation similarly. 6. Inspect the rear wheel. Depress MOTOR Switch And Brake Pedal (a) Turn the selector switch to the "REAR" position. (b) Push and hold in the MOTOR switch for a few seconds. (c) Depress the brake pedal and hold it until the step (g) is completed. Depress POWER Switch (d) Push the REAR switch while pressing the POWER switch. and check that the brake pedal does not go down. CAUTION: Do not keep the POWER switch pushed down for more than 10 seconds. (e) Release the REAR switch then the POWER switch, and check that the brake pedal goes down. Depress MOTOR Switch (f) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. (g) Release the brake pedal. Page 54 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4515 Four Wheel Drive Selector Switch: Component Tests and General Diagnostics 2-4 Selector Switch Inspect 2-4 selector switch continuity. Test continuity between terminals 1 and 2. Switch position: Specified condition. OFF: No continuity. ON: Continuity. If continuity is not as specified, replace the shift lever knob. Page 3065 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1913 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 4834 Warranty Information NOTE: Replacement of the front brake pad kit and/or shims is limited to correction of a problem based upon a customer's complaint and subject to all of the provisions of Toyota Warranty Policy Bulletin POL94-18, dated October 10, 1994. Page 2107 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 312 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4757 ABS Warning Light Circuit Inspection Procedure (Part 2 Of 2) CIRCUIT DESCRIPTION If the Electronic Control Unit (ECU) detects trouble, it lights the Anti-Lock Brake System (ABS) warning light while at the same time prohibiting ABS control. At this time, the ECU records a Diagnostic Trouble Code (DTC) in memory. After removing the short pin of the Data Link Connector (DLC)1, connect terminals Tc and E1 of the DLC1 to make the ABS warning light blink and output the DTC. Troubleshooting in accordance with the chart for each trouble symptom. Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection INSPECT SEAT BELT BUCKLE SWITCH CONTINUITY 1. Check that there is continuity between terminals on the switch side connector with the switch ON (belt unfastened). 2. Check that there is no continuity between terminals on the switch side connector with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. Page 2459 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4661 Junction Block And Wire Harness Connector Page 2388 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2614 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1721 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Integration Relay Key Reminder Switch: Testing and Inspection Integration Relay INTEGRATION RELAY INSPECTION INSPECT RELAY CIRCUIT Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 2816 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 4141 If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload. New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.) Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) If the preload is greater than the specification, replace the bearing spacer. 20. Install differential case. 21. Install side bearing retainer. a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer. b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol. c. Apply FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the side bearing retainer, as shown. HINT: Install the side bearing retainer within 10 minutes after applying FIPG. d. Install the side bearing retainer with the 10 bolts. Torque to 69 Nm (51 ft. lbs.) 22. Check total preload. 23. Recheck ring gear backlash. 24. Recheck tooth contact between ring gear and drive pinion. 25. Check runout of companion flange. 26. Stake drive pinion nut. 27. Install side oil seal. Using SST 09608-32010 and a hammer, install a new oil seal until its surface is flush with the differential carrier end. Side oil seal drive in depth: 0 mm (0 inch) b. Coat the oil seal lip with MP geese. 28. W/ A.D.D.: Install intermediate shaft. Page 2739 Page 2026 Page 4156 2. Install side bearings. Using SST 09950-60010 (09951-00480, 09951-00550), 09950-60020 (09951-00730) and a press, install the side bearings on the differential case. 3. Install ring gear on differential case. a. Clean the contact surfaces of the differential case and ring gear. b. Heat the ring gear to about 100° C (212° F) in boiling water. c. Carefully remove the ring gear from the water. d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. e. Align the matchmarks on the ring gear and differential case. f. Temporarily install new lock plates and set bolts. g. After the ring gear cools down enough, tighten the set bolts uniformly and a little at a time. Torque to 97 Nm (71 ft. lbs.) h. Using a drift. punch and hammer, stake the lock plates. HINT: Stake one claw flush with the fiat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake the half on the tightening side. 4. Check ring gear runout. a. Install the differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearings. Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: All Technical Service Bulletins Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Testing and Inspection Control Module HVAC: Testing and Inspection INSPECT AMPLIFIER CIRCUIT 1. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: - Ignition switch ON - Temperature control lever MAX COOL - Blower control lever HI If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 2. Connect the connector to A/C amplifier and inspect wire harness side connector from the back side, as shown. Test conditions: Ignition switch ON - A/C switch ON - Temperature control dial MAX COOL - Blower control lever HI - Install manifold gauge set If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 4869 Brake Shoe: Service and Repair Rear Brake Components (4WD) REMOVAL 1. Remove rear wheel. 2. Remove brake drum. NOTE: If the brake drum cannot be removed easily, do the following steps. (a) Remove the adjusting hole plug in the backing plate. (b) Insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjusting bolt. (c) Using another screwdriver, reduce the brake shoe adjustment by turning the adjusting bolt. 3. Remove rear shoe. Page 2375 Page 3901 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1543 Timing Belt: Service and Repair Timing Belt Installation 1. Install crankshaft timing pulley. (a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. 2. Install No. 1 idler pulley. (a) Using a 10 mm hexagon wrench, install the No. 1 idler pulley with the plate washer and bolt. Torque: 35 Nm (26 ft. lbs.) (b) Check that the pulley bracket moves smoothly. 3. Install No. 2 idler pulley. (a) Install the No. 2 idler pulley with the bolt. Torque: 40 Nm (30 ft. lbs.) (b) Check that the No. 2 idler pulley moves smoothly. 4. Install LH camshaft timing pulley. (a) Face the flange side of the timing pulley outward. (b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. (c) Using Special Service Tool (SST) Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, install the pulley bolt. Torque: 110 Nm (81 ft. lbs.) 5. Install RH camshaft timing pulley. (a) Face the flange side of the timing pulley outward. (b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. Page 4154 Differential Carrier (3RZ-FE, 5VZ-FE w/Differential Lock) 1. Assemble differential case. a. Apply all of the sliding and rotating surfaces with gear oil. b. Install the side gear thrust washer to the side gear. Testing and Inspection Dashpot: Testing and Inspection DASHPOT (DP) INSPECTION - M/T ONLY INSPECT DASHPOT (DP) (a) Allow the engine to warm up to normal operating temperature. (b) Check idle speed. Idle speed: 700 ± 50 rpm (c) Remove the cap, filter and separator from the DP. (d) Maintain engine speed at 2,500 rpm or more. (e) Plug the VTV hole with your finger. (f) Release the throttle valve. (g) Check the DP is set. DP setting speed: 1,800 - 2,200 rpm (h) If the setting speed is not as specified, adjust it with the DP adjusting screw. (i) Remove your finger from the hole and check that the engine returns to idle speed in approx. 1 second. (j) Reinstall DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). Page 3062 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2038 CHART 1 Page 2615 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 888 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3100 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1980 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2752 Step 3 Step 4 Step 5 Step 6 Page 1458 Engine Oil: Testing and Inspection Oil Pressure Check 1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the oil quality is visibly poor, replace it. 2. Check engine oil level. The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. 3. Remove oil pressure switch. Using Special Service Tool (SST) Oil Pressure Switch Socket # 09816 - 30010 or equivalent, remove the oil pressure switch. 4. Install oil pressure gauge. 5. Start engine. Allow the engine to warm up to normal operating temperature. 6. Measure oil pressure. Oil pressure: At idle speed: 29 kPa (4.3 psi) or more At 3,000 rpm: 245 - 520 kPa (36 - 75 psi) 7. Turn engine off. 8. Remove oil pressure gauge. 9. Install oil pressure switch. (a) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent. (b) Using SST Oil Pressure Switch Socket # 09816 - 30010 or equivalent, install the oil pressure switch. 10. Start engine and check for leaks. Page 707 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1178 Power Steering Fluid: Fluid Type Specifications LUBRICATION Lubricant Type Power Steering ........................................................................................................... ................................................................................. Dexron II/IIE/III Page 815 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2589 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 665 Page 531 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 2487 Page 3338 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 675 CHART 30 Page 3438 Throttle Body: Specifications Throttle Body to Intake (Nuts) 13 ft.lb Throttle Body to Intake (Bolts) 13 ft.lb Page 4883 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Page 3687 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Standard Values Of ECM Terminals Chart 1 Of 2 Specifications Wheel Cylinder: Specifications Brake line 11 ft.lb Mounting bolts 7 ft.lb Page 4736 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 3998 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4360 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3394 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4433 Page 3553 Glossary Of Term And Symbols (Part 1 Of 2) Page 3637 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4177 2. Install dust deflector to companion flange. Using SST 09726-40010 and a press, install a new dust deflector. Without Differential Lock 1. Remove dust deflector. Using SST 09950-00020, a socket wrench and a press, remove the dust deflector. 2. Install new dust deflector. Using SST 09523-36010 and a press, install a new dust deflector. Page 4166 b. Ensure that the matchmarks of the pinion of the actuator is in the extent between 0 - 5 degrees clockwise above the center line of the actuator. NOTICE: ^ If the matchmarks is not in this extent, rotate the pinion to be matched. ^ Don't supply the battery positive voltage directly between terminals. ^ If the matchmarks come to the extension limit of the rotation, don't electrify moreover. c. Install a new O-ring to the actuator. d. Apply a light coat of gear oil on the O-ring. e. Apply MP grease to the gear part. f. Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side. HINT: Don't damage the O-ring of the actuator. g. Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin reaches the right-hand side. h. Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the matchmarks of the pinion of the actuator. Torque to 26 Nm (20 ft. lbs.) Without Differential Lock Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Diagnosis and Testing. Page 3734 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 24) Application and ID Valve Spring Shim: Application and ID ADJUSTING SHIM SELECTION CHART (INTAKE) Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3795 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3638 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3091 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2793 Glossary Of Term And Symbols (Part 1 Of 2) Page 50 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Axle Shaft, Conventional Fixed/Floating Axle Shaft: Locations Axle Shaft, Conventional Fixed/Floating Rear Axle Shaft (1 Of 2) Locations Antenna Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 486 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Diagnostic Trouble Code Tests and Associated Procedures Idle Speed/Throttle Actuator - Electronic: Diagnostic Trouble Code Tests and Associated Procedures DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed and a VSV for idle up control is also added (for air conditioning). DETECTING CONDITION WIRING DIAGRAM Step 1 Page 709 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3538 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS (a) Assemble the holder and grommet. (b) Align the spline of the ignition coil with the spline of the holder and push in the cord. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration. (c) Check that the lock claw of the holder is engaged by lightly pulling the holder. 6. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS 7. REINSTALL AIR CLEANER HOSE Page 4700 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4417 Page 3703 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 945 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 3663 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2122 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Mechanical Specifications Axle Shaft: Mechanical Specifications SERVICE SPECIFICATIONS Axle Shaft Deviation [1] ................................................................................................................................................... 0.7 mm (0.027 inch) Maximum Deviation [2] ............................................................................................. ..................................................................... 0.1 mm (0.0039 inch) Maximum Bearing Backlash [1] ........................................................................................................................................................ 0.7 mm (0.027 inch) Maximum Flange Runout ......................................................................................... ......................................................................... 0.1 mm (0.004 inch) Maximum Shaft Runout ............ ......................................................................................................................................................... 2.0 mm (0.079 inch) Maximum TIGHTENING SPECIFICATIONS Backing Plate To Shaft Mounting Nuts ................................................................................................................................................ 68 Nm (50 ft. lbs.) [1]: Measured in the bearing shaft direction. [2]: At the surface of the axle shaft outside the hub bolt. Symptom Related Diagnostic Procedures One Touch 2-4 Selector System Page 2423 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 840 Page 3893 Position Of Parts In Instrument Panel (1 Of 2) (Fig 28) Page 2403 Glossary Of Term And Symbols (Part 1 Of 2) Page 1078 Drive Belt: Specifications Alternator Belt GENERATOR / SERVICE DATA DRIVE BELT New belt 2RZ-FE, 3RZ-FE: .............................................................................................................................................................. ..................................................... 165 ± 10 lb. 5VZ-FE: .............................................................................................................................................................. ..................................................... 160 ± 25 lb. Used belt 2RZ-FE, 3RZ-FE: .............................................................................................................................................................. ..................................................... 115 ± 20 lb. 5VZ-FE: .............................................................................................................................................................. ..................................................... 100 ± 20 lb. Page 4671 operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 2898 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4672 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2771 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1803 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Electrical Specifications EGR Temperature Sensor: Electrical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) Resistance 64 - 97 K ohms at 122 deg F 11 - 16 K ohms at 212 deg F 2 - 4 K ohms at 302 deg F Page 4486 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4805 Brake Pedal Assy: Adjustments BRAKE PEDAL INSPECTION Check Pedal Height 1. Check pedal height. Pedal height from asphalt sheet: 159.1 - 169.1 mm (6.262 - 6.657 inch) 2. IF necessary, adjust pedal height. (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut. Torque: 25 Nm (19 ft. lbs.) (f) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (g) Turn the stop light switch back one turn. Check Clearance (A) Between Stop Light Switch And Pedal (h) Check the clearance (A) between the stop light switch and pedal. Clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch) (i) Tighten the stop light switch lock nut. (j) Connect the connector to the stop light switch. (k) Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. (l) After adjusting the pedal height, check the pedal freeplay. NOTE: If clearance (A) between the stop light switch and the pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications. 3. Check pedal freeplay. (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. Page 3514 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2581 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 288 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 732 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4909 4. Set rear axle load. 5. Set valve body. (a) When pulling down the load sensing spring, confirm that the valve piston moves down smoothly. (b) Position the valve body so that the valve piston lightly contacts the load sensing spring. (c) Tighten the valve body mounting nuts. Torque: 13 Nm (9 ft. lbs.) 6. Bleed brake system. See: Brake Bleeding/Service and Repair 7. Check and adjust LSP & BV fluid pressure. Page 153 Engine Control-Connectors Page 2855 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2402 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 1801 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4502 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 2143 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4038 Upper Valve Body / Strainer Page 4301 Drive/Propeller Shaft: Service and Repair Overhaul DISASSEMBLY 1. Separate propeller shaft and intermediate shaft. a. Place matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers. 2. Remove center support bearing from intermediate shaft. a. Using a chisel and hammer, loosen the staked part of the nut. b. Using Special Service Tool (SST) 09930-00021 to hold the flange, remove the nut and spacer. c. Place matchmarks on the flange and shaft. d. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the flange from the intermediate shaft. e. Remove the spacer. 3. Remove center support bearing. 4. Remove sleeve yoke from propeller shaft. a. Place matchmarks on the sleeve yoke and shaft. b. Pull out the sleeve yoke from the shaft. c. Remove the dust cover from the shaft. Page 2208 Page 3691 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Inspection For Runout Crankshaft: Testing and Inspection Inspection For Runout 1. Place the crankshaft on V - blocks. 2. Using a dial indicator, measure the circle runout at the No. 2 and No. 3 journal. Maximum circle runout: 0.06 mm (0.0024 inch) If the circle runout is greater than maximum, replace the crankshaft. Page 4211 4. REMOVE OIL SEAL AND OIL SLINGER a. Using SST, remove the oil seal. SST 09350-32014 (09308-10010) b. Remove the oil slinger. 5. REMOVE REAR BEARING AND BEARING SPACER a. Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 b. Remove the bearing spacer. 6. INSTALL BEARING SPACER, REAR BEARING AND OIL SLINGER a. Install a new bearing spacer and place the rear bearing and oil slinger. b. Using SST and the companion flange, install the rear bearing, then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 7. INSTALL OIL SEAL a. Coat a new oil seal lip with MP grease. b. Using SST and a hammer, install the oil seal. SST 09554-22010 Oil seal drive in depth: 4.5 mm (0.177 inch) Page 3268 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1189 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The Vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deployed during servicing. possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement). be sure to read each step/warning carefully, then follow the correct procedure described. Page 3333 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3729 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Ground Points Ground Points Page 3983 Throttle Valve Cable/Linkage: Adjustments Adjustment 1. Check that the throttle valve is fully closed. 2. Check that the inner cable is not slack. 3. Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0.0 - 0.04 in.) If the distance is not the standard, adjust the cable by the adjusting nuts. Page 1341 Piston: Testing and Inspection Inspect Ring Groove Clearance Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearance: No. 1: 0.0.040 - 0.080 mm (0.0016 - 0.0031 inch) No. 2: 0.030 - 0.070 mm (0.0012 - 0.0028 inch) If the clearance is not as specified, replace the piston. A/T - Chatter When Shifted From R to P/N Valve Body: All Technical Service Bulletins A/T - Chatter When Shifted From R to P/N TRANSMISSION & CLUTCH TC001-98 FEBRUARY 13, 1998 TITLE: A340E, A343F "R" TO "P/N" CHATTER MODELS: '97-'98 TACOMA, 4RUNNER, T-100 & LAND CRUISER Introduction Some Tacoma, 4Runner, T-100 and Land Cruisers with A340E, A340F or A343F automatic transmissions may produce a chatter noise when shifted out of Reverse into either Neutral or Park. To prevent this noise, a check ball has been added to the valve body as indicated in the illustration. Affected Vehicles 1997-98 model year Tacoma, 4Runner, T-100 and Land Cruiser with A340E, A340F or A343F automatic transmissions with serial numbers from 97H*-00001 through 97K*-99999. Parts Information OLD PART NUMBER NEW PART NUMBER PART NAME 35495-22020 Same Ball, Check, No. 1 35433-30064 Same Valve Body Gasket No. 1 35434-30076 Same Valve Body Gasket No. 2 Warranty Information Applicable Warranty: This repair Is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Repair Procedure 1. Disassembly: A. Remove valve body as described in the Repair Manual for the vehicle being serviced. B. Turn over and remove 25 bolts. Page 2236 Page 2563 Engine Control-Connectors Page 4668 Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Locations-R/B No.2-Engine Compartment Left (Canada) (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-Ground: Approx 13 Ohms Page 197 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1822 Standard Values Of ECM Terminals Chart 2 Of 2 Page 120 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2742 Standard Values Of ECM Terminals Chart 1 Of 2 Specifications Brake Rotor/Disc: Specifications Front Brake Rotors Standard Thickness 0.866 in Minimum Thickness 0.787 in Maximum Runout 0.0028 in Page 642 Torque Specifications Fluid Pump: Specifications Torque Specifications Oil pump x Transmission case ............................................................................................................ ...................................................... 22 Nm (16 ft. lbs.) Stator shaft x Oil pump body ........................... ........................................................................................................................................... 10 Nm (7 ft. lbs.) Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 2201 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3146 (c) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV ASSEMBLY (a) install the VSV assembly with the 2 bolts. Torque: 8 N.m (80 kgf.cm 71 in.lbf) (b) Connect the 2 connectors and 4 vacuum hoses to the 2 VSV. Page 2522 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4303 d. Using SST 09930-00021 to hold the flange, press the bearing into position by tightening down a new nut. Torque: 181 N.m (134 ft. lbs.) e. Loosen the nut. f. Torque the nut again. Torque: 69 N.m (51 ft. lbs.) g. Using a chisel and hammer, stake the nut. 3. Install propeller shaft. a. Align the matchmarks on the flanges and connect the flanges with 4 bolts, washers and nuts. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. b. Torque the bolts. Torque: 74 N.m (54 ft. lbs.) 4. Insert sleeve yoke into propeller shaft. a. Apply grease to the propeller shaft spline and sleeve yoke sliding surface. Grease: molybdenum disulfide lithium base chassis grease, NLGI No.2. b. Install the dust cover to the shaft. c. Align the matchmarks on the yoke and propeller shaft. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Front Alignment: Specifications Front Camber, Caster and Steering Axis Inclination NOTE: RZN161L - 2.7L engine, SWB VZN160L - 3.4L engine, SWB RZN171L - 2.7L engine, LWB VZN170L - 3.4L engine, LWB RZN161L Camber: .............................................................................................................................. ...................................................... 0°15' ± 45' (0.25° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 35' ± 45' (1.58° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: ............................................................................................................................. .................................... 10° 00' ± 45' (10° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less VZN160L Camber: ............................................................................................................................... .................................................... 0° 15' ± 45' (0.25° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 35' ± 45' (1.58° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less RZN171L Camber: .............................................................................................................................. ..................................................... 0° 20' ± 45' (0.33° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 45' ± 45' (1.75° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less VZN170L Camber: ............................................................................................................................... .................................................... 0° 20' ± 45' (0.33° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 45' ± 45' (1.75° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Toe-In and Wheel Angle Total Toe-In: (A + B) = 0° 12' ± 12' (0.02° ± 0.02°) (C - D) = 2 ± 2 mm (0.08 ± 0.08 inch) Page 4606 1. Inspect drive sprocket thrust clearance. Using a feeler gauge, measure the drive sprocket thrust clearance. Standard Clearance: 0.10-0.25 mm (0.0039-0.0098 inch) Maximum Clearance: 0.25 mm (0.0098 inch) f the clearance exceeds the Maximum, replace the drive sprocket. 2. Remove high and low clutch sleeve assembly. a. Using a snap ring expander, remove the snap ring. b. Remove the clutch sleeve and 3 shifting keys. c. Using a press, remove the clutch hub, 2 key springs and key retainer. 3. Remove bearing, spacer and drive sprocket with front drive clutch sleeve assembly. a. Using SST 09555-55010 and a press, remove the bearing. b. Remove these parts. ^ Spacer and ball. ^ Drive sprocket with front drive clutch sleeve assembly. ^ Needle roller bearing. ^ Synchronizer ring. 4. Remove 3-shifting keys and 2 key springs from front drive clutch sleeve. INSPECTION Timing Belt Removal Timing Belt: Service and Repair Timing Belt Removal Page 565 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2464 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2625 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 3054 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1053 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T-Thickness of used shim A-Measured valve clearance N-Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. INSTALL CYLINDER HEAD COVERS 7. INSTALL INTAKE AIR CONNECTOR Page 1807 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 2250 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Specifications EGR Valve: Specifications Except VZN170 Models. EGR Valve to Air Intake Chamber 14 ft.lb EGR Valve to EGR Pipe 14 ft.lb Page 4551 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1981 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2915 Page 2395 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Specifications Shifter Transfer Case: Specifications Transmission Shift Control Rod To Shift Lever ...................................................................................................................................... 13 N.m (10 ft. lbs.) Transmission Shift Lever Assembly .................................................................................................................................................... 6.0 N.m (53 inch lbs.) Locations Tail Lamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 315 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Camshaft Bearing: Specifications TIGHTENING SPECIFICATIONS Camshaft Bearing Cap Bolts ........................................................................................................................................................... 16 Nm (12 ft. lbs.) TORQUE SEQUENCES CAMSHAFT BEARING CAP REMOVAL SEQUENCES - Right Side Cylinder Head Exhaust Camshaft - Right Side Cylinder Head Intake Camshaft - Left Side Cylinder Head Exhaust Camshaft - Left Side Cylinder Head Intake Camshaft CAMSHAFT BEARING CAP TIGHTENING SEQUENCES Page 187 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1658 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Fuel - Idle Speed Increased by Replacement ECM Idle Speed: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 2437 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 48 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 787 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 631 Engine Bank Identification Page 284 Glossary Of Term And Symbols (Part 1 Of 2) Page 2051 Page 2768 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Testing and Inspection Air Conditioning Switch: Testing and Inspection INSPECT A/C SWITCH CONTINUITY Switch Continuity: If continuity is not as specified, replace the switch. Illumination Circuit: If continuity is not as specified, replace the bulb. Page 373 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4926 Components Page 1596 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 113 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4441 f. Turn the reverse synchronizer pull ring. g. while pushing the 3 shifting keys, install the synchronizer ring assembly to the hub sleeve No.3. Page 1368 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using Special Service Tool (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) Page 2063 Page 4014 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 1322 Crankshaft Main Bearing: Testing and Inspection 1. Remove main bearing cap and check oil clearance. (a) Uniformly loosen and remove the main bearing cap bolts, in several passes, in the sequence shown. (b) Using a screwdriver, pry out the main bearing cap and remove the main bearing cap, lower main bearings and lower thrust washers (No. 2 journal position of main bearing cap only). NOTE: Keep the lower main bearings and lower thrust washers together with the main bearing cap. (c) Lift out the crankshaft. NOTE: Keep the upper main bearings and upper thrust washers 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, grind or 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 cap with the 8 bolts. Page 4051 LOWER VALVE BODY COMPONENTS Lower Valve Body VALVE BODY SPRING SPECIFICATIONS HINT: During reassembly please refer to the spring specifications below to help you to identify the different springs. Page 1603 Compression Check: Testing and Inspection NOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature. 2. Remove ignition coils. 3. Remove spark plugs. Using a 16 mm plug wrench, remove the 6 spark plugs. 4. Check cylinder compression pressure. (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (174 psi) or more. Minimum pressure: 1,000 kPa (145 psi) Difference between each cylinder: 100 kPa (15 psi) or less. (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. Reinstall spark plugs. Torque: 20 Nm (14 ft. lbs.) 6. Reinstall ignition coils. Page 4254 Rear Axle Shaft (2 Of 2) REMOVAL 1. Remove rear wheel and brake drum. Installation Hint: ^ Torque to 110 Nm (83 ft. lbs.) ^ After installation, bleed the brake system and check for leaks. 2. Check bearing backlash and axle shaft deviation. a. Using a dial indicator, check the backlash in the bearing shaft direction. If it is greater than the maximum, replace the bearing. Maximum: 0.7 mm (0.027 inch) b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. If it is greater than the maximum, replace the axle shaft. Maximum: 0.1 mm (0.0039 inch) 3. w/ ABS: Remove ABS speed sensor from rear axle housing. Installation Hint: Torque to 8.0 Nm (71 inch lbs.) 4. Remove rear brake assembly. Page 2582 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2022 Engine Bank Identification Page 1154 Fluid - Differential: Fluid Type Specifications Front Differential TYPE.................................................................................................................................................... ........................................................................ GL-5* CAPACITY Front .............................................. .............................................................................................................................................................. .. 1.1L (2.3 pints) With A.D.D [1] .......................................................................................................... .................................................................................... 1.2L (2.4 pints) VISCOSITY Below -18° C (0° F) ......................................................................................................................................................... ............................... 80W, 80W-90 Above -18° C (0° F) ...................................................................... ..................................................................................................................................... 90 With A.D.D .............................................................................................................................................................. ................................................. 75W-90 [1] Automatic Disconnecting Differential Oil Type and Viscosity Differential Type ..................................................................................................................................................... ......................................................... Hypoid gear oil Grade ................................................................ ...................................................................................................................................................... API GL-5 Viscosity: Front (w/ADD) ...................................................................................................................................... ........................................................... SAE 75W-90 Front (without ADD) Above 0° F (-18° C) ............................................................................................ ....................................................................................................... SAE 90 Below 0° F (18° C) ......... .............................................................................................................................................................. ....... SAE 80W or 80W-90 Rear Above 0° F (-18° C) .................................................................................................................... ............................................................................... SAE 90 Below 0° F (18° C) ................................. ............................................................................................................................................. SAE 80W or 80W-90 Special Service Materials w/ Differential Lock: Shaft Retainer X Differential Carrier .................................................................... ............................................................................................................. [1] Actuator x Differential Carrier .................................................................................................................................................. ........................................ [1] Shift Fork Shaft Set Bolt ........................................................................ ........................................................................................................................... [2] Pinion Shaft Pin .. .............................................................................................................................................................. ................................................. [2] Shaft Retainer Bolt ....................................................................... ..................................................................................................................................... [3] Screw Plug .............................................................................................................................................................. ........................................................... [3] w/o Differential Lock: Ring Gear Set Bolts ......................... .............................................................................................................................................................. .................... [4] [1]: Part No. 08826-00090; Seal Packing 1281, THREE BOND 1281 FIPG, or equivalent. [2]: Part No. 08833-00070; Adhesive 1324, THREE BOND 1324, or equivalent. [3]: Part No. 08833-00080; Adhesive 1344, THREE BOND 1344, LOCTITE 242, or equivalent [4]: Part No. 08833-00100: THREE BOND 1360K, or equivalent Page 1569 Idle Speed: Adjustments 1. Initial conditions. (a) Engine coolant at normal operating temperature. (b) Air cleaner installed. (c) All pipes and hoses of air induction system connected. (d) All accessories switched OFF. (e) All vacuum lines properly connected. NOTE: All vacuum hoses for Exhaust Gas Recirculation (EGR) systems, etc. should be properly connected. (f) Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged. (g) Ignition timing set correctly. (h) Transmission in neutral position. (i) A/C switch is OFF. 2. Connect TOYOTA hand-held tester or OBD II scan tool or equivalent. 3. Inspect idle speed. (a) Race the engine speed at 2,500 rpm for approximately 90 seconds. (b) Check the idle speed. Idle speed: 700 +/- 50 rpm NOTE: If the idle speed is not as specified, check the Idle Air Control (IAC) valve and air intake system. 4. Disconnect TOYOTA hand-held tester or OBD II scan tool or equivalent. Page 269 Wheel Speed Sensor: Description and Operation Speed Sensor Circuit Description CIRCUIT DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the Electronic Control Unit (ECU). These signals are used to control of the Anti-Lock Brake System (ABS) system. The front and rear rotors each have 48 serrations. When the Rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. FAIL SAFE FUNCTION If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Page 4213 Capacity: 1.15 liters (1.22 US qts., 1.01 Imp. qts.) 13. INSTALL UNDER COVER Page 941 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Oil Filter Housing: Specifications TIGHTENING SPECIFICATIONS Oil Filter Union To Cylinder Block ................................................................................................................................................ 25 Nm (18 ft. lbs.) Oil Hole Cover Plate To Cylinder Block ........................................................................................................................................ 60 Nm (44 ft. lbs.) Page 1534 Timing Belt: Testing and Inspection INSPECTION 1. Inspect timing belt. CAUTION: 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. If there are any defects as shown in the illustration, check these points: (a) 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. (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 belt cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. Inspect idler pulleys. (a) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. Inspect timing belt tensioner. Page 1120 * Warranty application is limited to correction of a problem based upon a customer's complaint. Parts Identification For parts before the production change, the circular machining marks can be felt by scraping a fingernail across the pressure feed hose banjo fitting. Machining marks cannot be felt on the new parts. There is no other identification method to distinguish old style service parts from new ones. Repair Procedure Replace Power Steering pressure feed hose and (2) gaskets with new parts. Recommended repair torque: 40 f-lbs (54 N-m, 550 kgf-cm). Refer to the appropriate Repair Manual (Section SR - Steering) for additional details. Service Specifications Camshaft Gear/Sprocket: Specifications Service Specifications DIMENSIONS Free Distance .............................................................................................................................................................. 18.2 - 18.8 mm (0.712 -0.740 inch) Gear Backlash: STD ............................................................................................................................................................. 0.020 - 0.200 mm (0.0008 - 0.0079 inch) Maximum ............................................................................ ..................................................................................................... 0.30 mm (0.0188 inch) Page 151 Standard Values Of ECM Terminals Chart 2 Of 2 Page 4135 b. Heat the ring gear to about 100° C (212° F) in boiling water. c. Carefully remove the ring gear from the water. d. after the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the ring gear and differential case. e. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case are not misaligned. f. After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque to 97 Nm (71 ft. lbs.) g. Using a hammer and a drift. punch, stake the lock plates. HINT: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half portion of the tightening side. 5. Install side bearings. Using SST 09226-10010 and a press, install the bearing into the differential case. 6. Install side bearing outer races. HINT: When replacing the side bearings, fit the thinnest washers to each bearing and when reusing the bearings, fit the washers with the same thickness as removed. a. Install a new plate washer to the bearing retainer. Page 1734 w/ Tachometer w/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 447 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 156 Standard Values Of ECM Terminals Chart 2 Of 2 Page 2585 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1935 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2682 Page 2218 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1688 Radiator: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove No. 1 fan shroud. Remove the 4 bolts and No. 1 fan shroud. 2. Remove radiator supports. Using a torx wrench, remove the 4 torx screws and the 2 radiator supports. Torx wrench: T30 (Part No. 09042 - 00010 or locally manufactured tool) or equivalent. NOTE: Lift up the floor carpet and loosen the screw. ASSEMBLY Assembly is in the reverse order of disassembly. Page 220 Starter Relay: Testing and Inspection STARTER RELAY INSPECTION Junction Box And Relay Box LOCATION: The relay is located in the Relay Block No.2 in the engine compartment. 1. REMOVE STARTER RELAY 2. INSPECT STARTER RELAY A. Inspect relay continuity a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there continuity, replace the relay. Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Brake Components (4WD) REMOVAL 1. Remove front wheel. 2. Disconnect flexible hose. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (22 ft. lbs.) CAUTION: Install the flexible hose lock securely in the lock hole in the caliper. 3. Remove caliper. Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Page 1975 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3942 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2035 Page 4363 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 1540 16. Remove starter wire bracket and No. 1 timing belt cover. (a) Remove the 2 bolts and starter wire bracket. (b) Remove the 4 bolts and timing belt cover. 17. Remove timing belt guide. 18. Set No. 1 cylinder at Top Dead Center (TDC)/compression. (a) Temporarily install the crankshaft pulley bolt to the crankshaft. (b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. CAUTION: Always turn the crankshaft clockwise. (c) Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). (d) Remove the crankshaft pulley bolt. 19. If reusing timing belt, check installation marks on timing belt. Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 20. Remove timing belt tensioner. Page 2680 Page 4669 P 1 PARK/NEUTRAL POSITION SW 4-Ground: Approx. 12 Volts with ignition SW ON position O 4-B, S 4-A O/D MAIN SW A-5-A-10, B-1-B-3: Open with O/D main SW at ON position Open with O/D main SW at OFF position S 5-A, B STOP LIGHT SW A-1-A-2, B-1-B-2: Closed with Brake Pedal Depressed E 5-A, E 6-D, E 7-C, E 8-B ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) IDL-E2: 0-3 Volts with Throttle Valve fully closed 9-14 Volts with Throttle Valve open VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with shift lever at expect 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at expect L position L4-E1: 10-14 Volts with Transfer Shift at H2 or H4 position 0 Volts with Transfer shift at L4 position OIL-W-E1: 0.1-4.9 Volts +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2598 and Hot is from 50°C (122°F) to 100°C (212°F). (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM (a) Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed is kept at 900 - 1300 rpm for 10 seconds, check that it returns to idle speed. (d) Stop the engine. (e) Disconnect the air assist hose from the IAC valve and plug it. (f) Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors." (g) Remove the SST from the DLC1. SST 09843-18020 (h) Reconnect the air assist hose to the IAC valve. Page 2738 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 674 CHART 29 Mechanical Specifications Intake Manifold: Mechanical Specifications Intake Manifold DIMENSIONS Warpage (Maximum) ........................................................................................................................... .................................... 0.10 mm (0.0039 inch) TIGHTENING SPECIFICATIONS Intake Manifold To Cylinder Head ................................................................................................................................................. 18 Nm (13 ft. lbs.) Intake Manifold Stay To Cylinder Head ......................................................................................................................................... 18 Nm (13 ft. lbs.) Throttle Body To Intake (Nuts) ...................................................................................................................................................... 18 Nm (13 ft. lbs.) Throttle Body To Intake (Bolts) ..................................................................................................................................................... 18 Nm (13 ft. lbs.) Throttle Body to Intake (Nuts) 13 ft.lb Throttle Body to Intake (Bolts) 13 ft.lb Page 363 Cruise Control Switch Page 2652 Page 4735 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Refill ..................................................................................................................................................... ........................................................................ 2.2 Pt Specifications Compression Check: Specifications Compression Pressure: Minimum [1] ......................................................................................................................................... ........................................ 1,000 kPa (145 psi) Standard [1] ................................................................ ..................................................................................................... 1,200 kPa (174 psi) or more Pressure Difference: Between Each Cylinder .......................................................................................................................................................... 100 kPa (15 psi) or less [1] @ 250 rpm Page 3390 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2482 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3731 Junction Block And Wire Harness Connector Page 4214 Seals and Gaskets: Service and Repair Rear Differential Pinion Seal REPLACEMENT HINT: Pre-runner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT 3. REMOVE COMPANION FLANGE Page 2716 Page 740 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Specifications Valve Clearance: Specifications Intake 0.13 - 0.23 mm Exhaust 0.27 - 0.37 mm Page 2524 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 884 Glossary Of Term And Symbols (Part 1 Of 2) Page 1849 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2476 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 673 CHART 28 Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Page 1687 Radiator: Service and Repair On-Vehicle Cleaning Using water or a steam cleaner, remove any mud or dirt from the radiator core. CAUTION: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle radiator core.) Page 4294 Procedure for Tacoma & PreRunner Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7, 8, 9, 13 and 14 grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5, 6, 10, 11 and 12 grease fittings (double cardan joint). Procedure for Tundra Page 4840 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plates. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the flow chart. G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illustration. H. Install the brake pads with the anti-squeal shims. I. If equipped with anti-squeal spring: Install the anti-squeal springs. J. Press the piston in firmly and install the brake caliper. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. K. Install the wheel assembly. 2. Fixed Type Brake Caliper There are two types of brake pads: Page 1052 Adjusting Shim Selection Chart (Exhaust) Page 3455 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4435 b. Install the synchronizer pull ring, cone ring and outer ring to the gear spline piece No.5. c. Check the braking effect of the synchronizer ring. turn the synchronizer ring in one direction while pushing it to the gear cone. check that the ring locks. If it does not lock, replace the synchronizer ring. 4. Inspect shift fork and hub sleeve clearance. Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or hub sleeve. 5. Inspect reverse idler gear radial clearance. Using a dial indicator, measure the reverse idler gear radial clearance. Standard Clearance: 0.040-0.082 mm (0.0016-0.0032 inch) Maximum Clearance: 0.130 mm (0.0051 inch) If the clearance exceeds the Maximum, replace the reverse idler gear or reverse idler gear shaft. Page 2622 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 2394 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3870 Fluid - A/T: Testing and Inspection 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 2949 CHART 23 Page 350 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3101 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3611 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1418 Drive Belt: Service and Repair DRIVE BELT REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kg.cm, 29 ft.lb) 4. LOOSEN AND REMOVE COMPRESSOR DRIVE BELT DRIVE BELT INSTALLATION Installation is in the reverse order of removal. A/T - Torque Converter Bolt Installation Precautions Flex Plate: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 199 Ignition Control Module: Description and Operation CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is a 2-cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one ignition coil. In the 2-cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the 2 spark plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 701 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSORS INSPECTION (Bank 1, Sensor 1, Bank 1 Sensor 2) INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connector. Bank 1 Sensor 1 Bank 1 Sensor 2 (b) Using an ohmmeter. measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F): 11 - 16 ohms If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Reconnect the oxygen sensor connector. Page 1194 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 2569 Standard Values Of ECM Terminals Chart 2 Of 2 Specifications Counter Gear: Specifications Counter 5th Gear Radial Clearance Standard .......................................................................................................................................................... 0.015-0.068 mm (0.0006-0.0027 inch) Maximum ................................................................................ ............................................................................................... 0.160 mm (0.0063 inch) Counter Gear Roller Bearing Journal Diameter Minimum .............................................................................................................................................. ............................... 27.860 mm (1.0968 inch) Page 356 Cruise Control Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4253 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating Removal and Installation Rear Axle Shaft (1 Of 2) Page 219 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Page 1079 Drive Belt: Specifications Power Steering Belt Drive Belt - Power Steering / Tension: New Belt .............................................................................................................................................. .................................................. 135 - 180 lbs. Used Belt ................................................................... ............................................................................................................................... 85 - 120 lbs. Page 2430 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2043 CHART 10 Page 2170 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 1215 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3074 Glossary Of Term And Symbols (Part 1 Of 2) Page 3145 EGR Control Solenoid: Testing and Inspection VACUUM SWITCHING VALVE FOR EGR INSPECTION Except Model No. VZN17O - 4wd Long Wheel Base 1. REMOVE VSV ASSEMBLY Disconnect the connector and 2 vacuum hoses and remove the 2 bolts and VSV assembly. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20°C (68°F): 33 - 39 ohm If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to port G. (b) Apply battery positive voltage across the terminals. Page 567 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2616 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2777 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4725 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 591 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 770 EGR Temperature Sensor: Testing and Inspection EGR GAS TEMPERATURE SENSOR INSPECTION Except Model No. VZN17O - 4wd Long Wheel Base 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50°C (122°F): 84 - 97 K ohms At 100°C (212°F): 11 - 16 K ohms At 150°C (302°F): 2 - 4 K ohms If the resistance is not as specified. replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) Page 1934 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 3565 Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4675 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 2811 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 1038 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Page 2909 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 1856 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2964 Warranty Information Applicable warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 2695 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Improvement ENGINE EG006-99 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma June 18, 1999 Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed 10 reduce the possibility of moisture contacting the ceramic element. Affected Vehicles ^ 1996-1999 model year Tacomas built before the VINs listed below. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Page 40 Electronic Brake Control Module: Testing and Inspection NOTE: - Tools Required: - TOYOTA hand-held tester, or equivalent. - TOYOTA break-out-box, or equivalent. Connect Hand-Held Tester And Break-Out-Box 1. Hook up the hand-held tester and break-out-box to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. NOTE: Hand-held tester has a "Snapshot" function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the hand-held tester/break-out-box operator's manual for further details. Page 2467 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Page 1712 Glossary Of Term And Symbols (Part 1 Of 2) Page 2962 * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 4563 Fluid - Transfer Case: Fluid Type Specifications API GL-4 or GL-5 SAE 75W-90 Page 3623 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 1132 Coolant: Fluid Type Specifications Coolant Classification Type: Ethylene Glycol Based Page 3671 Page 2667 CHART 7 Page 4724 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 4153 b. Using a dial indicator, measure the differential case runout. Maximum case runout: 0.04 mm (0.0016 inch) c. Remove the differential case. 10. Remove side bearings. Using SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), remove the side bearings from the differential case. HINT: Fix the claws of SST to the notch in the differential case. 11. Disassemble differential case assembly. a. Using a pin punch and a hammer, remove the straight pin. b. Remove these parts from the differential case: ^ Pinion shaft ^ 2 pinion gears ^ 2 pinion gear thrust washers ^ 2 side gears ^ 2 side gear thrust washers With Differential Lock Page 1031 Ignition Cable: Testing and Inspection HIGH-TENSION CORDS INSPECTION 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS Disconnect the high - tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS (a) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (b) Disconnect the high-tension cord at the grommet. DO NOT pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high-tension cord is disconnected. 4. INSPECT HIGH-TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 K ohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. Symptom Related Diagnostic Procedures One Touch 2-4 Selector System A/T - Torque Converter Bolt Installation Precautions Torque Converter: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 4050 2. CHECK BALL 3. STRAINER Page 1985 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2182 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2611 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2065 CHART 29 Page 4545 Position Of Parts In Body (Fig 30) Service Hints R15 REAR DIFF. LOCK SW 5-2: Closed with the diff. lock SW at ON position F 7 4WD CONTROL ECU (Disconnected wiring connector from ECU) 7-Ground: Always Continuity 10-Ground: Pulse generation with vehicle moving 5-Ground: 9-14 Volts with the ignition SW ON 1-Ground: About 0 Volts with the rear diff. lock indicator light ON 9-14 Volts with the rear diff. lock indicator light OFF R15 REAR DIFF. LOCK MOTOR 2-3: 0.3-100 Ohms Splice Points Page 3879 Fluid Pump: Specifications Service Specifications OIL PUMP Body Clearance Standard .............................................................................................................................................. .................. 0.07 - 0.15 mm (0.0028 - 0.0059 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Tip Clearance Standard .............................................................................................................................................. .................. 0.11 - 0.14 mm (0.0043 - 0.0055 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Side Clearance Standard .............................................................................................................................................. .................. 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Maximum ............................................................. .............................................................................................................................. 0.1 mm (0.004 inch) Pump Body Bushing Inside Diameter Maximum ............................................................................................................................................. ........................................ 38.19 mm (1.5035 inch) Stator Shaft Bushing Inside Diameter Front Side, Maximum .......................................................................................................................... ........................................ 21.58 mm (0.8496 inch) Rear Side, Maximum ........................................... ........................................................................................................................ 27.08 mm (1.0661 inch) Page 2006 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 1963 Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 3561 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2108 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2714 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection ABS Light: Testing and Inspection ABS Warning Light Circuit Wiring Diagram Page 2979 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3657 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1265 Compression Check: Testing and Inspection NOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature. 2. Remove ignition coils. 3. Remove spark plugs. Using a 16 mm plug wrench, remove the 6 spark plugs. 4. Check cylinder compression pressure. (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (174 psi) or more. Minimum pressure: 1,000 kPa (145 psi) Difference between each cylinder: 100 kPa (15 psi) or less. (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. Reinstall spark plugs. Torque: 20 Nm (14 ft. lbs.) 6. Reinstall ignition coils. Page 2385 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3000 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Heater - Snow Entry Into Heater Unit Heater Core: Technical Service Bulletins Heater - Snow Entry Into Heater Unit HEATING AND AIR CONDITIONING AC002-99 Title: SNOW ENTRY INTO HEATER UNIT Models: '96 - '98 Tacoma & 4Runner February 26, 1999 Introduction Production changes to the Cowl Top Louver and Heater Unit have been made to improve resistance to snow entry into the Heater Unit and improve durability of Air Mix Door. Affected Vehicles ^ All 1996 - 1997 Tacomas and 4Runners ^ 1998 Tacomas and 4Runners starting before the listed VINs: Warranty Information Applicable Warranty **: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Page 114 Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1167 Engine Oil: Technician Safety Information WARNING: - Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. Page 1916 Page 3563 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) Connect a voltmeter to terminals PTNK and E2 of the ECM and measure the output voltage under ambient atmospheric pressure. - Apply vacuum (2.0 kPa, 15 mm Hg. 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V - Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V - Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 2505 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2140 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4251 7. Remove drive shaft. Push the steering knuckle outward and remove the drive shaft HINT: When it is difficult to disconnect the drive shaft, tap the drive shaft with a plastic hammer. NOTICE: Be careful not to damage the oil seal, boots and dust seal. 8. Remove snap ring from inboard shaft. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the differential with differential oil. Disassembly / Assembly DISASSEMBLY 1. Check drive shaft. a. Check to see that there is no play in the inboard and outboard joints. b. Check to see that the inboard joint slides smoothly in the thrust direction. c. Check to see that there is no significant play in the radial direction of the inboard joint. d. Check the boot for damage. 2. Remove inboard joint boot clamps. a. Using pliers, draw hooks together and remove the large clamp. b. Using a side cutter, cut the small boot clamp. c. Slide the inboard joint boot toward the outboard joint. 3. Remove inboard joint tulip. a. Place matchmarks on the inboard joint and drive shaft b. Remove the inboard joint tulip from the drive shaft 4. Remove tripod joint from drive shaft. Page 2252 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Number One Cylinder: Locations Firing Order: 1-2-3-4-5-6 Page 730 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3015 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2513 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 366 Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (2 Of 3) Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (3 Of 3) INSPECTION PROCEDURE Page 2373 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3239 Fuel: Specifications Fuel Type Unleaded fuel only, Research Octane Number 91 (Octane Rating 87) or higher. Page 2877 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Brakes - Pad Knock Noise Brake Pad: All Technical Service Bulletins Brakes - Pad Knock Noise BRAKES BR005-97 March 14, 1997 Title: 4RUNNER AND TACOMA 4X4 BRAKE PAD KNOCK NOISE Models: '97 4Runner, & '97 Tacoma Introduction A brake pad modification has been made on 4Runner and Tacoma 4x4 models to reduce pad knocking noise. This problem usually occurs upon first pedal application after changing driving direction (i.e. forward to reverse). Affected Vehicles ^ 1997 4Runner starting VINs: JT3GM84R * V0004296 JT3HM84R * V0007803 JT3GN86R * V0010776 JT3HN86R * V0027427 JT3HN87R * V0027427 ^ 1997 Tacoma (4x4) starting VIN 4TA **** N * VZ220360 Modification Detail The steel backing plate of the brake pad was widened from 119.3 mm to 119.55 mm in order to reduce the pad movement in the brake caliper. Parts Information MODEL PART NUMBER 4Runner 04465-35190 Tacoma (4x4) 04465-35080 Page 3738 Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Locations-R/B No.2-Engine Compartment Left (Canada) (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-Ground: Approx 13 Ohms Page 3391 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 544 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3408 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram With Automatic Disconnecting Differential Page 3414 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 509 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2554 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1817 Engine Control-Connectors Page 1201 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Page 996 Alignment: Tools and Equipment Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer Specifications Parking Pawl: Specifications Parking lock pawl bracket .................................................................................................................... ................................................ 7.4 Nm (65 inch lbs.) Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 1416 Drive Belt: Testing and Inspection Alternator GENERATOR DRIVE BELT INSPECT DRIVE BELT 1. Visually check the belt for excessive wear, frayed cords etc. HINT: Cracks on the ribbed side of the belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. 2. Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG 20 (95506-00020) or Borroughs No. BT-33-73F Drive belt tension: New belt: 160 ± 25 lb Used belt: 100 ± 20 lb If necessary, adjust the drive belt tension. HINT: New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After 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. - After installing a new belt, run the engine for approx. 5 minutes and then recheck the tension. Page 190 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1037 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 2637 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2973 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3532 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 2835 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 3463 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3522 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1289 (i) Install and uniformly tighten the 10 beaning cap bolts, in several passes, in the sequence shown. Torque: 16 Nm (12 ft. lbs.) B. Exhaust. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears. (c) Place the exhaust camshaft on the cylinder head. (d) Install the 4 bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (f) Install and uniformly tighten the 8 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 Nm (12 ft. lbs.) (g) Remove the service bolt. (h) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. 2. Install camshafts of LH cylinder head. CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid Page 2160 EGR Temperature Sensor: Mechanical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) EGR Sensor to EGR Valve 14 ft.lb Page 517 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 330 Glossary Of Term And Symbols (Part 1 Of 2) Page 3004 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2936 CHART 8 CHART 9 Page 4603 Output Shaft: Application and ID Select a snap ring that will allow minimum axial play and install it to the shaft. A: ......................................................................................................................................................... .................... 2.10-2.15 mm (0.0827-0.0846 inch) B: ........................................................................... ................................................................................................... 2.15-2.20 mm (0.0846-0.0866 inch) C: ......................................................................................................................................................... ..................... 2.20-2.25 mm (0.0866-0.0886 inch) D: .......................................................................... ................................................................................................... 2.25-2.30 mm (0.0886-0.0906 inch) E: ......................................................................................................................................................... ..................... 2.30-2.35 mm (0.0906-0.0925 inch) F: .......................................................................... .................................................................................................... 2.35-2.40 mm (0.0925-0.0945 inch) G: ......................................................................................................................................................... .................... 2.40-2.45 mm (0.0945-0.0965 inch) H: ........................................................................... .................................................................................................. 2.45-2.50 mm (0.0965-0.0984 inch) J: .......................................................................................................................................................... ..................... 2.50-2.55 mm (0.0984-0.1004 inch) K: .......................................................................... ................................................................................................... 2.00-2.05 mm (0.0787-0.0807 inch) L: .......................................................................................................................................................... .................... 2.05-2.10 mm (0.0807-0.0827 inch) Page 1708 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 4359 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2255 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3335 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 547 Page 2685 Page 1159 Fluid - Transfer Case: Fluid Type Specifications API GL-4 or GL-5 SAE 75W-90 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2503 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1808 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 287 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2432 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4011 Page 3076 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 795 A/T, M/T - Alignment Pin Service Precaution Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T, M/T - Alignment Pin Service Precaution T-SB-0053-08 May 8, 2008 Alignment Pin Installation during Transmission/Transaxle Assembly Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of alignment pins during transmission/transaxle assembly installation. Missing alignment pins may result in incorrect alignment and failure of the transmission/transaxle assembly. Use the information below when installing a transmission/transaxle assembly. Parts Information Warranty Information Repair Procedure 1. Inspect the rear side of the engine block assembly for 2 alignment pins. ^ If there are less than 2 alignment pins present one may have been removed with the transmission/transaxle assembly. Check the removed assembly for the missing alignment pins. Go to step 2. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3895 Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Locations-R/B No.2-Engine Compartment Left (Canada) (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-Ground: Approx 13 Ohms Page 2294 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Specifications Timing Belt Tensioner: Specifications DIMENSIONS Protrusion From Housing Side ..............................................................................................................................10.0 - 10.8 mm (0.394 - 0.425 inch) TIGHTENING SPECIFICATIONS Timing Belt Tensioner To Oil Pump .............................................................................................................................................. 27 Nm (20 ft. lbs.) Page 2085 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 102 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2500 Glossary Of Term And Symbols (Part 1 Of 2) Page 697 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4676 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2993 Glossary Of Term And Symbols (Part 1 Of 2) Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Specifications Case Adapter: Specifications SERVICE SPECIFICATIONS Transfer Adaptor: Oil Seal Drive In Depth .................................................................................................................................. 45.6 +/- 0.5 mm (1.795 +/- 0.020 inch) TORQUE SPECIFICATIONS Transfer Adaptor To: Transmission Case .............................................................................................................................. ........................................... 37 N.m (27 ft. lbs.) Control Shift Lever Retainer .......................................................................................................................................................... 18 N.m (13 ft. lbs.) Page 144 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2706 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Front Differential Carrier Differential Carrier: Service and Repair Front Differential Carrier Disassembly Differential Carrier DISASSEMBLY 1. W/ A.D.D.: Remove A.D.D. actuator. a. Remove the 4 bolts. Page 2152 Vehicle Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 3531 Page 1875 Glossary Of Term And Symbols (Part 1 Of 2) Page 2986 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSORS INSPECTION (Bank 1, Sensor 1, Bank 1 Sensor 2) INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connector. Bank 1 Sensor 1 Bank 1 Sensor 2 (b) Using an ohmmeter. measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F): 11 - 16 ohms If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Reconnect the oxygen sensor connector. Page 103 Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3223 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3499 Page 1716 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1321 NOTE: If using a standard bearing, replace 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, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4", and "5" accordingly. Reference: Standard sized bearing center wall thickness: No. 1: Mark "1" ............................................................................................................................................... 1.991 - 1.994 mm (0.0784 - 0.0785 inch) Mark "2" ............................................................................................................................................... 1.994 1.997 mm (0.0785 - 0.0786 inch) Mark "3" ............................................................................................................................................... 1.997 2.000 mm (0.0786 - 0.0787 inch) Mark "4" ............................................................................................................................................... 2.000 2.003 mm (0.0787 - 0.0789 inch) Mark "5" ............................................................................................................................................... 2.003 2.006 mm (0.0789 - 0.0790 inch) Others: Mark "1" ............................................................................................................................................... 1.989 - 1.992 mm (0.0783 - 0.0784 inch) Mark "2" ............................................................................................................................................... 1.992 1.995 mm (0.0784 - 0.0785 inch) Mark "3" ............................................................................................................................................... 1.995 1.998 mm (0.0785 - 0.0787 inch) Mark "4" ............................................................................................................................................... 1.998 2.001 mm (0.0787 - 0.0788 inch) Mark "5" ............................................................................................................................................... 2.001 2.004 mm (0.0788 - 0.0789 inch) Cylinder block Main journal bore diameter: Mark "1" .......................................................................................................................................... 68.010 - 68.016 mm (2.6776 - 2.6778 inch) Mark "2" .......................................................................................................................................... 68.016 68.022 mm (2.6778 - 2.6780 inch) Mark "3" .......................................................................................................................................... 68.022 68.028 mm (2.6780 - 2.6783 inch) Crankshaft main journal diameter: Mark "O" .......................................................................................................................................... 63.996 - 64.000 mm (2.5195 - 2.5197 inch) Mark "1" .......................................................................................................................................... 63.990 63.996 mm (2.5193 - 2.5195 inch) Mark "2" .......................................................................................................................................... 63.985 63.990 mm (2.5191 - 2.5193 inch) Page 2922 A/F and 02 Sensor Identification Page 3784 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 1885 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Standard Values Of ECM Terminals Chart 1 Of 2 Page 3034 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3955 Page 584 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1950 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3711 Spark Plug: Testing and Inspection SPARK PLUGS INSPECTION 1. DISCONNECT HIGH -TENSION CORDS 2. REMOVE IGNITION COILS 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 4. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 5. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: ND: K16TR11 NGK: BKR5EKB-11 Page 2562 Standard Values Of ECM Terminals Chart 2 Of 2 Page 2489 Cranking Signal: Testing and Inspection Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. WIRING DIAGRAM INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix chart of problem symptoms. Step 1 Page 250 If continuity is not as specified, replace the switch. Page 2089 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3320 (c) Select the active test mode on the TOYOTA hand- held tester. (d) Please refer to the TOYOTA hand - held tester operators manual for further details. (e) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (f) Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (g) Turn the ignition switch to LOCK. (h) Disconnect the TOYOTA hand-held tester from the DLC3. Page 2876 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3122 Canister Purge Solenoid: Testing and Inspection VACUUM SWITCHING VALVE (VSV) FOR EVAP INSPECTION 1. REMOVE VSV Disconnect the connector and 2 EVAP hoses and remove the screw and VSV. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20°C (68°F): 30 - 34 ohms If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air does not flow from port E to port F. (b) Apply battery positive voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Page 189 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2938 CHART 11 Page 3576 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Specifications Clutch Switch: Specifications Clutch Start Switch: On-Off Stroke ...................................................................................................................................... .......................... 8 +/- 0.5 mm (0.31 +/- 0.20 inch) Page 2710 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Clutch Fluid: Specifications Fluid Type FMVSS No. 116 DOT 3 Brake Fluid Page 569 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2009 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 2857 Page 4542 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 26) Diagram Information and Instructions Cranking Signal: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 515 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4546 Splice Points Location Of Splice Points (Fig 36) Page 4361 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 669 CHART 26 Page 1912 Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3560 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3097 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4300 INSTALLATION Installation is in the reverse order of removal. HINT: Rear propeller shaft 3-joint type: ^ Center bearing center line and the center bearing housing center line must be adjusted within°1 mm of each other in the vehicles longitudinal direction when the vehicle is unloaded. ^ When adjusting the center bearing housing center line, it should be perpendicular to the axis of front propeller shaft. HINT: With a grease gun, pump grease into each fitting until it begins to flow around the oil seal. Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 4356 operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 374 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4319 Universal Joint: Service and Repair Dana Made REPLACEMENT Page 3614 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1840 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 1899 Glossary Of Term And Symbols (Part 1 Of 2) Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2691 CHART 29 Page 3098 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3899 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4083 Clutch Pedal Assembly: Adjustments 1. Check that pedal height is correct. Pedal height from floor panel: 70.0-180.0 mm (6.692-7.086 inch) Pedal height from asphalt sheet: 67.0-177.0 mm (6.574-6.968 inch) 2. If necessary, adjust pedal height. Loosen the lock nut and turn the stopper bolt until the height is correct. tighten the lock nut. 3. Check that pedal freeplay and push rod play are correct push in on the pedal until the beginning of clutch resistance is felt. Pedal freeplay: 5.0-15.0 mm (0.197-0.591 inch) Gently push on the pedal until the resistance begins to increase a little. Push rod play at pedal top: .0-5.0 mm (0.039-0.197 inch) 4. If necessary, adjust pedal freeplay and push rod play. a. Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct. b. Tighten the lock nut. c. After adjusting the pedal freeplay, check the pedal height. d. Connect the air duct and install the lower finish panel. 5. Check clutch release point. a. Pull the parking brake lever and install wheel stopper. b. Start the engine and idle the engine. c. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. d. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end Page 4919 Depress MOTOR Switch And Brake Pedal (h) Push and hold in the MOTOR switch for a few seconds. (i) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (j) Release the brake pedal. 7. Push MOTOR switch. Depress MOTOR Switch (a) Push and hold in the MOTOR switch for a few seconds. (b) Stop the engine. 8. Disconnect actuator checker (SST) from actuator. Disconnect the actuator checker (SST) and sub-wire harnesses (SST) from the actuator, control relay and body side wire harness. SST 09990-00150, 09990-00200, 09990-00210, 09990 - 00370 9. Connect connectors. (a) Connect the 2 connectors to the control relay. (b) Connect the connector to the actuator. 10. Clear the Diagnostic Trouble Code (DTC). Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2048 CHART 16 CHART 17 Page 3577 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3582 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1695 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Page 192 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection THROTTLE BODY ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) w/ EGR: Check the vacuum at each port. Start the engine. - Check the vacuum with your finger. 2. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Disconnect the sensor connector. Testing and Inspection Wiper Switch: Testing and Inspection INSPECT WIPER SWITCH CONTINUITY w/ Mist Wiper w/ Intermittent Wiper Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Specifications Idle Speed/Throttle Actuator - Electronic: Specifications At Cold At Hot Terminals +B and RSC or RSO 17.0 - 24.5 ohms at 14 - 122 deg F 21.5 - 28.5 ohms at 122 - 212 deg F Page 1472 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 1187 Refrigerant: Fluid Type Specifications Type R134a Page 2386 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1686 (b) Remove the 1 screw, 11 clips and radiator grille. 3. Disconnect upper radiator hose. 4. Disconnect radiator reservoir hose. 5. Disconnect lower radiator hose. 6. Remove No. 2 fan shroud. 7. A/T: Disconnect oil cooler hoses. 8. Remove radiator. Remove the 4 bolts and radiator. INSTALLATION Installation is in the reverse order of removal. NOTE: Insert the tabs of the radiator support through the radiator service holes. Torque the 4 bolts and radiator: 12 Nm (8.7 ft. lbs.) Page 3316 Fuel Supply Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened parts. INSPECTION INSPECT FUEL TANK AND LINE Page 1805 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2671 CHART 12 CHART 13 Page 4501 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3020 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 555 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 194 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1880 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4147 Differential Carrier (3RZ-FE, 5VZ-FE w/o Differential Lock) INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. Page 1883 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3161 EGR Valve: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION EGR VALVE INSPECTION Installation is in the reverse order of removal. 1. DRAIN ENGINE COOLANT 2. REMOVE EGR PIPE 3. REMOVE EGR GAS TEMPERATURE SENSOR 4. REMOVE EGR VALVE (a) Disconnect these hoses from the EGR valve: - Vacuum hose (from VSV for EGR) - EGR hose (from EGR vacuum modulator) - Water hose (from water bypass pipe) - Water bypass hose (from IAC valve) Initial Inspection and Diagnostic Overview Cruise Control Module: Initial Inspection and Diagnostic Overview MAIN SWITCH CIRCUIT (CRUISE CONTROL SWITCH) CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Cruise Control Switch WIRING DIAGRAM Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (1 Of 3) Page 272 - There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. Specifications Rear Engine Plate: Specifications TIGHTENING SPECIFICATIONS Rear Plate To Cylinder Head ..................................................................................................................................................... 8.0 Nm (71 inch lbs.) Rear End Plate To Cylinder Block ............................................................................................................................................. 7.5 Nm (66 inch lbs.) Page 3418 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2465 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3712 6. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) 7. REINSTALL SPARK PLUGS Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 8. REINSTALL IGNITION COILS 9. RECONNECT HIGH-TENSION CORDS Page 2840 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 790 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4357 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4418 Output Shaft: Application and ID Output Shaft Snap Ring Thickness: Clutch Hub No.1 Mark A ................................................................................................................................................. ............... 2.30-2.35 mm (0.0906-0.0925 inch) Mark B ........................................................................ ........................................................................................ 2.35-2.40 mm (0.0925-0.0945 inch) Mark C .............................................................................................................................................................. .. 2.40-2.45 mm (0.0945-0.0965 inch) Mark D ..................................................................................... ........................................................................... 2.45-2.50 mm (0.0965-0.0984 inch) Mark E ............ .................................................................................................................................................... 2.50-2.55 mm (0.0984-0.1004 inch) Mark F ........................................................................................ ......................................................................... 2.55-2.60 mm (0.1004-0.1024 inch) Mark G ............. ................................................................................................................................................... 2.60-2.65 mm (0.1024-0.1043 inch) Output Shaft Snap Ring Thickness: Clutch Hub No.2 Mark A ................................................................................................................................................. ............... 1.80-1.85 mm (0.0709-0.0728 inch) Mark B ........................................................................ ........................................................................................ 1.85-1.90 mm (0.0728-0.0748 inch) Mark C .............................................................................................................................................................. .. 1.90-1.95 mm (0.0748-0.0768 inch) Mark D ..................................................................................... ........................................................................... 1.95-2.00 mm (0.0768-0.0787 inch) Mark E ............ .................................................................................................................................................... 2.00-2.05 mm (0.0787-0.0807 inch) Mark F ........................................................................................ ......................................................................... 2.05-2.10 mm (0.0807-0.0827 inch) Mark G ............. ................................................................................................................................................... 2.10-2.15 mm (0.0827-0.0846 inch) Output Shaft Snap Ring Thickness, Rear Mark A ................................................................................................................................................. ............... 2.65-2.70 mm (0.1043-0.1063 inch) Mark B ........................................................................ ........................................................................................ 2.70-2.75 mm (0.1063-0.1083 inch) Mark C .............................................................................................................................................................. .. 2.75-2.80 mm (0.1083-0.1102 inch) Mark D ..................................................................................... ........................................................................... 2.80-2.85 mm (0.1102-0.1122 inch) Mark E ............ .................................................................................................................................................... 2.85-2.90 mm (0.1122-0.1142 inch) Mark F ........................................................................................ ......................................................................... 2.90-2.95 mm (0.1142-0.1161 inch) Mark G ............. ................................................................................................................................................... 2.95-3.00 mm (0.1161-0.1181 inch) Mark H ........................................................................................ ........................................................................ 3.00-3.05 mm (0.1181-0.1201 inch) Mark J ............... .................................................................................................................................................. 3.05-3.10 mm (0.1201-0.1220 inch) Mark K ........................................................................................ ........................................................................ 3.10-3.15 mm (0.1220-0.1240 inch) Mark L ............... ................................................................................................................................................. 3.15-3.20 mm (0.1240-0.1260 inch) Mark M ....................................................................................... ........................................................................ 3.20-3.25 mm (0.1260-0.1280 inch) Mark N ............... ................................................................................................................................................. 3.25-3.30 mm (0.1280-0.1299 inch) Mark P ........................................................................................ ......................................................................... 3.30-3.35 mm (0.1299-0.1319 inch) Mark Q ............. ................................................................................................................................................... 3.35-3.40 mm (0.1319-0.1339 inch) Mark R ........................................................................................ ........................................................................ 3.40-3.45 mm (0.1339-0.1358 inch) Mark S ............... .................................................................................................................................................. 3.45-3.50 mm (0.1358-0.1378 inch) Specifications Planetary Gears: Specifications FRONT PLANETARY GEAR Maximum Inside Diameter .............................................................................................................................................................. 24.08 mm (0.9480 inch) Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) PLANETARY SUN GEAR Sun Gear Bushing Inside Diameter, Maximum .............................................................................................................................. 27.08 mm (1.0661 inch) REAR PLANETARY GEAR Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. ......................................................................................................................... 1.00 mm (0.0394 inch) Page 2288 Components For Removal And Installation Part 2 Of 2 Page 1996 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4350 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 25) Page 4367 Electronically Controlled Transmission And A/T Indicator (Part 2 Of 3) Page 4756 ABS Warning Light Circuit Inspection Procedure (Part 1 Of 2) Page 2983 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1016 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 2559 Engine Control Module: Connector Views Standard Values Of ECM Terminals Chart 1 Of 2 Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Page 3953 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4260 Rear Axle Shaft (1 Of 2) Page 3115 Catalytic Converter: Description and Operation View: Typical Catalytic Converter View: Typical Catalytic Converter Catalytic converters are used to convert carbon monoxide (CO), hydrocarbon (HC) and oxides of nitrogen (NOx) into water vapor (H2O), carbon dioxide (CO2) and nitrogen (N2). The catalysts used to create these conversions are platinum, palladium and rhodium (depending on type of converter). During engine operation, all of the exhaust gases flow through the converter where a chemical change takes place. This change causes the temperature inside the converter to be higher than the temperature of the exhaust gases when they leave the engine. Due to this increase in heat the converter is insulated so that its outside temperature is about the same temperature as the muffler. However, due to its solid mass, the converter remains hot much longer than the muffler. The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle. Catalytic converters maybe of the monolith or pellet type. Although all vehicles with a catalytic converter must use unleaded fuel, small amounts of leaded fuel can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has a built-in restrictor. The conventional Oxidizing Catalytic (OC) converter, uses platinum and palladium, included as a fine coating on the substrate, to reduce harmful exhaust fumes. The Three-Way Catalytic (TWC) converter, contains platinum and palladium as conventional oxidizing agents in addition to rhodium. The Warm-Up (WU) converter, is installed in the exhaust system ahead of the main converter. This converter operates on the same principle as the main converter, but it reacts more rapidly to incoming gases. It is especially effective in converting gases immediately after start up. Page 4891 2. Remove pistons from cylinder. (a) Prepare the wooden plate to hold the pistons. (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. WARNING: Do not place your fingers in front of the piston when using compressed air. 3. Remove piston seals. Using a screwdriver, remove the 4 piston seals from the cylinder. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTE: Apply lithium soap base glycol grease to the parts indicated by arrows in EXPLODED VIEW. Page 2362 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4142 a. Install a new snap ring to the shaft b. Using a plastic-faced hammer, install the shaft to the differential case. c. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction. d. Check that the intermediate shaft will not come out by trying to pull it completely out by hand. 29. W/ A.D.D.: Install clutch case to differential tube. a. Install a new O-ring to the tube. b. Coat the O-ring with MP grease. c. Install the clutch case to the tube. d. Torque the 2 torx bolts using Torx socket E14 (Part No. 09044-00010, or locally manufactured tool). Torque to 78 Nm (58 ft. lbs.) 30. W/ A.D.D.: Install clutch sleeve. 31. Install differential tube to differential. a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case. b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol. c. Apply FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the differential, as shown. HINT: Install the differential tube within 10 minutes after applying FIPG. d. Install the differential tube to the differential. e. Clean the threads of the 4 bolts (W/O A.D.D.) or 2 torx bolts (W/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene. f. Apply adhesive Part No. 08833-00070, THREE BOND 1324, or equivalent, to 2 or 3 threads of the bolts end. g. Torque the 4 bolts (W/O A.D.D.) or 4 torx bolts (W/ A. D.D.) using Torx socket E14 (Part No. 09044-00010 or locally manufactured tool). Torque: W/O A.D.D.: 105 Nm (77 ft. lbs.) W/ A.D.D.: 78 Nm (58 ft. lbs.) 32. W/ A.D.D.: Install A.D.D. actuator. a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case. Page 2372 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2042 CHART 8 CHART 9 Page 1311 Connecting Rod: Testing and Inspection Thrust Clearance CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - 0.0130 inch) Maximum thrust clearance: 0.380 mm (0.0150 inch) If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. Specifications Shift Fork: Specifications SERVICE SPECIFICATIONS Shift Fork To Hub Sleeve Clearance: Maximum ............................................................................................................................................. ........................................ 1.0 mm (0.039 inch) TORQUE SPECIFICATIONS Shift Fork To Shift Fork Shaft ............................................................................................................................................................. 20 N.m (14 ft. lbs.) Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3730 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Junction Block and Wire Harness Connector Page 2124 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1764 Exhaust Manifold: Testing and Inspection INSPECTION Measure the surfaces contacting the cylinder head for warpage. Maximum warpage: 1.00 mm (0.0394 inch) If warpage is greater than the maximum, replace the exhaust manifold. Page 4308 Procedure for Tacoma & PreRunner Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7, 8, 9, 13 and 14 grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5, 6, 10, 11 and 12 grease fittings (double cardan joint). Procedure for Tundra Page 798 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 4246 HUB BOLT REPLACEMENT 1. Remove front wheel. 2. Remove brake caliper and disc. 3. Remove hub bolt. Using Special Service Tool (SST), remove the hub bolt. 4. Install hub bolt. Install a washer and nut to the hub bolt, as shown in the illustration, and install the hub bolt by tightening the nut. 5. Install brake disc and caliper. 6. Install front wheel. Torque: 110 Nm (83 ft. lbs.) Free Wheel Hub Page 2059 Page 1725 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Page 2937 CHART 10 Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2553 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Main Switch Circuit (Cruise Control Switch) Cruise Control Switch: Testing and Inspection Main Switch Circuit (Cruise Control Switch) MAIN SWITCH CIRCUIT (CRUISE CONTROL SWITCH) CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Cruise Control Switch WIRING DIAGRAM Inspection Procedure / Main Switch Circuit (Cruise Control Switch) (1 Of 3) Page 1673 Heater Core: Service and Repair HEATER RADIATOR REMOVAL Heater Unit 1. REMOVE HEATER UNIT See: Heating and Air Conditioning/Heater Core Case 2. REMOVE HEATER RADIATOR a. Remove the 2 screws and the 2 plates. b. Pull the heater radiator out. HEATER RADIATOR INSTALLATION Installation is in the reverse order of removal. Page 1887 Page 4526 Page 950 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2661 Locations Horn Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 1994 Glossary Of Term And Symbols (Part 1 Of 2) Page 587 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 452 Inspection Procedure / Stop Light Switch Circuit (2 Of 4) Inspection Procedure / Stop Light Switch Circuit (3 Of 4) Page 752 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4143 b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol. c. Apply FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the clutch case, as shown. HINT: Install the actuator within 10 minutes after applying FIPG. d. Torque the 4 bolts. Torque to 21 Nm (15 ft. lbs.) Companion Flange Dust Deflector 1. Remove dust deflector. Using SST 09950 - 00020 and a press, remove the dust deflector. 2. Install new dust deflector. Using SST 09636 - 20010 and a press, install a new dust deflector. Page 2827 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications TIGHTENING SPECIFICATIONS Oil Dipstick Guide To Generator Bracket ........................................................................................................................................... 8 Nm (71 inch lbs.) Page 491 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 935 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Electrical Specifications Oxygen Sensor: Electrical Specifications Bank 1: Sensor 1, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1: Sensor 2, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1 Sensor 1 Bank 1 Sensor 2 Page 3517 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 4320 1. Place matchmarks on shaft and yoke. 2. Remove snap rings. a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using pliers, remove the 4 snap rings from the grooves. 3. Remove spider bearings. a. Using Special Service Tool (SST) 09332-25010, push out the bearing from the propeller shaft. HINT: Sufficiently raise the part indicated by a so that it does not come into contact with the bearing. b. Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the bearing on opposite side in the same procedure. c. Install the 2 removed bearing outer races to the spider. d. Using SST 09332-25010, push out the bearing from the yoke. e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. 4. Select spider bearing. Select the bearing according to whether or not there is a drill mark on the yoke section. Page 1917 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 3644 Specifications Fluid Pan: Specifications Oil pan x Transmission case ............................................................................................................... .................................................. 7.4 Nm (65 inch lbs.) Drain Plug ....................................................... ......................................................................................................................................... 20 N.m (15 ft. lbs.) Service and Repair Gear: Service and Repair NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY 1. Remove front bearing. Using a press, remove the front bearing. 2. Remove rear bearing. Using Special Service Tool (SST) 09555-55010 and a press, remove the rear bearing. Specifications Coolant Drain Plug: Specifications TIGHTENING SPECIFICATIONS Drain Plug To Cylinder Block ............................................................................................................... ................................................ 39 Nm (29 ft. lbs.) Page 2919 Applicable Vehicles Page 1997 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2705 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 693 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4718 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Diagram Information and Instructions Differential: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness And Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Page 2370 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 902 Knock Sensor: Oscilloscope Patterns and Waveforms Page 145 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Specifications Fuel Rail: Specifications Fuel Rail to Intake Manifold 10 ft.lb Page 550 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 4570 If the clearance exceeds the Maximum, replace the drive rotor, driven rotor or pump body. ASSEMBLY Assembly us in the reverse order of disassembly. Page 3350 and Hot is from 50°C (122°F) to 100°C (212°F). (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM (a) Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed is kept at 900 - 1300 rpm for 10 seconds, check that it returns to idle speed. (d) Stop the engine. (e) Disconnect the air assist hose from the IAC valve and plug it. (f) Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors." (g) Remove the SST from the DLC1. SST 09843-18020 (h) Reconnect the air assist hose to the IAC valve. Description and Operation Malfunction Indicator Lamp: Description and Operation OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTC prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 trips, the MIL goes off but the DTC remain recorded in the ECM memory. Page 1657 Removal and Installation Brake Proportioning/Combination Valve: Service and Repair Removal and Installation REMOVAL 1. Disconnect shackle No.2 from bracket. (a) Remove the nut and disconnect the shackle No.2. (b) Remove the cushion retainer, 2 cushions and collar. 2. Remove LSP & BV assembly. Disconnect Brake Lines And Mounting Bolts (a) Using SST, disconnect the brake lines from the valve body. SST 09023 - 00100 (b) Remove the clip from the flexible hose bracket. (c) Remove the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt, and remove the LSP & BV assembly and flexible hose bracket. INSTALLATION 1. Install LSP & BV assembly to frame. Install the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt with the LSP & BV assembly and flexible hose bracket. Torque: 29 Nm (22 ft. lbs.) 2. Connect brake line. Using SST, connect the brake lines. Torque: 15 Nm (11 ft. lbs.) SST 09023 - 00100 3. Connect shackle No. 2 bracket. (a) Set dimension A. Initial set: 120 mm (4.72 inch) (c) Tighten the lock nut. Torque: 24 Nm (18 ft. lbs.) (c) Connect the shackle No.2 with the 2 cushions and collar to the shackle bracket. Torque: 13 Nm (9 ft. lbs.) Page 4322 b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 7. Check spider bearing. ^ Check that the spider baring moves smoothly. ^ Check the spider bearing axial play. Bearing axial play: Maximum 0.05 mm (0.0020 inch) HINT: Install new spider bearings on the shaft side in the procedure described above. Page 3604 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 488 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2050 CHART 20 Page 2994 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4024 C. Lift off upper valve body and plate as a single unit holding the valve body plate to the upper valve body as shown in the illustration. Caution: Be careful that the check balls and strainer do not fall out. 2. Modification: A. Turn over the upper valve body, remove plate & gaskets. B. Add new check ball in the location shown in illustration. 3. Assembly: A. GReassemble upper and lower valve body halves using new gaskets. B. GInstall 25 bolts to upper valve body. Torque: 56 in. lbs. (6.4 N/m, 65 kgf/cm) Caution: Careful to reinstall the bolts in their proper locations as shown in the illustration. Bolt Length: A: 38 mm (1.50") B: 20 mm (0.79") C: 28 mm (1.10") C. Complete reassembly as described in the Repair Manual for the vehicle being serviced. Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately. NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. Fill Brake Reservoir BRAKE FLUID BLEEDING 1. Fill brake reservoir with brake fluid. Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAEJ17O3 or FMVSS No.116 DOT 3 2. Bleed master cylinder. NOTE: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plugs with your fingers, and release the Brake Pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Page 2896 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1314 Connecting Rod: Service and Repair Assembly 1. Assemble piston and connecting rod. (a) Using a small screwdriver, install a new snap ring on one side of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. (b) Gradually heat the piston to 60° C (140° F). (c) Coat the piston pin with engine oil. (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Page 2828 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1071 (a) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. CAUTION: Always turn the crankshaft clockwise. (b) Check that the timing marks of the RH and LH timing pulleys 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. (c) Remove the crankshaft pulley bolt. 11. Install timing belt guide. Install the guide, facing the cup side outward. 12. Install No. 1 timing belt cover and starter wire bracket. (a) Check that the timing belt cover gaskets has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: ^ Using a screwdriver and gasket scraper, remove all the old gasket material. ^ Thoroughly clean all components to remove all the loose material. No. 1 Cover (Back) ^ Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. (b) Install the timing belt cover with the 4 bolts. Torque: 9 Nm (80 inch lbs.) Page 4488 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3192 (l) Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) (m)Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator. and plug the hose end. (o) Measure the fuel pressure at idle. Fuel pressure 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm. 21 psi) or more If pressure is not as specified. check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (s) Remove the other union bolt. 3 gaskets and fuel pipe from the delivery pipes. (t) Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 4911 Inspect valve piston pin and load sensing spring contact surface for wear. Wear limit: 0.7 mm (0.028 inch) REASSEMBLY 1. Assemble these parts to load sensing spring: (a) Load sensing valve boot. (b) Load sensing spring boot. (c) 4 bushings. (d) 2 rubber plates. (e) 2 collars. NOTE: Apply lithium soap-base glycol grease to all rubbing areas. - Do not mistake the valve side for the shackle side of the load sensing spring. 2. Install shackles No.1 and No.2. (a) Install the lock nut and shackle No.1 to the shackle No.2. (b) Torque the nut. Torque: 24 Nm (18 ft. lbs.) 3. Install load sensing spring to shackle No.1. (a) Install the load sensing spring and 2 plate washer to the shackle No.1. (b) Torque the bolt and nut. Torque: 18 Nm (13 ft. lbs.) 4. Install load sensing spring to valve body. Install the load sensing spring to the load sensing valve with the clip. 5. Install valve bracket. (a) Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts. (b) Torque the bolt and nut with the 2 plate washers. Torque: 18 Nm (13 ft. lbs.) Page 2506 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4161 11. Inspect tooth contact between ring gear and drive pinion. a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. b. Hold the companion flange firmly and rotate the ring gear in both directions. c. Inspect the tooth pattern. If the teeth are not contacting properly, use the following chart to select a proper washer for correction. Thickness: 1.70 mm (0.0669 inch) 1.73 mm (0.0681 inch) 1.76 mm (0.0693 inch) 1.79 mm (0.0705 inch) 1.82 mm (0.0717 inch) 1.85 mm (0.0728 inch) 1.88 mm (0.0740 inch) 1.91 mm (0.0752 inch) 1.94 mm (0.0764 inch) 1.97 mm (0.0776 inch) 2.00 mm (0.0787 inch) 2.03 mm (0.0799 inch) 2.06 mm (0.0811 inch) 2.09 mm (0.0823 inch) 2.12 mm (0.0835 inch) 2.15 mm (0.0846 inch) 2.18 mm (0.0858 inch) 2.21 mm (0.0870 inch) 2.24 mm (0.0882 inch) 2.27 mm (0.0894 inch) 2.30 mm (0.0906 inch) 2.33 mm (0.0917 inch) 12. Remove companion flange. 13. Remove oil slinger and front bearing. 14. Install bearing spacer and front bearing. a. Place a new bearing spacer on the shaft. b. Place the front bearing and oil slinger. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 4148 Maximum vertical runout: 0.09 mm (0.0035 inch) Maximum lateral runout: 0.09 mm (0.0035 inch) If the runout is not within the specification, replace the companion flange. 2. Check ring gear runout. Using a dial indicator, measure the ring gear runout. Maximum runout: 0.05 mm (0.0020 inch) If the runout is not within the specification, replace the ring gear. 3. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. 4. Check tooth contact between ring gear and drive pinion. 5. Check side gear backlash. Measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch) Page 3017 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 789 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2383 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 645 Page 93 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2927 Page 1993 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1323 Torque: 1st pass: 61 Nm (45 ft. lbs.) 2nd pass: Turn additional 90° CAUTION: Do not turn the crankshaft. (i) Remove the 8 bolts and main bearing cap. (See procedure (a) and (b) above). (j) Measure the Plastigage at its widest point. Standard clearance: No. 1: STD: 0.020 - 0.038 mm (0.0008 - 0.0015 inch) U/S 0.25: 0.019 - 0.059 mm (0.0007 - 0.0023 inch) Others: STD: 0.024 - 0.042 mm (0.0009 - 0.0017 inch) U/S 0.25: 0.023 - 0.063 mm (0.0009 - 0.0025 inch) Maximum clearance: 0.08 mm (0.0031 inch) NOTE: If replacing the cylinder block subassembly, the bearing standard clearance will be: No. 1: 0.010 - 0.049 mm (0.0004 - 0.0020 inch) Others: 0.014 - 0.053 mm (0.0006 - 0.0021 inch) If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft. Page 2694 * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 2845 Glossary Of Term And Symbols (Part 1 Of 2) Page 559 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 167 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2377 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Specifications Air Bag Control Module: Specifications TORQUE SPECIFICATIONS Airbag Sensor Assembly...................................................................................................................... .................................................. 21 Nm (15 ft. lb.) Testing and Inspection PCV Valve Hose: Testing and Inspection PCV HOSES AND CONNECTORS INSPECTION VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. Page 715 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4035 Valve Body: Specifications Tightening Specifications Upper valve body x Lower valve body ................................................................................................................................................ 6.4 Nm (56 inch lbs.) Solenoid x Valve body ................................................................................................... ............................................................................ 10 Nm (7 ft. lbs.) Oil strainer x Valve body ............. .............................................................................................................................................................. . 10 Nm (7 ft. lbs.) Detent spring x Valve body .................................................................................... .................................................................................... 10 Nm (7 ft. lbs.) Valve body x Transmission case ..................................................................................................................................................... ............ 10 Nm (7 ft. lbs.) Page 4491 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2263 Page 2495 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 489 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3464 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2782 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY 1. Check that there is continuity between terminals with the switch ON (switch pin released). 2. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 2901 Components For Removal And Installation Part 2 Of 2 Page 198 Page 1925 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 139 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 319 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1884 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Valve Guide Seal: Specifications DIMENSIONS Inside Diameter .................................................................................................................................................. 6.010 - 6.030 mm (0.2366 - 0.2374 inch) Outside Diameter For Repair Part STD ......................................................................................................................................................... 11.033 - 11.044 mm (0.4344 - 0.4348 inch) O/S 0.05 .................................................................................................................................................. 11.083 - 11.094 mm (0.4363 - 0.4368 inch) Page 2734 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 831 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Specifications Exhaust Pipe: Specifications TIGHTENING SPECIFICATIONS Exhaust Crossover Pipe To Exhaust Manifold ............................................................................................................................... 45 Nm (33 ft. lbs.) Front Pipe To Exhaust Crossover Pipe ........................................................................................................................................... 48 Nm (35 ft. lbs.) Front Exhaust Pipe Support Bracket To Front Pipe ............................................................................................................................................ ..................................... 44 Nm (33 ft. lbs.) Transmission .................................................................... ......................................................................................................... 44 Nm (33 ft. lbs.) Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Testing and Inspection Turn Signal Switch: Testing and Inspection TURN SIGNAL SWITCH INSPECTION INSPECT SWITCH CONTINUITY Reference If continuity is not as specified, replace the switch. Page 1694 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: N-cap, 108 kPa Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2955 Page 629 Applicable Vehicles Page 3219 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1645 Glossary Of Term And Symbols (Part 1 Of 2) Page 2659 Page 1109 C. Transfer the Pressure Switch. a. Remove Pressure Switch from Liquid Tube. b. Using the new O-Ring (P/N 90099-14122) install the Pressure Switch to new Liquid and Suction Tube Assembly. Tightening Torque: 7.2 ft/lbf (9.8 N.m, 100 Kgf/cm) CAUTION: Use double wrenches when removing or installing the pressure switch. NOTE: Lubricate new O-Ring with 134a Compressor oil. D. Assemble in reverse order. 2. Replacement of Suction Hose: Tightening Torque: Page 2435 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2109 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Throttle Valve Angle Specifications Throttle Body: Specifications Throttle Angle Specifications Throttle Angle Specifications Throttle Valve Fully Closed 10 deg Page 933 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2183 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2654 A/F and 02 Sensor Identification Page 1461 Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration with SAE 5W-30 being the preferred engine oil. Oil capacity: Drain and refill w/o Oil filter change: 4.9 liters (5.2 US qts.) w/ Oil filter change: 5.2 liters (5.5 US qts.) Dry fill: 5.9 Liters (6.2 US qts.) (c) Reinstall the oil filler cap. 4. Start engine and check for oil leaks. 5. Check engine oil level. Specifications Clutch Switch: Specifications Clutch Start Switch: On-Off Stroke ...................................................................................................................................... .......................... 8 +/- 0.5 mm (0.31 +/- 0.20 inch) Page 4494 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 661 CHART 21 Page 376 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 4006 Page 3012 Glossary Of Term And Symbols (Part 1 Of 2) Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 2992 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3213 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Axle Shaft, Conventional Fixed/Floating Axle Shaft: Diagrams Axle Shaft, Conventional Fixed/Floating Rear Axle Shaft (1 Of 2) Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 4232 Rear Axle Shaft (2 Of 2) Page 2177 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2079 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1015 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 2141 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 589 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2351 Adjusting Shim Selection Chart (Intake) Page 2247 Glossary Of Term And Symbols (Part 1 Of 2) Page 1466 Oil Cooler: Service and Repair REMOVAL 1. Drain engine coolant. 2. Disconnect oil cooler hoses. Disconnect the No. 1 and No. 2 oil cooler hoses. 3. Remove oil cooler. Remove the union bolt, gaskets, oil cooler and O-ring. INSTALLATION Installation is in the reverse order of removal. NOTE: Replace the O-ring with a new part. - Use a new gasket to the union bolt. P/S - Pressure Feed Hose Modified Power Steering Line/Hose: Technical Service Bulletins P/S - Pressure Feed Hose Modified STEERING ST001-98 April 17, 1997 Title: POWER STEERING PRESSURE FEED HOSE Models: '97 - '98 Tacoma Introduction The Power Steering Pressure Feed Hose for 4 cylinder Tacomas has been changed to improve sealing effectiveness, and the surface finish (circular machining marks) of the pressure feed hose banjo fitting has been refined. Production Change Information ^ 1997 - 1998 Tacoma 4x2 and 4x4 vehicles with 4 cylinder engine. MODEL ENGINE STARTING VIN Tacoma 4x2 and 4x4 2RZ-FE and 3RZ-FE 4TA******WZ047962 Required Tools & Materials TOOLS & MATERIALS QUANTITY 24 mm Open End Wrench 1 Torque Wrench with 24 mm socket 1 Power Steering Fluid (Automatic Transmission Fluid Dextron II or III) 1 Parts Information CURRENT PART NUMBER PART NAME APPLICATION 44411-04010 Hose, Pressure Feed (4x2) 9609 - 9706 44411-04020 Hose, Pressure Feed (4x2) 9706-Present 44411-04030 Hose, Pressure Feed (4x4) 9706-Present (MTM) 44411-04040 Hose, Pressure Feed (4x4) 9706-Present (ATM) 90430-16242 Gasket, Pressure Feed All Warranty Information Applicable Warranty: This repair Is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date, Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3085 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Locations Daytime Running Lamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2590 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3896 P 1 PARK/NEUTRAL POSITION SW 4-Ground: Approx. 12 Volts with ignition SW ON position O 4-B, S 4-A O/D MAIN SW A-5-A-10, B-1-B-3: Open with O/D main SW at ON position Open with O/D main SW at OFF position S 5-A, B STOP LIGHT SW A-1-A-2, B-1-B-2: Closed with Brake Pedal Depressed E 5-A, E 6-D, E 7-C, E 8-B ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) IDL-E2: 0-3 Volts with Throttle Valve fully closed 9-14 Volts with Throttle Valve open VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with shift lever at expect 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at expect L position L4-E1: 10-14 Volts with Transfer Shift at H2 or H4 position 0 Volts with Transfer shift at L4 position OIL-W-E1: 0.1-4.9 Volts +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Page 3690 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 641 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 3662 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3022 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2226 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2578 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3467 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Specifications Brake Fluid: Specifications Required Brake Fluid SAE DOT3 Page 2283 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2366 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2206 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3454 Glossary Of Term And Symbols (Part 1 Of 2) Page 1219 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4117 INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. If the runout is greater than the maximum, replace the companion flange. Maximum runout: 0.10 mm (0.0039 inch) 2. Check ring gear backlash. Using SST 09564-32011 and a dial indicator, measure the ring gear backlash. If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) 3. Measure drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) 4. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. If necessary, disassemble and inspect the differential. Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) Page 2849 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Locations Page 1066 Alternately loosen the 2 bolts and remove them, then remove the belt tensioner and dust boot. 21. Remove timing belt. 22. Remove RH camshaft timing pulley. (a) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, loosen the pulley bolt. (b) Remove the bolt, knock pin and camshaft timing pulley with timing belt. 23. Remove LH camshaft timing pulley. (a) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, loosen the pulley bolt. (b) Remove the bolt, knock pin and camshaft timing pulley. 24. Remove No. 2 idler pulley. Remove the bolt and No. 2 idler pulley. 25. Remove No. 1 idler pulley. Using a 10 mm hexagon wrench, remove the pivot bolt, No. 1 idler pulley and plate washer. 26. Remove crankshaft timing pulley. NOTE: If the pulley cannot be removed by hand, use SST Puller C Set # 09950 - 50010 (Hanger 150 # 09551 - 05010, Slide Arm # 09552 - Page 2888 Glossary Of Term And Symbols (Part 1 Of 2) Page 4328 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Page 624 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 3496 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4793 - There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. Page 1672 Heater Core: Testing and Inspection HEATER RADIATOR INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Page 4848 Warranty Information NOTE: Replacement of the front brake pad kit and/or shims is limited to correction of a problem based upon a customer's complaint and subject to all of the provisions of Toyota Warranty Policy Bulletin POL94-18, dated October 10, 1994. Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness And Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Page 1750 (c) Install the water pump with the 7 bolts. Torque: 20 Nm (14 ft. lbs.) 2. Connect No. 2 oil cooler hose. 3. Install thermostat and water inlet. 4. Install timing belt. Refer to Engine. Page 2925 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 125 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2365 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2942 CHART 16 CHART 17 Locations One Touch 2-4 Selector System Page 1390 Valve Seat: Testing and Inspection INSPECT AND CLEAN VALVE SEATS 1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. 2. Check the valve seating position. Apply a thin coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate the valve. 3. Check the valve face and seat for the following: - If blue appears 360° around the face, the valve is concentric. If not, replace the valve. - If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. - Check that the seat contact is in the middle of the valve face with these widths: 1.0 - 1.4 mm (0.039 - 0.055 inch) If not, correct the valve seats as follows: (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 60° and 45° cutters to correct the seat. Page 3949 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4720 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2287 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 4680 Electronically Controlled Transmission And A/T Indicator-Connectors Page 4265 9. Replace oil seal (inner side). a. Using SST 09308-00010, remove the oil seal. b. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150), install a new oil seal. c. Apply MP grease to the oil seal lip. 10. install rear axle shaft in backing plate. a. Apply MP grease to the oil seal lip. b. Install the backing plate and bearing retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing plate. d. Using snap ring pliers, install a new snap ring. 11. w/ ABS: Install ABS speed sensor rotor and bearing retainer (differential side). Using SST 09316-60011 (09316-00051) and a press, install a new sensor rotor and new bearing retainer to the axle shaft. Standard length: 122.2 ±1.0 mm (4.811 ±0.039 inch) Hub Bolt Removal and Installation Specifications Exhaust Manifold: Specifications DIMENSIONS Warpage (Maximum) ........................................................................................................................... .................................... 1.00 mm (0.0394 inch) TIGHTENING SPECIFICATIONS Exhaust Manifold To Cylinder Head .............................................................................................................................................. 40 Nm (30 ft. lbs.) Page 2906 Knock Sensor: Oscilloscope Patterns and Waveforms Page 2997 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2058 CHART 25 Page 1098 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 3319 (b) Using SST, tighten the flare nut to specified torque. SST 09631-22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 28 N.m (285 kgf.cm, 21 ft.lbf) for using SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). 3. Observe these precautions when removing and installing the injectors. (a) Never reuse the O-ring. (b) When placing a new O-ring on the injector, take care not to damage it in any way. (c) Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. 4. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. 5. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTICE: Do not start the engine. Page 1546 (a) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. CAUTION: Always turn the crankshaft clockwise. (b) Check that the timing marks of the RH and LH timing pulleys 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. (c) Remove the crankshaft pulley bolt. 11. Install timing belt guide. Install the guide, facing the cup side outward. 12. Install No. 1 timing belt cover and starter wire bracket. (a) Check that the timing belt cover gaskets has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: ^ Using a screwdriver and gasket scraper, remove all the old gasket material. ^ Thoroughly clean all components to remove all the loose material. No. 1 Cover (Back) ^ Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. (b) Install the timing belt cover with the 4 bolts. Torque: 9 Nm (80 inch lbs.) Page 4218 Torque: 2RZ-FE: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 3RZ-FE, 5VZ-FE w/o Diff. lock: 147 Nm (1,500 kgf-cm, 109 ft. lbs.) 3RZ-FE, 5VZ-FE w/ Diff. lock: 196 Nm (2,000 kgf-cm, 145 ft. lbs.) 14. ADJUST DRIVE PINION PRELOAD 15. STAKE DRIVE PINION NUT 16. CONNECT REAR PROPELLER SHAFT 17. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: Above - 18°C (O°F) SAE 90 Below - 18°C (0°F) SAE 80W or 80W - 90 Capacity Page 563 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2232 Page 2920 Page 2717 Oxygen Sensor: Description and Operation Sensor Cut-Away Reference CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 1324 NOTE: If using a standard bearing, replace 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, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4", and "5" accordingly. Reference: Standard sized bearing center wall thickness: No. 1: Mark "1": 1.991 - 1.994 mm (0.0784 - 0.0785 inch) Mark "2": 1.994 - 1.997 mm (0.0785 - 0.0786 inch) Mark "3": 1.997 - 2.000 mm (0.0786 - 0.0787 inch) Mark "4": 2.000 - 2.003 mm (0.0787 0.0789 inch) Mark "5": 2.003 - 2.006 mm (0.0789 - 0.0790 inch) Others: Mark "1": 1.989 - 1.992 mm (0.0783 - 0.0784 inch) Mark "2": 1.992 - 1.995 mm (0.0784 - 0.0785 inch) Mark "3": 1.995 - 1.998 mm (0.0785 - 0.0787 inch) Mark "4": 1.998 - 2.001 mm (0.0787 0.0788 inch) Mark "5": 2.001 - 2.004 mm (0.0788 - 0.0789 inch) Cylinder block Main journal bore diameter: Mark "1": 68.010 - 68.016 mm (2.6776 - 2.6778 inch) Mark "2": 68.016 - 68.022 mm (2.6778 2.6780 inch) Mark "3": 68.022 - 68.028 mm (2.6780 - 2.6783 inch) Crankshaft main journal diameter: Mark "O": 63.996 - 64.000 mm (2.5195 - 2.5197 inch) Mark "1": 63.990 - 63.996 mm (2.5193 2.5195 inch) Mark "2": 63.985 - 63.990 mm (2.5191 - 2.5193 inch) (k) Completely remove the Plastigage. Page 2154 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 762 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Power Window Switch / Master Switch Power Window Switch: Testing and Inspection Power Window Switch / Master Switch INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's Switch / Window Unlock Driver's switch: Window unlock Driver's Switch / Window Lock Driver's switch: Window lock Passenger's Switch / Window Unlock Passenger's switch: Window unlock Passenger's Switch / Window Lock Passenger's switch: Window lock If operation is not as specified, replace the switch. Testing and Inspection Shift Interlock Solenoid: Testing and Inspection Inspect shift lock solenoid. a. Disconnect the solenoid connector. b. Using an ohmmeter, measure the resistance at each terminal. Standard Resistance 20-28 ohms. If resistance value is not as specified. Replace the solenoid. c. Apply battery positive voltage at each terminal. At this time, confirm that the solenoid operates. If the solenoid does not operate, replace the solenoid. Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2330 Page 4157 b. Using a dial indicator, check the ring gear runout. Maximum runout: 0.10 mm (0.0039 inch) c. Remove the differential case. 5. Install new oil strange ring and drive pinion front and rear bearing outer races. a. Using SST 09316-60011 (09316-00011, 09316-00021) and a hammer, install new oil storage ring. b. Using SST 09316-60011 (09316-00011, 09316-00021, 09316-00051) and a press, install the outer races. 6. Install drive pinion front bearing. a. Install the plate washer on the drive pinion. b. Using SST 09506-30012 and a press, install the rear bearing onto the drive pinion. 7. Temporarily adjust drive pinion preload. a. Install the drive pinion, front bearing and oil slinger. HINT: Assemble the spacer and oil seal After adjusting the gear contact pattern. b. Install the companion flange with SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020). Page 3786 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2431 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Radiator: Specifications TIGHTENING SPECIFICATIONS Radiator Support To Body ........................................................................................................................................................... 12 Nm (107 in. lbs.) Page 2348 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only those valves indicated in the illustration. 1. Using a thickness gauge, measure the clearance between the valve lifter and camshaft. Valve Clearance (Cold): 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Page 1040 6. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) 7. REINSTALL SPARK PLUGS Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 8. REINSTALL IGNITION COILS 9. RECONNECT HIGH-TENSION CORDS Page 323 Inspection Procedure / Stop Light Switch Circuit (2 Of 4) Inspection Procedure / Stop Light Switch Circuit (3 Of 4) Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Standard Values Of ECM Terminals Chart 1 Of 2 Page 3226 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Page 4176 c. Using SST 09330-00021 to hold the flange, torque the nut. Torque to 147 Nm (109 ft lbs.) 19. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting): New bearing: 1.1 - 1.7 Nm (10.0 - 15.2 inch lbs.) Reused bearing: 0.6 - 0.9 Nm (5.7 - 8.3 inch lbs.) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) a little at a time until the specified preload is reached. Maximum torque: 451 Nm (333 ft. lbs.) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload. 20. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) 21. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) 22. Recheck tooth contact between ring gear and drive pinion. 23. Check runout of companion flange. 24. Stake drive pinion nut. With Differential Lock 1. Remove dust deflector to companion flange. Using SST 09950-00020 and a press, remove the dust deflector. Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 56 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Page 3060 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2003 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1532 Timing Belt: Diagrams Page 3908 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1 Of 3) Page 1170 Engine Oil: Testing and Inspection Oil Pressure Check 1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the oil quality is visibly poor, replace it. 2. Check engine oil level. The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. 3. Remove oil pressure switch. Using Special Service Tool (SST) Oil Pressure Switch Socket # 09816 - 30010 or equivalent, remove the oil pressure switch. 4. Install oil pressure gauge. 5. Start engine. Allow the engine to warm up to normal operating temperature. 6. Measure oil pressure. Oil pressure: At idle speed: 29 kPa (4.3 psi) or more At 3,000 rpm: 245 - 520 kPa (36 - 75 psi) 7. Turn engine off. 8. Remove oil pressure gauge. 9. Install oil pressure switch. (a) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent. (b) Using SST Oil Pressure Switch Socket # 09816 - 30010 or equivalent, install the oil pressure switch. 10. Start engine and check for leaks. Page 1372 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T-Thickness of used shim A-Measured valve clearance N-Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. INSTALL CYLINDER HEAD COVERS 7. INSTALL INTAKE AIR CONNECTOR Specifications Accumulator: Specifications ACCUMULATOR SPRING (A340F) ACCUMULATOR SPRING (A343F) Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 4425 6. Remove hub sleeve No.2 assembly and 3rd gear assembly. a. Using a snap ring expander, remove the snap ring. b. Using a press, remove the hub sleeve No.2 assembly and 3rd gear assembly. c. Remove the needle roller bearing. 7. Remove shifting key and spring from hub sleeve No.2 assembly. Using a screwdriver, remove the 3 shifting keys and 2 springs. Page 3105 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3128 (e) While holding port F closed, apply vacuum (2.94 kPa 22 mm Hg, 0.87 in. Hg) to port D, check that the vacuum does not decrease when port C is closed and check that the vacuum decreases when port C is released. If a problem is found, replace the charcoal canister. (f) Remove the plugs. 5. REINSTALL CHARCOAL CANISTER Page 2821 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4614 If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve. ASSEMBLY 1. Install front drive clutch sleeve onto drive sprocket. Install the front drive clutch sleeve onto the drive sprocket. HINT: Make sure to install the clutch sleeve in the correct direction. 2. Install drive sprocket with front drive clutch sleeve, spacer and bearing. a. Apply gear oil to the shaft and needle roller bearing. b. Install the needle roller bearing in the drive sprocket. c. Install the drive sprocket with the front drive clutch sleeve assembly. d. Install the spacer to align it with the ball. e. Using SST 09316-60011 (09316-00011 ,09316-00071) and a press, install a new bearing with the outer race snap ring groove toward the rear. 3. Inspect drive sprocket thrust clearance. Using a feeler gauge, measure the drive sprocket thrust clearance. Standard Clearance. 0.10-0.25 mm (0.0039-0.0098 inch) Page 3498 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4170 HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary. 6. Install drive pinion rear bearing. Using SST 09506-35010 and a press, install the rear bearing onto the drive pinion. 7. Temporarily adjust drive pinion preload. a. Install the drive pinion and front bearing. HINT: Assemble the spacer, washers and oil seal after adjusting the gear contact pattern. b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050), install the companion flange. c. Coat the threads of the nut with hypoid gear oil. d. Adjust the drive pinion preload by tightening the companion flange nut. Using SST 09330-00021 to hold the flange, torque the nut. NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. e. Using a torque wrench, measure the preload. Preload (at starting): New bearing: 1.1 - 1.7 N*m (10.0 - 15.2 inch lbs.) Reused bearing: 0.6 - 0.9 Nm (5.7 - 8.3 inch lbs.) Page 4139 f. Inspect the tooth contact pattern. If the teeth are not contacting properly, use the following chart to select a proper washer for correction. Washer thickness 1.69 - 1.71 mm (0.0665 - 0.0673 inch) 1.72 - 1.74 mm (0.0677 - 0.0685 inch) 1.75 - 1.77 mm (0.0689 - 0.0697 inch) 1.78 - 1.80 mm (0.0701 - 0.0709 inch) 1.81 - 1.83 mm (0.0713 - 0.0720 inch) 1.84 - 1.86 mm (0.0724 - 0.0732 inch) 1.87 - 1.89 mm (0.0736 - 0.0744 inch) 1.90 - 1.92 mm (0.0748 - 0.0756 inch) 1.93 - 1.95 mm (0.0760 - 0.0768 inch) 1.96 - 1.98 mm (0.0772 - 0.0780 inch) 1.99 - 2.01 mm (0.0783 - 0.0791 inch) 2.02 - 2.04 mm (0.0795 - 0.0803 inch) 2.05 - 2.07 mm (0.0807 - 0.0815 inch) 2.08 - 2.10 mm (0.0819 - 0.0827 inch) 2.11 - 2.13 mm (0.0831 - 0.0839 inch) 2.14 - 2.16 mm (0.0843 - 0.0850 inch) 2.17 - 2.19 mm (0.0854 - 0.0862 inch) 2.20 - 2.22 mm (0.0866 - 0.0874 inch) 2.23 - 2.25 mm (0.0878 - 0.0886 inch) 2.26 - 2.28 mm (0.0890 - 0.0898 inch) 2.29 - 2.31 mm (0.0902 - 0.0909 inch) 2.32 - 2.34 mm (0.0913 - 0.0921 inch) 14. Remove companion flange and oil slinger. 15. Remove rear bearing. Page 3855 Overdrive Brake Page 3511 Page 1143 Fluid - A/T: Testing and Inspection 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Electrical Specifications Oxygen Sensor: Electrical Specifications Bank 1: Sensor 1, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1: Sensor 2, Terminals +B & HT 11 - 16 ohms at 68 deg F Bank 1 Sensor 1 Bank 1 Sensor 2 Page 3769 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Diagrams Page 3995 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 866 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. INSTALL MANIFOLD GAUGE SET See: Heating and Air Conditioning/Service and Repair/Manifold Gauge Installation/Removal 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM PRESSURE SWITCH 4. RUN ENGINE AT APPROX. 1,500 RPM 5. INSPECT PRESSURE SWITCH OPERATION Check continuity between 3 and 4 terminals when refrigerant pressure is changed. as shown, in the illustration. If operation is not as specified, replace the pressure switch. 6. STOP ENGINE AND REMOVE MANIFOLD GAUGE SET 7. CONNECT CONNECTOR TO PRESSURE SWITCH 8. INSTALL GLOVE COMPARTMENT DOOR Page 2765 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Specifications Fuel Supply Line: Specifications Fuel Line (Union Bolt & Flare Nut Type) 25 ft.lb Fuel Line (Flare Nut Type) Using/SST 21 ft.lb Fuel Inlet Pipe to Intake Manifold 71 in.lb Torque Specifications Case: Specifications Torque Specifications Overdrive support x Transmission case .................................................................................................................................................... 25 Nm (19 ft. lbs.) Oil pan x Transmission case ....................................................................................... .......................................................................... 7.4 Nm (65 inch lbs.) Transmission housing 14 mm bolt ............................................................................................................................................................ 34 Nm (25 ft. lbs.) Transmission housing 17 mm bolt ............................................................................................................................................................ 57 Nm (42 ft. lbs.) Union ...................................................................................................................... .................................................................................. 29 Nm (22 ft. lbs.) Transmission case x Transfer adaptor ...................................................................................................................................................... 34 Nm (25 ft. lbs.) Transfer adaptor x Transfer ........................................................................................ .............................................................................. 36 Nm (27 ft. lbs.) Park/Neutral position switch .... ............................................................................................................................................................ 6.9 Nm (61 inch lbs.) Park/Neutral position switch adjusting bolt ................................................................................................................................................ 13 Nm (9 ft. lbs.) Vehicle speed sensor .......................................................................................................... ...................................................................... 16 Nm (12 ft. lbs.) Control Shaft Lever ......................... ....................................................................................................................................... 16 N.m (160 kgf-cm, 12 ft.lb.) Dynamic Damper ...................................................................................................... ............................................................. 37 N.m (380 kgf-cm, 27 ft.lb.) Page 2418 Step 2 Step 3 INSPECTION PROCEDURE Page 2977 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2434 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Specifications Valve Clearance: Specifications Intake 0.13 - 0.23 mm Exhaust 0.27 - 0.37 mm Page 4890 Brake Caliper: Service and Repair Disassembly and Reassembly Front Brake Components (4WD) DISASSEMBLY 1. Remove cylinder boot set rings and boots. Using a screwdriver, remove the 4 cylinder boot set rings and 4 boots from the caliper. Page 2078 Glossary Of Term And Symbols (Part 1 Of 2) Page 3592 Knock Sensor: Oscilloscope Patterns and Waveforms Page 2940 CHART 14 Page 805 Glossary Of Term And Symbols (Part 1 Of 2) Page 1612 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T-Thickness of used shim A-Measured valve clearance N-Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. INSTALL CYLINDER HEAD COVERS 7. INSTALL INTAKE AIR CONNECTOR Page 4538 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Junction Block and Wire Harness Connector Junction Block And Wire Harness Connector Page 2276 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4237 Rear Axle Shaft (2 Of 2) Page 4694 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3396 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 829 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3084 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 590 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Removal Piston Ring: Service and Repair Removal 1. Using a piston ring expander, remove the 2 compression rings. 2. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only. Page 939 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 81 Control Module HVAC: Service and Repair AMPLIFIER REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR Remove the 2 screws and the glove compartment door. 2. REMOVE A/C AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. AMPLIFIER INSTALLATION Installation is in the reverse order of removal. Page 334 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 756 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4429 10. Install output shaft center bearing. Using SST 09316-60011 (09316-00011, 09316-00071) and a hammer, drive in the bearing with the outer race snap ring groove toward the rear. 11. Inspect 1st gear thrust clearance. 12. Inspect 2nd gear thrust clearance. 13. Install 5th gear. Using SST 09316-60011 (09316-00031) and a press, install the 5th gear. Page 3658 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Specifications Drain Plug: Specifications TIGHTENING SPECIFICATIONS Plug: Front .................................................................................................................................................... ........................................... 39 Nm (29 ft. lbs.) Rear ........................................................................... ..................................................................................................................... 49 Nm (39 ft. lbs.) Page 931 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2485 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4666 Position Of Parts In Instrument Panel (1 Of 2) (Fig 28) Drivetrain - Propeller Shaft Joint Grease/Fittings Universal Joint: Technical Service Bulletins Drivetrain - Propeller Shaft Joint Grease/Fittings DRIVELINE & DIFFERENTIAL DL001-99 Title: PROPELLER SHAFT JOINT GREASE Models: '96-'99 4Runner 4WD, '95-'99 Tacoma 4WD, '98-'99 PreRunner, & '00 Tundra 4WD August 27, 1999 Introduction This Service Bulletin provides the location of the grease fittings for the propeller shaft joints as well as the type of grease to use with each fitting location. See the Scheduled Maintenance Guide of each vehicle for recommended lubrication intervals. Applicable Vehicles ^ 1996-1999 4Runner 4WD, 1995-1999 Tacoma 4WD, 1998-1999 PreRunnner, & 2000 Tundra 4WD Warranty Information Procedure for 4Runner Use a grease gun to apply multi-purpose grease to the No. 1, 2, 3, 7 and 8 grease fittings. Apply molybdenum disulfide lithium base chassis grease, NLGI No. 2, to the No. 4, 5 and 6 grease fittings (double cardan joint). Page 354 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 351 Glossary Of Term And Symbols (Part 1 Of 2) Page 4553 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4364 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Page 3262 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2649 A/F and 02 Sensor Identification Page 3439 Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2872 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Firing Order: Specifications Firing Order: 1-2-3-4-5-6 Page 2831 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ...................................................... 1.1 mm (0.043 in.) Page 727 Glossary Of Term And Symbols (Part 1 Of 2) Page 4607 1. Inspect rear output shaft. Using a micrometer, measure the outer diameter of the rear output shaft journal surface. Minimum Diameter: Part A: 27.98 mm (1.1016 inch) Part B: 36.98 mm (1.4561 inch) 2. Inspect drive sprocket radial clearance. Using a dial indicator, measure the radial clearance between the sprocket and shaft with the needle roller bearing installed. Standard Clearance: 0.010-0.055 mm (0.0004-0.0022 inch) Maximum Clearance: 0.055 mm (0.0022 inch) If the clearance exceeds the Maximum, replace the drive sprocket, rear output shaft or needle roller bearing. 3. Inspect front drive shift fork and clutch sleeve clearance. Using a feeler gauge, measure the clearance between the front drive shift fork and clutch sleeve. Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve. 4. Inspect high and low shift fork and clutch sleeve clearance. Using a feeler gauge, measure the clearance between the high and low shift fork and clutch sleeve. Maximum Clearance: 1.0 mm (0.039 inch) Page 989 Alignment: Specifications Model Front (A-B) Rear (C-D) A: Ground clearance of spindle center. B: Ground clearance C: Ground clearance of leaf spring front hanger pin center. of front adjusting cam bolt center. D: Ground clearance of rear axle shaft center 2.7L SWB M/T 46 mm 38 mm 2.7L SWB A/T 46 mm 38 mm 3.4L SWB 46 mm 38 mm 2.7L LWB M/T 44 mm 34 mm 2.7L LWB A/T 44 mm 34 mm 3.4 LWB M/T DLX 44 mm 35 mm 3.4 LWB A/T DLX 44 mm 35 mm 3.4 LWB M/T SR5 44 mm 34 mm 3.4 LWB A/T SR5 44 mm 34 mm Page 755 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Diagrams Specifications Tires: Specifications Tire Runout .......................................................................................................................................... ............................... less than 3.0 mm (0.118 inch) Tire Size And Pressure (Cold): P225/75R15 31 x 10.5R 15LT Front .................................................................................................................................................... ......................................... 180 kPa (26 psi) Rear ................................................................................ .............................................................................................................. 200 kPa (29 psi) Page 1050 HINT: 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. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size according to these Formula or Charts: Page 2090 Page 371 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3791 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 566 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3343 Specifications Piston Ring: Specifications DIMENSIONS End Gap Standard: No. 1 ...................................................................................................................................................... 0.300 - 0.500 mm (0.0118 - 0.0197 inch) No. 2 ...................................................................................................................................................... 0.400 - 0.600 mm (0.0157 - 0.0236 inch) Oil ......................................................................................................................................................... 0.150 - 0.550 mm (0.0059 - 0.0217 inch) Maximum: No. 1 .................................................................................................................................................... ............................ 1.100 mm (0.0433 inch) No. 2 ................................................................................ ................................................................................................ 1.200 mm (0.0472 inch) Oil ................ .............................................................................................................................................................. ...... 1.150 mm (0.0453 inch) Page 3387 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1783 Heat Shield: Specifications TIGHTENING SPECIFICATIONS Heat Insulator To Exhaust Manifold ............................................................................................................................................. 8 Nm (71 inch lbs.) Page 2488 Cranking Signal: Description and Operation CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. Specifications Fan Blade: Specifications TIGHTENING SPECIFICATIONS Fan To Fluid Coupling ......................................................................................................................... ...................................... 7.4 Nm (65 inch lbs.) Fluid Coupling To Fan Bracket .................................................................................................................................................. 5.4 Nm (48 inch lbs.) Page 541 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3842 Second Coast Brake Page 2549 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1108 Contents of Parts Kits Warranty Information Applicable Warranty: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Repair Procedure 1. Replacement of the Liquid and Suction Tube Assembly. A. Remove evaporator unit from vehicle. B. Disassemble the evaporator unit and remove the Liquid and Suction Tube assembly from evaporator. Page 1711 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 949 Description and Operation Malfunction Indicator Lamp: Description and Operation OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTC prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 trips, the MIL goes off but the DTC remain recorded in the ECM memory. Page 2982 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2617 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Locations Number One Cylinder: Locations Firing Order: 1-2-3-4-5-6 Page 1144 Fluid - A/T: Service and Repair 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 1960 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1003 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the 6 bolts and disconnect the No.2 timing belt cover. (d) Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. (e) Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (f) Wipe off any splattered gasoline. (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Reconnect the negative (-) terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high. replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections - Fuel pump - Fuel filter - Fuel pressure regulator (k) Disconnect the TOYOTA hand-held tester from the DLC3. Page 4366 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1 Of 3) Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Oil Clearance: STD ............................................................................................................................................................. 0.024 - 0.053 mm (0.0009 - 0.0021 inch) U/S 0.25 ..................................................................................................................................................... 0.023 - 0.069 mm (0.0009 - 0.0027 inch) Maximum ............................................................................ ..................................................................................................... 0.08 mm (0.0031 inch) Page 639 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4349 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 24) Page 1851 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 4912 Brake Proportioning/Combination Valve: Tools and Equipment Load Sensing Proportioning Valve (LSPV) gauge set ..................................................................................................................................... 09709 - 29017 Union nut wrench 10 mm ..................................................................................................................... ........................................................... 09023 - 00100 Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2509 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Brake Shoe: Specifications Standard Lining Thickness 0.236 in Minimum Lining Thickness 0.039 in Page 612 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2996 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2743 Standard Values Of ECM Terminals Chart 2 Of 2 Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2712 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2572 Step 7 INSPECTION PROCEDURE Page 4674 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 143 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Page 2146 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Vehicle Speed Sensor Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection Vehicle Speed Sensor INSPECT VEHICLE SPEED SENSOR OPERATION Check that there is continuity between terminals A and B 4 times for every revolution of the speedometer shaft. If operation is not as specified, replace the speedometer. Page 2829 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2656 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 1898 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2512 Page 483 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3543 Ignition Coil: Mechanical Specifications Ignition Coil to Cylinder Head 69 in.lb Electrical Specifications EGR Control Solenoid: Electrical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) Resistance 33 - 39 ohms at 68 deg F Page 1928 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4856 Brake Rotor/Disc: Testing and Inspection DISC THICKNESS 1. Using a micrometer, measure the disc thickness. - Standard thickness: 22.0 mm (0.866 inch) - Minimum thickness: 20.0 mm (0.787 inch) 2. If the disc is scored or worn, or if Its thickness is less than the minimum, repair or replace the disc. NOTE: Before measuring the runout, confirm that the front bearing play is within specification. DISC RUNOUT 1. Tighten the disc with the 3 hub nuts. 2. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. - Maximum disc runout: 0.07 mm (0.0028 inch) 3. If the runout is greater than maximum, replace the disc. 4. If necessary, adjust disc runout. See: Adjustments Page 2374 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3297 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 3202 Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Removal Camshaft: Service and Repair Removal 1. Remove camshafts of RH cylinder head. CAUTION: 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, 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, these steps should be carried out. A. Exhaust: (a) Boring the service bolt hole of the driven sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. (b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. (c) Secure the exhaust camshaft sub-gear to the main gear with a service bolt. Recommended service bolt: Thread diameter: 6.0 mm Thread pitch: 1.0 mm Bolt length: 16 - 20 mm NOTE: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. (d) Uniformly loosen and remove the 8 bearing cap bolts, in several passes, in the sequence shown. (e) Remove the 4 bearing caps and exhaust camshaft. B. Intake: Page 4904 Brake Proportioning/Combination Valve: Testing and Inspection Load Sensing Proportioning And By-Pass Valve Components FLUID PRESSURE INSPECTION 1. Set rear axle load. Rear axle load (include vehicle weight): 850 kg (1,874 lbs.) Page 1862 Page 4806 Check Pedal Freeplay (b) Push in the pedal by hand until the beginning of the resistance is felt, then measure the distance, as shown. Pedal freeplay: 3 - 6 mm (0.12 - 0.24 inch) NOTE: The freeplay to the 1st point of resistance is due to the play between the clevis and pin. It is 1 - 3 mm (0.04 - 0.12 inch) on the pedal. If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. 4. Check pedal reserve distance. Release the parking brake. Check Pedal Reserve Distance With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance, "a" at 490 N (110.2 lbs.): More than 72 mm (2.83 inch) If the reserve distance incorrect, troubleshoot the brake system. Page 4780 (j) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down. push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (k) Release the brake pedal. 5. Inspect the other wheels. (a) Change the connection of the actuator checker (SST) to the sub-wire harness E (SST) from the sub-wire harness MAIN connector to the SUB connector, or vice versa. (b) Repeating (c) to (j) of the step 4, check the actuator operation similarly. 6. Inspect the rear wheel. Depress MOTOR Switch And Brake Pedal (a) Turn the selector switch to the "REAR" position. (b) Push and hold in the MOTOR switch for a few seconds. (c) Depress the brake pedal and hold it until the step (g) is completed. Depress POWER Switch (d) Push the REAR switch while pressing the POWER switch. and check that the brake pedal does not go down. CAUTION: Do not keep the POWER switch pushed down for more than 10 seconds. (e) Release the REAR switch then the POWER switch, and check that the brake pedal goes down. Depress MOTOR Switch (f) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. (g) Release the brake pedal. Page 2833 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction. Specifications Ignition Cable: Specifications Maximum Resistance per Cord 25 K ohms Page 4493 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3066 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 635 Electrical - SRS And HV Wiring Repairs Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 290 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3332 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4162 c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) and the companion flange, install the front bearing then remove the companion flange. 15. Install oil seal. a. Apply MP grease to the oil seal lip. b. Using SST 09214-76011, install a new oil seal. Oil seal drive in depth: 1.0 mm (0.039 inch) 16. Install companion flange. a. Place the companion flange on the drive pinion. b. Install a new nut. HINT: Coat the threads of a new nut with hypoid gear oil. c. Using SST 09330-00021 to hold the flange, tighten the nut. Torque to 196 Nm (145 ft. lbs.) 17. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (starting): New bearing: 0.9 - 1.6 Nm (8.7 - 13.9 inch lbs.) Reuse bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.) If preload is greater than specification, replace the bearing spacer. If preload is less than specification, retighten the nut a little at a time with a Page 804 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1742 (b) Install the thermostat with the jiggle valve downward. (c) Install the water inlet with the 3 bolts. Torque: 20 Nm (14 ft. lbs.) 2. Connect lower radiator hose. 3. Fill with engine coolant. 4. Start engine and check for leaks. Page 57 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3546 Ignition Coil: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION IGNITION COILS REMOVAL 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS 3. REMOVE IGNITION COILS (a) Disconnect the 3 connectors from the ignition coils. (b) Remove the 3 bolts and 3 ignition coils from the LH cylinder head. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) HINT: Arrange the ignition coils in correct order. IGNITION COILS INSTALLATION Installation is in the reverse order of removal. Diagram Information and Instructions Clutch Switch: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Symptom Related Diagnostic Procedures One Touch 2-4 Selector System Page 1932 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Timing Cover: Specifications TIGHTENING SPECIFICATIONS No. 1 Timing Belt Cover To Oil Pump ............................................................................................................................................... 9 Nm (80 inch lbs.) No. 2 Timing Belt Cover To No. 3 Timing Belt Cover......................................................................................................................... 9 Nm (80 inch lbs.) No. 3 Timing Belt Cover To Cylinder Head ....................................................................................................................................... 9 Nm (80 inch lbs.) Page 3218 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 4665 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 25) Page 3495 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Hydraulic Hose: Specifications Clutch Line Union ................................................................................................................................ ................................................... 15 N.m (11 ft. lbs.) Pressure, Vacuum and Temperature Specifications Power Steering Fluid: Pressure, Vacuum and Temperature Specifications Fluid Pressure ..................................................................................................................................... ............................. 8,336 kPa (1,209 psi) Minimum Page 3527 Page 2953 Capacity Specifications Engine Oil: Capacity Specifications ENGINE OIL Dry Fill ............................................................................................................................ .................................................................................. 5.9L (6.2 Qt) Drain And Refill w/o Oil Filter Change ................................................................................................. ....................................................................................... 4.9L (5.2 Qt) w/ Oil Filter Change ................ .............................................................................................................................................................. ............ 5.2L (5.5 Qt) Page 3787 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (174 ft.lb) Page 2956 CHART 27 Page 4048 Upper Valve Body VALVE BODY SPRING SPECIFICATIONS HINT: During reassembly please refer to the spring specifications below to help you to identify the different springs. Page 2730 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Service and Repair Solenoid: Service and Repair 1. Remove A.D.D. switch. 2. Remove sleeve fork pin. a. Using a hexagon wrench, remove the screw plug. b. Using a pin punch and a hammer, remove the pin through the hole of clutch case cover. 3. Separate actuator from clutch case cover and remove sleeve fork. Using a hexagon wrench, remove the screw plug. b. Remove the spring seat, spring and steel ball. c. Remove the 2 bolts and actuator from the clutch case cover. d. Separate the actuator from the clutch case cover and remove the sleeve fork. e. Remove the O-ring from the actuator. 4. Install sleeve fork and actuator into clutch case cover. a. Install a new O-ring to the actuator. b. Coat the O-ring with MP grease. c. Place the sleeve fork and install the actuator to the clutch case cover. d. Torque the 2 bolts. Torque to 21 Nm (15 ft. lbs.) e. Install the steel ball, spring and spring seat. f. Coat the threads of screw plug with FIPG. FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. g. Using a hexagon wrench, install the screw plug. Torque to 13 Nm (9 ft. lbs.) 5. Install sleeve fork pin. a. Using a pin punch and a hammer, install the pin through the hole of clutch case cover. b. Coat the threads of screw plug with FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. c. Using a hexagon wrench, install the screw plug. Torque to 20 Nm (14 ft. lbs.) 6. Install A.D.D. switch. Install a new gasket and indicator switch. Torque to 40 Nm (30 ft. lbs.) Page 3041 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3024 Page 1929 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 480 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 2484 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1400 Valve: Testing and Inspection 1. Inspect and grind valves. (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 inch) Minimum margin thickness: 0.5 mm (0.020 inch) If the margin thickness is less than the minimum, replace the valve. (d) Check the valve overall length. Standard overall length: Intake: 95.15 mm (3.7461 inch) Exhaust: 94.90 mm (3.7362 inch) Minimum overall length: Intake: 94.60 mm (3.7244 inch) Exhaust: 94.40 mm (3.7165 inch) If the overall length is less than the minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. Page 4784 Hydraulic Control Assembly - Antilock Brakes: Tools and Equipment Union nut wrench 10 mm, to disconnect Brake lines from Anti-Lock Brake System (ABS) actuator ............................................................ 09023 - 00100 ABS actuator checker and sub-harness ........................................................................................................................................................... 09990 - 00150 ABS actuator checker sub-harness "C" ........................................................................................................................................................... 09990 - 00200 ABS actuator checker sub-harness "E" ........................................................................................................................................................... 09990 - 00210 ABS actuator checker sheet "L" .................................................................................. .................................................................................... 09990 - 00370 Page 4183 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Specifications Firing Order: Specifications Firing Order: 1-2-3-4-5-6 Page 793 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2749 Standard Values Of ECM Terminals Chart 1 Of 2 Page 2535 Data Link Connector: Testing and Inspection Data Link Connector (DLC3) Terminal Identification Reference DATA LINK CONNECTOR 3 (DLC3) INSPECTION The vehicle's ECM uses the ISO 9141-2 communication protocol for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable of the OBD II scan tool or TOYOTA hand-held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool's instruction manual. Page 2231 Page 867 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Fuel - Idle Speed Increased by Replacement ECM Engine Control Module: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 4004 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3575 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 721 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 4172 f. Remove the plate washers and differential case. g. Install the plate washer into the ring gear back side of the carrier. h. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier. i. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear. j. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) k. If the backlash is not within the specification, adjust by either increasing or decreasing the number of washers on both sides by an equal amount. Ensure that there is ring gear backlash. HINT: There should be no clearance between the plate washer and case. 10. Adjust side bearing preload. a. after adjustment with the backlash as reference, remove the ring gear teeth side plate washer and measure the thickness. b. Install a new washer of 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the washer removed. HINT: Select a washer which can be pressed in 2/3 of the way by finger. c. Using a plastic hammer, install the plate washer. Page 3038 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 70 Standard Values Of ECU Terminals (2 Of 2) 5VZ-FE Page 342 Park / Neutral Position Switch Brakes - Pad Clicking Noise Brake Pad: Customer Interest Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to Drive/Forward). This is a normal noise caused by the required brake pad-to-caliper clearances. When the direction of travel is changed, the brake pads may "shift" towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard. To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under normal usage conditions this grease should be effective for a period of 6 months to 1 year. Applicable Vehicles ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly. 1. Floating Type Brake Caliper A. Lift up or remove the brake caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the brake caliper. B. If equipped with anti-squeal spring: Remove the anti-squeal springs. C. Remove the brake pads with anti-squeal shims. D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads. ABS Control (Motor) Relay ABS Main Relay: Description and Operation ABS Control (Motor) Relay Codes 13, 14: ABS Control (Motor) Relay Circuit DTC Chart ABS Control (Motor) Relay Circuit Wiring Diagram Page 3083 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4312 Universal Joint: Testing and Inspection Inspect spider bearings. a. Inspect the spider bearings for wear or damage. b. Using a dial indicator, check the spider bearing axial play by turning the yoke while holding the shaft tightly. Bearing axial play: w/o double cardan joint propeller shaft Maximum 0.05 mm (0.0020 inch.) If necessary, replace the spider bearing. w/ double cardan joint propeller shaft Maximum 0.05 mm (0.0020 inch.) If necessary, replace the propeller shaft. Page 1798 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2032 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2929 Page 2935 CHART 7 Page 4171 8. Install differential case in carrier. a. Place the bearing outer races on their respective bearings. Make sure the left and right races are not interchanged. b. Install the differential case in the carrier. 9. Adjust ring gear backlash. a. Only install the plate washer on the ring gear backside. HINT: Ensure that the ring gear has a backlash. b. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear. c. Hold the side bearing boss on the teeth surface of the ring gear and measure the backlash. Backlash (reference): 0.13 - 0.18 mm (0.0051 - 0.0071 inch) d. Select a ring gear back side plate washer, using the backlash as reference. e. Select a ring gear teeth side plate washer of a thickness which eliminates any clearance between the outer race and case. Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Locations ECT Temperature Sender Gauge / Low Oil Pressure Warning Switch Page 3566 Ignition Control Module: Description and Operation CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is a 2-cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one ignition coil. In the 2-cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the 2 spark plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 735 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2773 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2847 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2264 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 3389 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4355 Location Of Splice Points (Fig 36) System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module Specifications Valve Clearance: Specifications Intake 0.13 - 0.23 mm Exhaust 0.27 - 0.37 mm Page 2127 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2852 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1516 Valve Guide Seal: Service and Repair 1. w/ Snap ring: Insert an old valve wrapped with tape into the valve guide bushing, and break off the valve guide bushing by hitting it with a hammer. Remove the snap ring. NOTE: Wrap the tape approximately 8 mm (0.31 inch) from the valve stem end. CAUTION: Be careful not to damage the valve lifter hole. 2. Gradually heat the cylinder head to 80° - 100° C (176° - 212° F). 3. Using Special Service Tool (SST) Valve Guide Bushing Remover & Replacer Set # 09201 10000 (Valve Guide Bushing Remover & Replacer 6 # 09201 - 01060), Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap out the guide bushing. 4. Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Page 710 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 157 Standard Values Of ECM Terminals Chart 1 Of 2 Page 3702 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 2427 Glossary Of Term And Symbols (Part 1 Of 2) Page 1547 (c) Install the starter wire bracket with the 2 bolts. 13. Install crankshaft pulley. (a) Align the pulley set key with the key groove of the pulley, and slide the pulley. (b) Using SST Crankshaft Pulley Holding Tool # 09213 - 54015 (Bolt # 90119 - 08216), Companion Flange Holding Tool # 09330 - 00021 or equivalents, install and torque the bolt. Torque: 250 Nm (184 ft. lbs.) 14. Install fan bracket. (a) Install the fan bracket with the bolt and nut. (b) Install the PS pump adjusting strut with the nut. 15. Install No. 2 timing belt cover. (a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: ^ Using a screwdriver and gasket scraper, remove all the old gasket material. ^ Thoroughly clean all components to remove all the loose material. ^ Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. (b) Install the timing belt cover with the 6 bolts. Torque: 9 Nm (80 inch lbs.) (c) Connect the 4 high-tension cord clamps and camshaft position sensor connector to the No. 2 timing belt cover. 16. Install oil dipstick and guide. (a) Install a new O-ring to the dipstick guide. (b) Install the oil dipstick and guide to the cylinder block. (c) Install the bolt to the generator bracket. Torque: 8 Nm (71 inch lbs.) 17. w/ A/C: Install A/C compressor bracket. Torque: 47 Nm (35 ft. lbs.) 18. w/ A/C: Connect A/C compressor to engine. 19. Connect PS pump to engine. 20. Install fan with fluid coupling and fan pulleys. Page 539 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2436 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2363 Glossary Of Term And Symbols (Part 1 Of 2) Page 2371 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2571 Step 3 Step 4 Step 5 Step 6 Page 1727 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm. 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 3603 Glossary Of Term And Symbols (Part 1 Of 2) Page 3585 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3040 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2508 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Symptom Related Diagnostic Procedures One Touch 2-4 Selector System Page 338 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3655 Glossary Of Term And Symbols (Part 1 Of 2) Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TIGHTENING SPECIFICATIONS Attaching Nuts ..................................................................................................................................... ................................................. 19 Nm (14 ft. lbs.) Bracket Attaching Nuts ........................................ ............................................................................................................................. 5.4 Nm (48 inch lbs.) Brake Line Union ......................................................................................................................... ......................................................... 15 Nm (11 ft.lbs.) Page 2277 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 2179 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2376 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 779 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 2800 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4250 a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 5. Disconnect drive shaft. Using a brass bar and hammer, disconnect the drive shaft Removal Hint: When it is difficult to disconnect the drive shaft, tap in a screwdriver between differential tube/differential carrier and drive shaft. Installation Hint: Before installation, set the snap ring opening side facing downward. Using SST 09631-10030 and a hammer, strike the inboard joint into the differential. At that time, strike the snags evenly to avoid snags deformation. Check that the drive shaft cannot be pull out by hand NOTICE: Be careful not to damage the dust cover of the drive shaft. 6. Disconnect lower suspension arm. a. Remove the cotter pin and nut. Torque to 140 Nm (103 ft. lbs.) b. Using SST 09628-62011, disconnect the lower suspension arm. Installation Hint: Face the cotter pin hole of the lower ball joint forward. Page 2289 Page 3263 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 31 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Specifications Firing Order: Specifications Firing Order: 1-2-3-4-5-6 Page 52 Cruise Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4311 Universal Joint: Application and ID TMC-made: Mark ..................................................................................................................................................... .................................................... Thickness 1 ........................................................................................................................................................... ..... 2.100-2.150 mm (0.0827-0.0846 inch) 2 ....................................................................................... ......................................................................... 2.150-2.200 mm (0.0846-0.0866 inch) 3 ................... ............................................................................................................................................. 2.200-2.250 mm (0.0866-0.0886 inch) Brown ........................................................................................................................................................ 2.250-2.300 mm (0.0886-0.0906 inch) Blue ........................................................................................................................................................... 2.300-2.350 mm (0.0906-0.0925 inch) 6 ............................................................................................. ................................................................... 2.350-2.400 mm (0.0925-0.0945 inch) 7 ......................... ....................................................................................................................................... 2.400-2.450 mm (0.0945-0.0965 inch) 8 ................................................................................................................. ............................................... 2.450-2.500 mm (0.0965-0.0984 inch) Dana-made: Color .................................................................................................................................................... .................................................... Thickness Green ................................................................................................................................................... ............................ 1.384 mm (0.0545 inch) Red .................................................................................. ................................................................................................. 1.435 mm (0.0565 inch) Black ........... .............................................................................................................................................................. ....... 1.486 mm (0.0585 inch) Copper .................................................................................................. ........................................................................... 1.511 mm (0.0595 inch) Silver ................................. ............................................................................................................................................... 1.537 mm (0.0605 inch) Yellow ..................................................................................................................... ........................................................ 1.588 mm (0.0625 inch) Blue ..................................................... ............................................................................................................................ 1.638 mm (0.0645 inch) Page 2463 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 2466 Specifications Brake Caliper: Specifications Line Union 22 ft.lb Mounting Bolt 90 ft.lb Page 2224 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1651 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1830 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 317 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 658 CHART 18 CHART 19 Page 3197 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Page 889 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 336 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3900 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3788 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2853 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 813 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 2350 HINT: 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. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size according to these Formula or Charts: Page 3274 Components For Removal And Installtion Part 2 Of 2 Page 2851 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Throttle Valve Cable/Linkage: Specifications Throttle Cable Adjustment (Throttle Valve Fully Closed) Between Boot And Face: And Inner Cable Stopper ............................................................................................................................................................. 0 - 1 mm (0.04 inch) Page 3740 Location Of Splice Points (Fig 36) System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module Page 4528 3. If necessary, replace extension housing oil seal. a. Using a screwdriver and hammer, drive out the oil seal. b. Using SST 09554-22010 and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface. c. Coat the lip of the oil seal with MP grease. 4. If necessary, replace front and rear companion flange oil seals. a. Using a screwdriver and hammer, drive out the oil seals from the 2 flanges. b. Using SST 09950-60010 (09951-00220, 09951-00350, 09952-06010), 09950-70010 (09951-07100) and a hammer, drive in a new oil seal. c. Coat the lip of the oil seal with MP grease. 5. If necessary, replace shift fork shaft oil seals. a. Using a screwdriver, pry out the oil seal. b. Using SST 09304-12012 and a hammer, drive in a new oil seal. Oil seal depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch) Page 4762 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Specifications Crankshaft Main Bearing Seal: Specifications TIGHTENING SPECIFICATIONS Rear Oil Seal Retainer To Cylinder Block .................................................................................................................................... 8 Nm (71 inch lbs.) Page 4492 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 324 Inspection Procedure / Stop Light Switch Circuit (4 Of 4) INSPECTION PROCEDURE Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 49 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 451 Brake Light Switch: Component Tests and General Diagnostics STOP LIGHT SWITCH CIRCUIT CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Stop Light Switch Circuit WIRING DIAGRAM Inspection Procedure / Stop Light Switch Circuit (1 Of 4) Page 4163 torque of 13 Nm (9 ft. lbs.) until the specified preload is reached. Maximum torque: 343 Nm (253 ft. lbs.) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload. 18. Recheck ring gear backlash. 19. Recheck tooth contact between ring gear and drive pinion. 20. Check runout of companion flange. 21. Stake drive pinion nut. 22. Install adjusting nut locks. a. Install 2 new nut locks on the bearing caps. Torque to 13 Nm (9 ft. lbs.) b. after tightening bolts, bend the nut locks. 23. Install shift fork shaft. a. Apply MP grease onto the outer circuit of the fork shaft. b. Install the fork shaft to match the hole of the shift fork and that of the shift fork shaft c. Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and shaft retainer. d. Apply FIPG Part No. 08826-00090, THREE BOND 1281, or equivalent, to the carrier, as shown. HINT: Install the shaft retainer within 10 minutes after applying FIPG. e. Clean the threads of the bolts and retainer bolts holes with toluene or trichloroethylene. Page 806 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3217 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Capacity Specifications Engine Oil: Capacity Specifications ENGINE OIL Dry Fill ............................................................................................................................ .................................................................................. 5.9L (6.2 Qt) Drain And Refill w/o Oil Filter Change ................................................................................................. ....................................................................................... 4.9L (5.2 Qt) w/ Oil Filter Change ................ .............................................................................................................................................................. ............ 5.2L (5.5 Qt) Page 3555 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 289 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2676 CHART 20 Page 4119 Maximum vertical runout: 0.10 mm (0.0039 inch) Maximum lateral runout: 0.10 mm (0.0039 inch) 2. Check ring gear runout. Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 inch) If the runout is not within the specification, replace the ring gear. 3. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. Locations Ignition Switch Page 165 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2461 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2478 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3063 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 2628 Knock Sensor: Oscilloscope Patterns and Waveforms Page 3419 Page 4443 e. Select a snap ring that will allow minimum axial play. Mark A: 2.00-2.05 mm (0.0787-0.0807 inch) Mark B: 2.05-2.10 mm (0.0807-0.0827 inch) Mark C: 2.10-2.15 mm (0.0827-0.0846 inch) Mark D: 2.15-2.20 mm (0.0846-0.0866 inch) Mark E: 2.20-2.25 mm (0.0866-0.0886 inch) Mark F: 2.25-2.30 mm (0.0886-0.0906 inch) f. Using a snap ring expander, install the snap ring. Page 3910 Electronically Controlled Transmission And A/T Indicator (Part 3 Of 3) Page 1957 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4790 Wheel Speed Sensor: Description and Operation Speed Sensor Circuit Description CIRCUIT DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the Electronic Control Unit (ECU). These signals are used to control of the Anti-Lock Brake System (ABS) system. The front and rear rotors each have 48 serrations. When the Rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. FAIL SAFE FUNCTION If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Page 2529 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3067 Page 2062 CHART 27 Page 4716 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2704 Glossary Of Term And Symbols (Part 1 Of 2) Page 1404 Valve: Service and Repair Cleaning 1. Using a gasket scraper, chip off any carbon from the valve head. 2. Using a wire brush, thoroughly clean the valve. Page 1926 Glossary Of Term And Symbols (Part 1 Of 2) Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 1107 Hose/Line HVAC: Technical Service Bulletins A/C - Suction Hose Improved HEATING & AIR CONDITIONING AC006-97 December 5, 1997 Title: A/C SUCTION HOSE IMPROVEMENT Models: '95 - '97 Tacoma Introduction The air conditioning Suction Hose on Tacoma has been changed: ^ The Suction Hose length has been increased from 316 mm to 356 mm to reduce vibrations transmitted by compressor movement. Affected Vehicles 1995-1997 model year Tacomas. Parts Information In addition One (1) O-ring (P/N 90099-14122) for the pressure switch is required. Component Tests and General Diagnostics Fuel Injector: Component Tests and General Diagnostics INJECTORS INSPECTION 1. INSPECT INJECTOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: At 2O°C (68°F): Approx. 13.8 ohms If the resistance is not as specified, replace the injector. 2. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. (a) Disconnect the fuel inlet pipe from the fuel tube. (b) Connect SST (attachment and hose) to the fuel tube. SST 09288-41046 (09268-52011) (c) Connect the fuel return hose, SST (union) and SST (hose) to the fuel pressure regulator. SST 09268-41046 (09268-41091) (d) Install the O-ring to the injector. (e) Connect SST (union and hose) to the injector and hold the injector and union with SST (clamp). SST 09268-41046 (f) Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Page 508 Glossary Of Term And Symbols (Part 1 Of 2) Page 1864 Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately. NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. Fill Brake Reservoir BRAKE FLUID BLEEDING 1. Fill brake reservoir with brake fluid. Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAEJ17O3 or FMVSS No.116 DOT 3 2. Bleed master cylinder. NOTE: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plugs with your fingers, and release the Brake Pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Page 2013 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 1039 Spark Plug: Testing and Inspection SPARK PLUGS INSPECTION 1. DISCONNECT HIGH -TENSION CORDS 2. REMOVE IGNITION COILS 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 4. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 5. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: ND: K16TR11 NGK: BKR5EKB-11 Page 651 CHART 8 CHART 9 Testing and Inspection Piston Pin: Testing and Inspection INSPECT PISTON PIN OIL CLEARANCE 1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 - 22.017 mm (0.8663 - 0.8668 inch) 2. Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.009 mm (0.8660 - 0.8665 inch) 3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch) Maximum oil clearance: 0.05 mm (0.0020 inch) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. Page 1412 Drive Belt: Specifications Alternator Belt GENERATOR / SERVICE DATA DRIVE BELT New belt 2RZ-FE, 3RZ-FE: .............................................................................................................................................................. ..................................................... 165 ± 10 lb. 5VZ-FE: .............................................................................................................................................................. ..................................................... 160 ± 25 lb. Used belt 2RZ-FE, 3RZ-FE: .............................................................................................................................................................. ..................................................... 115 ± 20 lb. 5VZ-FE: .............................................................................................................................................................. ..................................................... 100 ± 20 lb. Page 733 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3742 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3261 Glossary Of Term And Symbols (Part 1 Of 2) Locations One Touch 2-4 Selector System Page 2700 Page 2947 CHART 22 Page 3747 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 830 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 794 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4766 ABS Control (Motor) Relay Circuit Inspection Procedure (Part 2 Of 2) CIRCUIT DESCRIPTION The Anti-Lock Brake System (ABS) control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the Electronic Control Unit (ECU) switches the ABS control (motor) relay ON and operates the ABS pump motor. FAIL SAFE FUNCTION If trouble occurs in the ABS control (motor) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Disassembly Output Shaft: Service and Repair Disassembly NOTE: For removal and installation procedures refer to "Manual Transmission/Transaxle, Service and Repair." 1. Inspect each gear thrust clearance. Measure the thrust clearance of each gear. Standard Clearance: 1st gear: 0.16-0.45 mm (0.0059-0.0177 inch) 2nd and 3rd gears: 0.10-0.25 mm (0.0039-0.0098 inch) Maximum Clearance: 1st gear: 0.50 mm (0.0197 inch) 2nd and 3rd gears: 0.30 mm (0.0118 inch) Page 2479 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2102 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 380 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2499 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 178 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3659 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4504 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 4336 Flywheel: Specifications Tightening Specifications Sequence TORQUE SPECIFICATIONS Flywheel To Crankshaft: 83 N.m (61 ft. lbs.) Page 3988 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Page 4085 b. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 3 and the negative (-) lead to terminal 1. c. Check the there is no continuity between terminals 2 and 3. If the continuity is not as specified, replace the clutch start cancel switch. 9. Check operation of clutch start cancel switch. a. Connect positive (+) lead from the battery to terminal 3 and connect negative lead to terminal 1. b. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 1. c. When pushing the switch and check that the indicator light comes on and there is continuity between terminal 1 and 2. d. Check that there is no continuity between terminals 1 and 2 when disconnect the battery lead. If continuity is not as specified, replace the clutch start cancel switch. Page 636 Engine Bank Identification Locations Number One Cylinder: Locations Firing Order: 1-2-3-4-5-6 Cooling System - Radiator Cap Inspection Procedure Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure ENGINE EG014-05 Title: RADIATOR CAP INSPECTION Models: All Toyota Models March 28, 2005 Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models. Applicable Vehicles ^ All Toyota and Scion models. Required Equipment Warranty Information Page 2914 Applicable Vehicles Page 2203 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2091 Oxygen Sensor: Description and Operation Sensor Cut-Away Reference CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2073 Oxygen Sensor: Mechanical Specifications Heated Oxygen Sensor to Exhaust Pipe 14 ft.lb Page 4259 b. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150), install a new oil seal. c. Apply MP grease to the oil seal lip. 10. install rear axle shaft in backing plate. a. Apply MP grease to the oil seal lip. b. Install the backing plate and bearing retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing plate. d. Using snap ring pliers, install a new snap ring. 11. w/ ABS: Install ABS speed sensor rotor and bearing retainer (differential side). Using SST 09316-60011 (09316-00051) and a press, install a new sensor rotor and new bearing retainer to the axle shaft. Standard length: 122.2 ±1.0 mm (4.811 ±0.039 inch) Removal and Installation Page 1911 Page 1620 (c) Install the water pump with the 7 bolts. Torque: 20 Nm (14 ft. lbs.) 2. Connect No. 2 oil cooler hose. 3. Install thermostat and water inlet. 4. Install timing belt. Refer to Engine. Page 2455 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3684 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4495 Page 2546 Glossary Of Term And Symbols (Part 1 Of 2) Page 4123 6. Check drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.6 - 0.9 Nm (5.7 - 8.3 inch lbs.) 7. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) If necessary, disassemble and inspect the differential. Page 2087 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2532 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 720 Page 1063 1. Remove engine under cover. 2. Drain engine coolant. 3. Disconnect upper radiator hose. 4. Remove drive belt for Power Steering (PS) pump. 5. w/ A/C: Remove drive belt for A/C compressor. 6. Remove drive belt for generator. 7. Remove No. 2 fan shroud. 8. Remove fan with fluid coupling and fan pulleys. 9. Disconnect PS pump from engine. Page 3447 (a) Disconnect these vacuum hoses from the throttle body: (1) Vacuum hose of throttle opener (2) w/EGR: Vacuum hose (from port R of EGR vacuum modulator) (3) w/EGR: Vacuum hose (from port E of EGR vacuum modulator) (b) Disconnect these hoses from the IAC valve: (1) Water bypass hose (w/ EGR: from EGR valve. w/o EGR: from water bypass pipe) (2) Water hose (from intake manifold) (3) Air assist hose (c) Remove the 2 bolts, 2 nuts. throttle body and gasket. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) INSTALLATION HINT: Place a new gasket on the air intake chamber facing the protusion upward. THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Page 2197 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4922 Hydraulic Control Assembly - Antilock Brakes: Tools and Equipment Union nut wrench 10 mm, to disconnect Brake lines from Anti-Lock Brake System (ABS) actuator ............................................................ 09023 - 00100 ABS actuator checker and sub-harness ........................................................................................................................................................... 09990 - 00150 ABS actuator checker sub-harness "C" ........................................................................................................................................................... 09990 - 00200 ABS actuator checker sub-harness "E" ........................................................................................................................................................... 09990 - 00210 ABS actuator checker sheet "L" .................................................................................. .................................................................................... 09990 - 00370 Exhaust System - Sulfur Smell Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell ENGINE EG003-03 February 24, 2003 Title: SULFUR ODOR FROM EXHAUST Models: All Models Introduction Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably between gasoline brands and locations. Applicable Vehicles ^ All Models. Repair Procedure A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's running condition, but is most likely directly related to the fuel. ^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed: ^ If the MIL light is ON, check for DTCs and repair as necessary. If no trouble is found after performing the above check, recommend the customer try a different source of fuel. Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered warrantable. Warranty Information Page 2049 CHART 18 CHART 19 Page 3897 Location Of Splice Points (Fig 36) System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module Page 101 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Testing and Inspection Switch: Testing and Inspection 1. Inspect relay operation. a. Jack up the vehicle. b. Use a heater main relay and connect it, as shown below. c. Rotate the tire and check that differential lock has occurred. if operation is not as specified, replace the actuator. 2. Inspect Diff. Lock control switch continuity. Inspect the switch continuity between terminal 1 to terminal 4. HINT: If it is not continuity, replace the switch. 3. Inspect Diff. Lock position switch. a. Check that there is continuity between terminals when the switch is pushed (differential connected position). b. Check that there is no continuity when the switch is free (differential disconnected position). HINT: If operation is not as specified, replace the switch. 4. Inspect transfer 4WD switch. 5. Inspect vehicle speed sensor. Page 498 Air Flow Meter/Sensor: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (c) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified. replace the MAF meter. (d) Disconnect the MAF meter connector. Page 2237 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Specifications Idle Speed/Throttle Actuator - Mechanical: Specifications Setting Specifications Setting Specifications Actuator Setting Speed 900 - 1,950 rpm Page 152 Engine Control-Connectors Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 572 Page 4158 c. Adjust the drive pinion preload by tightening the companion flange nut. d. Using SST 09330-00021 to hold the flange, tighten the nut. NOTICE: As there is no spacer, tighten a little at a time, being careful not to overtighten. e. Using a torque wrench, measure the preload. Preload (starting): New bearing: 0.9 - 1.6 Nm (8.7 - 13.9 inch lbs.) Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.) HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to mark the bearing smooth. 8. Install differential case in carrier. a. Apply MP grease on the rack of the shift fork and connecting part of the indicator switch. b. Insert the shift fork into the differential carrier, as shown. c. Place the outer races, adjusting nuts and left side to sleeve. HINT: Check that the sleeve moves smoothly. Page 785 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1876 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4242 3. Disconnect drive shaft. w/o Free wheel hub: a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. c. With applying the brakes, remove the lock nut. Torque to 235 Nm (174 ft. lbs.) w/ Free wheel hub: a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 4. w/ABS: Remove ABS speed sensor and wire harness clamp from steering knuckle. Torque to 8.0 Nm (71 inch lbs.) 5. Remove front brake caliper and disc. 6. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Torque to 80 Nm (59 ft. lbs.) 7. Remove steering knuckle. a. Remove the cotter pin and loosen the nut. Torque to 105 Nm (80 ft. lbs.) b. Using SST 09950-40010 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04030, 09958-04010), disconnect the steering knuckle. c. Remove the nut and steering knuckle. Page 2887 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2974 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4121 Differential Carrier (3RZ-FE, 5VZ-FE w/o Differential Lock) INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. Front Planetary Gear Front Planetary Gear Page 2826 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4693 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4315 1. Place matchmarks on shaft and yoke. 2. Remove snap rings. a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using 2 screwdrivers, remove the 4 snap rings from the grooves. 3. Remove spider bearings. a. Using Special Service Tool (SST) 09332-25010, push out the bearing from the propeller shaft. HINT: Sufficiently raise the part indicated by a so that it does not come into contact with the bearing. b. Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the bearing on opposite side in the same procedure. c. Install the 2 removed bearing outer races to the spider. d. Using SST 09332-25010, push out the bearing from the yoke. e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. 4. Select spider bearing. Select the bearing according to whether or not there is a drill mark on the yoke section. Page 2530 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3737 Position Of Parts In Instrument Panel (2 Of 2) (Fig 29) Relay Blocks Relay Blocks Page 4930 Torque: 15 Nm (11 ft. lbs.) 4. Remove master cylinder. (a) Remove the 4 mounting nuts and 3-way and check valve bracket. Torque: 13 Nm (9 ft. lbs.) (b) Pull out the master cylinder and gasket. Page 2830 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2934 CHART 5 CHART 6 Page 1824 Step 3 Step 4 Step 5 Step 6 Page 608 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3363 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2128 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2290 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 440 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2249 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2186 Page 4881 Loosen/Tighten Bleeder Plug Insert other end of the tube in a half-full container of brake fluid. NOTE: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. Bleed brake line. (a) Slowly depress the brake pedal several times. (b) While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning (LSP) & By-Pass Valve (BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 Page 1528 Camshaft Gear/Sprocket: Specifications Tightening Specifications Camshaft Timing Pulley Torque ................................................................................................................................................. ......................... 110 N-m (1,100 kgf-cm, 91 ft-lbf) Page 3287 Fuel Pressure Regulator: Diagrams Components For Removal And Installation Part 1 Of 2 Page 670 Page 1113 Hose/Line HVAC: Testing and Inspection Refrigerant Lines 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. See: Heating and Air Conditioning/Testing and Inspection/Initial Inspection and Diagnostic Overview/Leakage of Refrigerant Page 3331 Glossary Of Term And Symbols (Part 1 Of 2) Page 4622 3. If necessary, replace planetary gear outer bearing. a. Using a snap ring expander, remove the snap ring. b. Using Special Service Tool (SST) 09554-30011, 09555-55010 and a press, remove the bearing. c. Using SST 09223-15020, 09515-30010, 09950-70010 (09951-07100) and a press, install a new bearing with the groove faced forward. d. Select a snap ring that will allow minimum axial play. Using a snap ring expander, install the snap ring. 4. If necessary, replace planetary gear thrust inner bearing. a. Using SST 09612-65014 (09612-01030, 09612-01050) and a press, remove the bearing. NOTICE: Hang SST securely to the clearance between the thrust inner bearing and planetary gear. b. Using SST 09950-60010 (09951-00570), 09950-70010 (09951-07100) and a press, install a new bearing. Bearing depth: 7.7-8.3 mm (0.303-0.327 inch) Page 1821 Standard Values Of ECM Terminals Chart 1 Of 2 Specifications Timing Belt: Specifications Timing Belt Replacement Interval 60,000 miles (96,000 km) Page 1084 Drive Belt: Service and Repair DRIVE BELT REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kg.cm, 29 ft.lb) 4. LOOSEN AND REMOVE COMPRESSOR DRIVE BELT DRIVE BELT INSTALLATION Installation is in the reverse order of removal. Page 940 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4352 Position Of Parts In Instrument Panel (2 Of 2) (Fig 29) Relay Blocks Relay Blocks Page 753 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 331 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3888 Junction Block And Wire Harness Connector Page 4084 position. Standard Distance: 5 mm (0.98 inch) or more. (from pedal stroke end position to release point) If the distance not as specified, perform the following operations. ^ Check pedal height. ^ Check push rod play and pedal freeplay. ^ Bleed the clutch line. ^ Check the clutch cover and disc. 6. Check clutch start system a. 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. 7. Check continuity of clutch start switch check the continuity between terminals when the switch is ON and OFF. Switch ON (Pushed): Continuity. Switch OFF (Free): No Continuity. If continuity is not as specified, replace the switch. 8. Check continuity of clutch start cancel switch. a. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 1. Page 3607 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 353 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3956 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1287 Camshaft: Service and Repair Assembly 1. Assemble exhaust camshafts. (a) Mount the hexagonal wrench head portion of the camshaft in a vise. CAUTION: Be careful not to damage the camshaft. (b) Install these parts: (1) Camshaft gear spring. (2) Camshaft sub-gear. NOTE: Attach the pins on the gears to the gear spring ends. (3) Wave washer. (c) Using snap ring pliers, install the snap ring. (d) Using Special Service Tool (SST) Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin # 09963 - 00600) or equivalents, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear clockwise, and temporarily install a service bolt. (e) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt. Page 3996 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3613 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1652 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2025 Applicable Vehicles Page 573 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 594 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3564 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT 1. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. 2. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 4849 Brake Pad: Specifications Front Brake Pad Thickness Standard Thickness 0.453 in Minimum Thickness 0.039 in Page 497 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 1698 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Page 3802 Page 891 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Front Companion Flange: Specifications Front TIGHTENING SPECIFICATIONS Flange Nuts ......................................................................................................................................... ................................................. 108 Nm (80 ft lbs.) Front Wheel Fastener: Service and Repair Front HUB BOLT REPLACEMENT 1. Remove front wheel. 2. Remove brake caliper and disc. 3. Remove hub bolt. Using Special Service Tool (SST), remove the hub bolt. 4. Install hub bolt. Install a washer and nut to the hub bolt, as shown in the illustration, and install the hub bolt by tightening the nut. 5. Install brake disc and caliper. 6. Install front wheel. Torque: 110 Nm (83 ft. lbs.) Page 938 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 381 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2709 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2561 Standard Values Of ECM Terminals Chart 1 Of 2 Page 3639 Page 2027 Engine Bank Identification Page 654 CHART 12 CHART 13 Page 3689 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2890 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2426 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2893 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1616 Water Pump: Testing and Inspection 1. Inspect water pump. (a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. Inspect fluid coupling. (a) Remove the 4 nuts and fan from the fluid coupling. (b) Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. (c) Install the fan and fluid coupling with the 4 nuts. Torque: 7.4 Nm (65 inch lbs.) 3. Inspect fan pulley bracket. Check the turning smoothness of the fan pulley. If necessary, replace the fan pulley bracket. 4. Inspect timing belt. Refer to Engine. Page 2280 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2092 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSORS INSPECTION (Bank 1, Sensor 1, Bank 1 Sensor 2) INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connector. Bank 1 Sensor 1 Bank 1 Sensor 2 (b) Using an ohmmeter. measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F): 11 - 16 ohms If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (c) Reconnect the oxygen sensor connector. Page 4733 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3666 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2900 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 1104 Warranty information Applicable Warranty: This repair Is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's In-service date. Repair Procedure 1. Replace Condenser Bracket A. Remove the 6 x 30 mm bolt with large washer (see illustration). B. Remove the original condenser bracket and 6 x 16 mm condenser mounting bolts (see illustration). CAUTION: Remove the 6 x 30 mm bolts first, then the 6 x 16 mm bolts to prevent damage to the condenser's plastic supports. C. Remove the 6 x 18 mm radiator mounting bolts (see illustration). D. Replace the original condenser brackets with the (2) new brackets, retaining the original collars and rubber mounts for use on the new brackets (see illustration). Page 3369 (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 2174 Glossary Of Term And Symbols (Part 1 Of 2) Page 3406 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4864 2. Pull the parking brake lever all the way up until a clicking sound can no longer be heard. 3. Check clearance between brake shoes and drum. (a) Remove the drum. Check Clearance Between Brake Shoes And Drum (c) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 inch) - If it is incorrect, check the parking brake system. Page 4667 Position Of Parts In Instrument Panel (2 Of 2) (Fig 29) Relay Blocks Relay Blocks Page 1134 Coolant: Service and Repair 1. Drain engine coolant. (a) Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the drain plugs, and drain the engine coolant. (c) Close the drain plugs. 2. Fill engine coolant. (a) Slowly fill the system with engine coolant. ^ Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. ^ Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. CAUTION: Do not use an alcohol type engine coolant. - The engine coolant should be mixed with demineralized water or distilled water. Capacity: A/T: 9.5 liters (10.0 US qts.) M/T: 9.7 liters (10.3 US qts.) (b) Reinstall the radiator cap. (c) Start the engine, and bleed the cooling system. (d) If necessary, refill the radiator reservoir with coolant until it reaches the "FULL" line. 3. Check engine coolant for leaks. Page 4681 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1 Of 3) Component Locations Fig. 68 Air Bag Sensor Assembly Replacement Page 4137 b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), install the rear bearing, oil slinger and companion flange. c. Coat the threads of the nut with hypoid gear oil. d. Adjust the drive pinion preload by tightening the companion flange nut. Using SST 09330-00021 to hold the flange, tighten the nut. NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. e. Using a torque wrench, measure the preload. New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.) Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) 10. Install differential case in differential carrier. 11. Adjust ring gear backlash. a. Install the side bearing retainer with the 10 bolts. Torque to 69 Nm (51 ft. lbs.) b. Using SST 09564-32011 and a dial indicator, measure the ring gear backlash. If it is not within the specification, adjust by either in creasing or decreasing the washers on both sides by an equal amount. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) HINT: There should be no clearance between the plate washer and case. Ensure that there is ring gear backlash. Page 682 Oxygen Sensor: Mechanical Specifications Heated Oxygen Sensor to Exhaust Pipe 14 ft.lb Page 4850 Brake Pad: Testing and Inspection MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch) - Minimum thickness: 1.0 mm (0.039 inch) - Replace the pad if the pad's thickness is at the minimum thickness or less (the 1.0 mm slit is no longer visible), or if the pad shows signs of uneven wear. Page 4684 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 4613 1. Inspect rear output shaft. Using a micrometer, measure the outer diameter of the rear output shaft journal surface. Minimum Diameter: Part A: 27.98 mm (1.1016 inch) Part B: 36.98 mm (1.4561 inch) 2. Inspect drive sprocket radial clearance. Using a dial indicator, measure the radial clearance between the sprocket and shaft with the needle roller bearing installed. Standard Clearance: 0.010-0.055 mm (0.0004-0.0022 inch) Maximum Clearance: 0.055 mm (0.0022 inch) If the clearance exceeds the Maximum, replace the drive sprocket, rear output shaft or needle roller bearing. 3. Inspect front drive shift fork and clutch sleeve clearance. Using a feeler gauge, measure the clearance between the front drive shift fork and clutch sleeve. Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve. 4. Inspect high and low shift fork and clutch sleeve clearance. Using a feeler gauge, measure the clearance between the high and low shift fork and clutch sleeve. Maximum Clearance: 1.0 mm (0.039 inch) Page 2161 EGR Temperature Sensor: Testing and Inspection EGR GAS TEMPERATURE SENSOR INSPECTION Except Model No. VZN17O - 4wd Long Wheel Base 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50°C (122°F): 84 - 97 K ohms At 100°C (212°F): 11 - 16 K ohms At 150°C (302°F): 2 - 4 K ohms If the resistance is not as specified. replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) Testing and Inspection Pilot Bearing: Testing and Inspection Inspect pilot bearing. Turn the bearing by hand while applying force in the rotation direction. If the bearing sticks or has much resistance, replace the pilot bearing. HINT: the bearing is permanently lubricated and re-quires no clearing or lubrication. Page 2688 CHART 27 Specifications Water Pump: Specifications TIGHTENING SPECIFICATIONS Water Pump To Cylinder Block ..................................................................................................................................................... 20 Nm (14 ft. lbs.) Water Inlet To Water Pump ............................................................................................................................................................ 20 Nm (14 ft. lbs.) Diagram Information and Instructions Cruise Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 839 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2899 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3523 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 640 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 2556 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4264 6. Replace rear axle bearing. a. Using SST 09223-56010, 09950-60010 (09951-00560), remove the bearing. b. Using SST 09515-30010, 09950-60020 (09951-00890), install a new bearing. 7. Install new outer oil seal. a. Using SST 09950-60010 (09951-00610), 09950-70010 (09951-07150), install a new oil seal. b. install 4 nuts to the serration bolts. c. Using a hammer, remove the serration bolts and remove the bearing case. d. Position the backing plate on a new bearing case and, using 2 socket wrenches, install the serration bolts. Install a new bearing and oil seal (outer side). 8. Replace bearing case. a. Remove the oil seal (outer side) and bearing. b. Install 4 nuts to the serration bolts. c. using a hammer, remove the serration bolts and the bearing case. d. Position the backing plate on a new bearing case and, using 2 socket wrenches, install the serration bolts. e. Install a new bearing and outer oil seal. Page 1349 Piston: Service and Repair Installation INSTALL PISTON AND CONNECTING ROD ASSEMBLIES 1. Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. 2. 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. Page 3152 EGR Temperature Sensor: Testing and Inspection EGR GAS TEMPERATURE SENSOR INSPECTION Except Model No. VZN17O - 4wd Long Wheel Base 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50°C (122°F): 84 - 97 K ohms At 100°C (212°F): 11 - 16 K ohms At 150°C (302°F): 2 - 4 K ohms If the resistance is not as specified. replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) Page 4412 Input Shaft: Testing and Inspection Inspect synchronizer ring. a. Check for wear or damage. b. Check the braking effect of the synchronizer ring. ^ Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. ^ If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. lightly rub the synchronizer ring and gear cone together. NOTICE: ensure the fine lapping compound is completely washed off after rubbing. c. Check again the braking effect of the synchronizer ring. d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum Clearance: 0.8 mm (0.031 inch) If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound. NOTICE: ensure the fine lapping compound is completely washed off after rubbing. Page 1967 Page 1083 Drive Belt: Testing and Inspection Power Steering TENSION CHECK Using a belt tension gauge, check the tension. Belt tension gauge: Nippondenso BTG-20 (95506-00020) or Borroughs No.BT-33-73F Drive belt tension: New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. NOTICE: After installing the belt, check that it fits properly in the ribbed grooves. HINT: New belt refers to a belt which has been 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. Page 4682 Electronically Controlled Transmission And A/T Indicator (Part 2 Of 3) Page 1931 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2103 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1473 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 4140 16. Install new bearing spacer, rear bearing and oil slinger. a. Install a new bearing spacer and place the rear bearing and oil slinger. b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) and the companion flange, install the rear bearing then remove the companion flange. 17. Install oil seal. a. Coat a new oil seal lip with MP grease. b. Using SST 09554-22010 and a hammer, install the oil seal. Oil seal drive in depth: 4.5 mm (0.177 inch) 18. Install companion flange. a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST 09330-00021 to hold the flange, torque the nut. Torque to 108 Nm (80 ft. lbs.) 19. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) a little at a time until the specified preload is reached. Maximum torque: 223 Nm (165 ft. lbs.) Page 3039 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Harmonic Balancer - Crankshaft Pulley: Specifications TIGHTENING SPECIFICATIONS Crankshaft Pulley To Crankshaft ................................................................................................................................................ 250 Nm (184 ft. lbs.) Page 2775 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Page 3385 Glossary Of Term And Symbols (Part 1 Of 2) Page 4381 6. Inspect reverse idler gear and shift arm clearance. Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm. Standard Clearance: 0.05-0.35 mm (0.0020-0.0138 inch) Maximum Clearance: 0.50 mm (0.0197 inch) If the clearance exceeds the Maximum, replace the shift arm or reverse idler gear. Page 59 ECU Power Source Circuit Page 4496 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 3281 Components For Removal And Installtion Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION INJECTORS REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR 3. REMOVE FUEL PRESSURE REGULATOR 4. DISCONNECT FUEL INLET PIPE CAUTION: Catch leaking fuel in a container. 5. REMOVE FUEL PIPE 6. DISCONNECT INJECTOR CONNECTORS 7. REMOVE DELIVERY PIPES AND INJECTORS NOTICE: Be careful not to drop the injectors when removing the delivery pipes. (a) Remove the 4 bolts and delivery pipes together with the 6 injectors (b) Remove the 4 spacers from the intake manifold. (c) Pull out the 6 injectors from the delivery pipes. Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 2253 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 842 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 3973 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1910 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1678 w/ Tachometer w/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 2591 Page 852 Page 719 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 311 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3397 Page 4419 Output Shaft: Testing and Inspection 1. Inspect output shaft. a. Using a micrometer, measure the output shaft flange thickness. Minimum thickness: 4.70 mm (0.1850 inch) If the thickness is less than the minimum, replace the output shaft. b. Using a micrometer, measure the outer diameter of the output shaft journal. Minimum Diameter: A 1st gear: 38.860 mm (1.5299 inch) B 2nd gear: 46.860 mm (1.8449 inch) C 3rd gear: 37.860 mm (1.4905 inch) If the outer diameter is less than the minimum, replace the output shaft. Page 632 A/F and 02 Sensor Identification Page 4144 Differential Carrier: Service and Repair Rear Differential Carrier With Differential Lock Differential Carrier (3RZ-FE, 5VZ-FE w/Differential Lock) INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. If the runout are not within the specification, replace the companion flange. Diagrams Fuel Return Line: Diagrams CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened parts. Page 2609 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1857 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Specifications Center Support: Specifications Center Bearing To Frame .................................................................................................................... .................................................... 36 N.m (27 ft. lbs.) Intermediate Shaft To Center Support Bearing To Joint Flange 1st Pass ............................................................................................................................................... ............................................. 181 N.m (134 ft. lbs.) 2nd Pass ............................................................. .............................................................................................................................................. Loosen Nut 3rd Pass ........................................................................................................................................ ....................................................... 69 N.m (51 ft. lbs.) Page 611 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4102 Pressure Plate: Testing and Inspection Inspect diaphragm spring for wear. Using calipers, measure the diaphragm spring for depth and width of wear. Maximum Depth: A: 0.6 mm (0.024 inch) Maximum Width: B: 5.0 mm (0.197 inch) If necessary, replace the clutch cover. Page 3420 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 1092 - Using SST, tighten the flare nut to specified torque. (SST 09631-22020) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Torque for using SST: 28 N.m (285 kgf.cm, 21 ft.lbf) NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness And Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 32) Page 1947 Page 4003 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 894 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2147 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2862 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Page 3362 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 309 Glossary Of Term And Symbols (Part 1 Of 2) Page 2209 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 647 CHART 1 Page 2728 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2557 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Service Data Flywheel: Specifications Service Data Flywheel Runout: Maximum ............................................................................................................................................. .............................................. 0.1 mm (0.004 inch) Page 4829 Type "B" Brake Pad A. Remove the clip, pins and anti-rattle spring/pad retainer clip. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 3521 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Capacity Specifications Refrigerant: Capacity Specifications Refrigerant R134A 20.8 oz Page 4118 Differential Carrier: Testing and Inspection Rear Differential Carrier With Differential Lock Differential Carrier (3RZ-FE, 5VZ-FE w/Differential Lock) INSPECTION 1. Check runout of companion flange. Using a dial indicator, measure the vertical and lateral runout of the companion flange. If the runout are not within the specification, replace the companion flange. Page 1976 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1598 Spark Plug: Testing and Inspection SPARK PLUGS INSPECTION 1. DISCONNECT HIGH -TENSION CORDS 2. REMOVE IGNITION COILS 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 4. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 5. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: ND: K16TR11 NGK: BKR5EKB-11 Page 4252 a. Using a snap ring expander, remove the snap ring. b. Place matchmarks on the shaft and tripod. c. Using a brass bar and hammer, remove the tripod joint. NOTICE: Do not tap the roller. 5. Remove inboard and outboard joint boots. a. Remove the inboard joint boot from the drive shaft b. Using a side cutter, cut the outboard boot clamps. c. Remove the outboard joint boot from the drive shaft. NOTICE: Do not disassemble the outboard joint. 6. Remove dust cover. Using a screwdriver, remove the dust cover from the inboard joint tulip. 7. Remove dust seal. Using a screwdriver and hammer, remove the dust seal from the drive shaft ASSEMBLY 1. Install dust cover. Using a screwdriver and hammer, install a new cover. 2. Install dust seal. Using a screwdriver and hammer, install a new dust seal. 3. Temporarily install new boots to drive shaft. HINT: ^ Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boot. ^ Place new clamps to boot's small ends and install its to the drive shaft. 4. Assemble tripod joint. a. Place the beveled side of the tripod axial spline toward the outboard joint. b. Align the matchmarks placed before disassembly. c. Using a brass bar and a hammer, install the tripod joint onto the drive shaft. NOTICE: Do not tap the roller. d. Using a snap ring expander, install a new snap ring. 5. Assemble boot to outboard joint. Before assembling the boot, pack in grease. HINT: Use the grease supplied in the boot kit. 6. Assemble boot and inboard joint tulip. a. Pack the inboard joint and boot with grease. HINT: Use the grease supplied in the boot kit. b. Align the matchmarks placed before assembly. c. Install the inboard joint tulip to the drive shaft d. Temporarily install the boot to the inboard joint tulip. 7. Assemble new boot clamps to both boots. a. Ensure that the boots are in the shaft groove. b. Ensure that the boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: 436.2 ± 2.0 mm (17.173 ± 0.079 inch) c. Place a new inboard joint large boot clamp. d. Holding the clamp near the closing hooks, position the holes in the clamp's free end over the closing hooks with pliers. e. Secure clamps by drawing the closing hooks together. To assemble the other boot clamps, pinch the clamps and adjust clearance with SST. NOTICE: Do not overtighten the SST 09521-24010. g. Measure the clearance of the boot clamps with SST 09240-00020. Clearance: 1.0 - 1.5 mm (0.039 - 0.059 inch) 8. Check drive shaft. Page 1060 (a) Visually check the seal portion of the tensioner for oil leakage. NOTE: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. (b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. CAUTION: Never hold the tensioner push rod facing downward. (c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. Page 1544 (c) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, install the pulley bolt. Torque: 110 Nm (81 ft. lbs.) 6. Set No. 1 cylinder to Top Dead Center (TDC)/compression. (a) Crankshaft Timing Pulley Position: ^ Temporarily install the crankshaft pulley bolt to the crankshaft. ^ Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. (b) Camshaft Timing Pulley Positions: Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, turn the camshaft pulley, align the timing marks of the timing pulley and No. 3 timing belt cover. 7. Install timing belt. CAUTION: The engine should be cold. (a) Remove any oil or water on the pulleys, and keep them clean. CAUTION: Only wipe the pulleys; do not use any cleansing agent. (b) Face the front mark on the timing belt forward. (c) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. Page 2047 CHART 15 Page 3445 (c) Using an ohmmeter, measure the resistance between each terminal. Page 3602 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1230 Malfunction Indicator Lamp: Testing and Inspection Check the MIL (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter. (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system Page 1715 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2892 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 827 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 2727 Glossary Of Term And Symbols (Part 1 Of 2) Page 1480 Oil Pan: Service and Repair REMOVAL 1. Remove the 15 bolts and 4 nuts. 2. Using Special Service Tool (SST) Oil Pan Seal Cutter # 09032 - 00100 or equivalent and a brass bar, separate the oil pan from the cylinder block. NOTE: When removing the oil pan, be careful not to damage the oil pan flange. INSTALLATION 1. Apply seal packing to the oil pan, as shown in the illustration. Seal packing: Part No. 08826 - 00080 or equivalent. Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening. NOTE: Avoid applying an excess amount to the surface. - If parts are not assembled within 5 minutes of applying the seal packing, the effectiveness of the seal packing is lost and the seal packing must be removed and reapplied. - Immediately remove the nozzle from the tube and reinstall the cap after using the seal packing. 2. Install the oil pan with the 2 nuts and 17 bolts. Torque: 7.6 Nm (67 inch lbs.) Page 335 Clutch Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3135 (c) Check that air flows from ports E to F and does not flow from ports E to P. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Page 2741 Standard Values Of ECM Terminals Chart 2 Of 2 Page 4173 d. Recheck the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) If the backlash is not within the specification, adjust by either increasing or decreasing the washers on both sides by equal amounts. HINT: The backlash will change about 0.20 mm (0.0079 inch) with 0.03 mm (0.0012 inch) alteration of the side washer. Mark and Washer thickness: 58 2.58 (0.1015) 60 2.60 (0.1024) 62 2.62 (0.1031) 64 2.64 (0.1039) 66 2.66 (0.1047) 68 2.68 (0.1055) 70 2.70 (0.1063) 72 2.72 (0.1071) 74 2.74 (0.1079) 76 2.76 (0.1087) 78 2.78 (0.1094) 80 2.80 (0.1102) 82 2.82 (0.1110) 84 2.84 (0.1118) 86 2.86 (0.1126) 88 2.88 (0.1134) 90 2.90 (0.1142) 92 2.92 (0.1150) 94 2.94 (0.1157) 96 2.96 (0.1165) 98 2.98 (0.1173) 00 3.00 (0.1181) 02 3.02 (0.1189) 04 3.04 (0.1197) 06 3.06 (0.1205) 08 3.08 (0.1213) 10 3.10 (0.1220) 12 3.12 (0.1228) 14 3.14 (0.1236) 16 3.16 (0.1244) 18 3.18 (0.1252) 20 3.20 (0.1260) 24 3.24 (0.1276) 26 3.26 (0.1283) 28 3.28 (0.1291) 30 3.30 (0.1299) 32 3.32 (0.1307) 34 3.34 (0.1315) 36 3.36 (0.1323) 38 3.38 (0.1331) 40 3.40 (0.1339) 42 3.42 (0.1346) 44 3.44 (0.1354) 46 3.46 (0.1362) 48 3.48 (0.1370) 11. Install side bearing cap. a. Align the matchmarks on the cap and carrier. b. Torque the 4 bolts. Torque to 113 Nm (83 ft. lbs.) 12. Measure total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) Page 1059 Timing Belt: Testing and Inspection INSPECTION 1. Inspect timing belt. CAUTION: 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. If there are any defects as shown in the illustration, check these points: (a) 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. (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 belt cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. Inspect idler pulleys. (a) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. Inspect timing belt tensioner. Page 4863 Brake Drum: Service and Repair Rear Brake Components (4WD) REMOVAL 1. Remove rear wheel. 2. Remove brake drum. NOTE: If the brake drum cannot be removed easily, do the following steps. (a) Remove the adjusting hole plug in the backing plate. (b) Insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjusting bolt. (c) Using another screwdriver, reduce the brake shoe adjustment by turning the adjusting bolt. INSTALLATION 1. Install the drum. Page 1285 ^ Arrange the camshafts in the correct order. ^ Arrange the bearing caps in the correct order. Page 1439 Idler Pulley: Specifications TIGHTENING SPECIFICATIONS No. 1 Idler Pulley To Oil Pump: .............................................................................................................................................................. ................................................ 35 Nm (26 ft. lbs.) No. 2 Idler Pulley To No. 2 Idler Pulley Bracket: .............................................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) Locations Page 2332 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS (a) Assemble the holder and grommet. (b) Align the spline of the ignition coil with the spline of the holder and push in the cord. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration. (c) Check that the lock claw of the holder is engaged by lightly pulling the holder. 6. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS 7. REINSTALL AIR CLEANER HOSE Page 696 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3033 Glossary Of Term And Symbols (Part 1 Of 2) Page 1342 Piston: Testing and Inspection Piston Pin Fit At 60° C (140° F), you should be able to push the piston pin into the piston pin hole with your thumb. Page 2131 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 616 Components For Removal And Installation Part 2 Of 2 Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ...................................................... 1.1 mm (0.043 in.) Page 4527 Case: Service and Repair 1. If necessary, replace front bearing retainer oil seal. a. Using a screwdriver and hammer, drive out the oil seal. b. Using Special Service Tool (SST) 09950-60010 (09951-00590), 09950-70010 (09951-07100) and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface. c. Coat the lip of the oil seal with MP grease. 2. If necessary, replace front case oil seal. a. Using a screwdriver and hammer, drive out the oil seal. b. Using SST 09316-60011 (09316-00011) and a hammer, drive in a new oil seal until its surface is flush with the case upper surface. c. Coat the lip of the oil seal with MP grease. Page 4030 C. Lift off upper valve body and plate as a single unit holding the valve body plate to the upper valve body as shown in the illustration. Caution: Be careful that the check balls and strainer do not fall out. 2. Modification: A. Turn over the upper valve body, remove plate & gaskets. B. Add new check ball in the location shown in illustration. 3. Assembly: A. GReassemble upper and lower valve body halves using new gaskets. B. GInstall 25 bolts to upper valve body. Torque: 56 in. lbs. (6.4 N/m, 65 kgf/cm) Caution: Careful to reinstall the bolts in their proper locations as shown in the illustration. Bolt Length: A: 38 mm (1.50") B: 20 mm (0.79") C: 28 mm (1.10") C. Complete reassembly as described in the Repair Manual for the vehicle being serviced. Page 3735 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 25) Page 3605 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 637 A/F and 02 Sensor Identification Page 2121 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1258 NOTE: After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or resuming towing. NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are observed. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Page 2961 Oxygen Sensor: Technical Service Bulletins Emissions - Oxygen Sensor Modified ENGINE EG011-99 October 15, 1999 Title: 5VZ OXYGEN SENSOR IMPROVEMENT Models: '96 - '99 Tacoma Introduction The design of the 5VZ Oxygen Sensor inner cover has been changed to reduce the possibility of moisture contacting the ceramic element. Applicable Vehicles ^ 1996-1999 model year Tacomas built before the VIN listed. Repair Procedure Please refer to the appropriate repair manual for diagnostic and installation information for the Oxygen Sensor. Part Number Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. Page 2610 Glossary Of Term And Symbols (Part 1 Of 2) Testing and Inspection Fuel Pump Relay: Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION CIRCUIT OPENING RELAY INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals ST and E1 If there no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there no continuity, replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals ST and E1. Page 1999 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1133 Coolant: Testing and Inspection COOLANT CHECK 1. Check engine coolant level at radiator reservoir. The engine coolant level should be between the "LOW" and "FULL" lines, when the engine is cold. If low, check for leaks and add engine coolant up to the "FULL" line. 2. Check engine coolant quality. (a) Remove the radiator cap from the water outlet. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. (c) Reinstall the radiator cap. Page 3374 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2731 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 699 Page 3023 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2681 CHART 23 Page 4386 f. Turn the reverse synchronizer pull ring. g. while pushing the 3 shifting keys, install the synchronizer ring assembly to the hub sleeve No.3. Specifications Fluid Pump: Specifications SERVICE SPECIFICATIONS Oil Pump Body Body Clearance Standard ........................................................................................................................................................ 0.09-0.16 mm (0.0035-0.0063 inch) Maximum .................................................................................... ....................................................................................... 0.16 mm (0.0063 inch) Tip Clearance Standard ........................................................................................................................................................ 0.05-0.15 mm (0.0020-0.0059 inch) Maximum .................................................................................... ....................................................................................... 0.15 mm (0.0059 inch) Side Clearance Standard ........................................................................................................................................................ 0.03-0.10 mm (0.0012-0.0039 inch) Maximum .................................................................................... ....................................................................................... 0.10 mm (0.0039 inch) TIGHTENING SPECIFICATIONS Relief Valve ......................................................................................................................................... ............................................. 29.4 N.m (21 ft. lbs.) Oil Pump Plate ..................................................... ........................................................................................................................... 7.4 N.m (65 inch lbs.) Page 3334 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 2869 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 490 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2533 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3743 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4255 5. Disconnect brake line and parking brake cable. Using SST 09751-36011, disconnect the brake line from the wheel cylinder. Installation Hint: Torque to 15 Nm (11 ft. lbs.) 6. Remove rear axle shaft assembly. a. Remove the 4 backing plate mounting nuts. Installation Hint: Torque to 68 Nm (50 ft. lbs.) b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 7. Remove o-ring from rear axle housing. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed brake system and check ABS speed sensor signal. Hub Bolt HUB BOLT REPLACEMENT 1. Remove wheel and brake drum. 2. Remove hub bolt. Using SST, 09650-17011 Page 3661 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 868 Page 4175 05 2.05 mm (0.0807 inch) 06 2.06 mm (0.0811 inch) 07 2.07 mm (0.0815 inch) 08 2.08 mm (0.0819 inch) 09 2.09 mm (0.0823 inch) 10 2.10 mm (0.0827 inch) 11 2.11 mm (0.0831 inch) 12 2.12 mm (0.0835 inch) 13 2.13 mm (0.0839 inch) 14 2.14 mm (0.0843 inch) 15 2.15 mm (0.0846 inch) 16 2.16 mm (0.0850 inch) 17 2.17 mm (0.0854 inch) 18 2.18 mm (0.0858 inch) 19 2.19 mm (0.0862 inch) 20 2.20 mm (0.0866 inch) 21 2.21 mm (0.0870 inch) 22 2.22 mm (0.0874 inch) 23 2.23 mm (0.0878 inch) 24 2.24 mm (0.0882 inch) 25 2.25 mm (0.0886 inch) 26 2.26 mm (0.0890 inch) 27 2.27 mm (0.0894 inch) 28 2.28 mm (0.0898 inch) 14. Remove companion flange. 15. Remove front bearing. 16. Install new bearing spacer, 2 washers and front bearing. a. install a new bearing spacer and 2 washers, and place the front bearing. b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050) and the companion flange, install the front bearing then remove the companion flange. 17. Install new oil seal. a. Coat a new oil seal lip with MP grease. b. Using SST 09649-17010, 09316-12010, install the oil seal until its surface is flush with the differential carrier end. HINT: Connect SST with vinyl tape. 18. Install companion flange. a. Place the companion flange. b. Coat the threads of a new nut with hypoid gear oil. Page 4133 Differential Carrier ASSEMBLY 1. W/A.D.D.: Install new bearings. Using SST 09950-60010 (09951-00380) and a press, install new bearings. Bearing press in depth: 0.3 ± 0.3 mm (0.012 ± 0.012 inch) Page 2952 CHART 25 Locations Page 1200 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3318 Fuel Supply Line: Service and Repair 1. Before working on the fuel System, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. 3. Keep gasoline away from rubber or leather parts. FUEL SYSTEM 1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: (a) Disconnect the fuel pump connector. (b) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (c) Put a container under the connection. (d) Slowly loosen the connection. (e) Disconnect the connection. (f) Plug the connection with a rubber plug. 2. When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures: Union Bolt Type: (a) Always use 2 new gaskets. (b) Tighten the union bolt by hand. (c) Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: (a) Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 4927 Brake Master Cylinder: Adjustments Set SST On Gasket 1. Install the gasket on the master cylinder. 2. Set the Special Service Tool (SST) # 09737-00010 on the gasket, and lower the pin until its tip slightly touches the piston. 3. Turn the SST upside down, and set it on the booster. 4. Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 inch) 5. Adjust the booster push rod length until the push rod lightly touches the pin head. Page 2846 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Testing and Inspection Shift Interlock Solenoid: Testing and Inspection Inspect shift lock solenoid. a. Disconnect the solenoid connector. b. Using an ohmmeter, measure the resistance at each terminal. Standard Resistance 20-28 ohms. If resistance value is not as specified. Replace the solenoid. c. Apply battery positive voltage at each terminal. At this time, confirm that the solenoid operates. If the solenoid does not operate, replace the solenoid. Testing and Inspection Instrument Panel Relay: Testing and Inspection INSPECT BULB CHECK RELAY OPERATION 1. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up. 2. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Page 1749 REMOVAL 1. Remove timing belt. Refer to Engine. 2. Remove water inlet and thermostat. 3. Disconnect No. 2 oil cooler hose from water pump. 4. Remove water pump. INSTALLATION 1. Install water pump. (a) Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. ^ Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the water pump groove as shown in the illustration. Seal packing: Part No. 08826 - 00100 or equivalent. ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. Page 4145 Maximum vertical runout: 0.10 mm (0.0039 inch) Maximum lateral runout: 0.10 mm (0.0039 inch) 2. Check ring gear runout. Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 inch) If the runout is not within the specification, replace the ring gear. 3. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. Page 562 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3044 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1607 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only those valves indicated in the illustration. 1. Using a thickness gauge, measure the clearance between the valve lifter and camshaft. Valve Clearance (Cold): 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Page 1863 Ignition Control Module: Description and Operation CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is a 2-cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one ignition coil. In the 2-cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the 2 spark plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Electrical Specifications Camshaft Position Sensor: Electrical Specifications Resistance Cold Resistance Hot 835 - 1,400 ohms at 14 - 122 deg F 1,060 - 1,645 ohms at 122 - 212 deg F Page 738 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 744 Page 992 Adjustment Chart Example (VZN160L): Camber: 0° 15' (0.25°) Caster: 1° 35'(1.58°) c. Mark on the adjustment chart the alignment values measured at the non-loaded vehicle height. Example: Camber: 0° 10'(0.17°) Caster: 2° 20' (2.33`°) d. As shown in the illustration, read the distance from the standard value to the measured value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: +(Longer) 2.4 Rear cam: -(Shorter) 2.4 Page 4353 Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Locations-R/B No.2-Engine Compartment Left (Canada) (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-Ground: Approx 13 Ohms Page 2119 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3094 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 690 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1722 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4732 Page 3064 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 378 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1440 Idler Pulley: Testing and Inspection INSPECTION 1. Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. 2. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. Page 2014 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 859 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3616 Ignition Control Module: Description and Operation CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is a 2-cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one ignition coil. In the 2-cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the 2 spark plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 4583 ASSEMBLY 1. Install rear bearing. Using a press, install a new rear bearing. 2. Install front bearing. Using a press, install a new front bearing. Page 3524 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3615 Fuel - Idle Speed Increased by Replacement ECM Idle Speed: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 3668 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 2679 CHART 22 Page 3032 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Knock Sensor: Specifications Knock Sensor to Cylinder Block 29 ft.lb Page 2233 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 1240 Wheels: Technical Service Bulletins Wheels - Full Wheel Cap Improvement BODY BO009-97 April 4, 1997 Title: TACOMA 4X4 FULL WHEEL CAP IMPROVEMENT Models: '97 Tacoma 4X2 Introduction To prevent rotation of the outer wheel cap face, a strip of butyl rubber has been added between the wheel cap retainer (inner portion) and the wheel cover face (outer portion). Production Change Information ^ 1997 Tacoma 4x2 models starting with VIN 4TA ***** VZ221212 Parts Information PREVIOUS PART NUMBER NEW PART NUMBER PART NAME 42621-AD010 Same Wheel Cap NOTE: New style service parts are identified by a "B" after the part number or a manufacturing date code after 8/21/96. This information is located after the part number that is printed on a label adhered to the back side of the wheel cover. Page 602 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 877 Ignition Switch: Testing and Inspection IGNITION SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3693 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Ignition Switch Testing and Inspection Headlamp Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY Reference If continuity is not as specified, replace the switch. Page 36 ABS Main Relay: Description and Operation ABS Control (Solenoid) Relay CIRCUIT DESCRIPTION This relay supplies power to each Anti-Lock Brake System (ABS) solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. FAIL SAFE FUNCTION If trouble in the ABS control (solenoid) relay circuit, the Electronic Control Unit (ECU) cuts off current to the ABS control (solenoid) relay and prohibits ABS control. Page 1886 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 689 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2315 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 2029 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 4377 Page 3247 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 2526 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1413 Drive Belt: Specifications Power Steering Belt Drive Belt - Power Steering / Tension: New Belt .............................................................................................................................................. .................................................. 135 - 180 lbs. Used Belt ................................................................... ............................................................................................................................... 85 - 120 lbs. Page 3948 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1562 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the 6 bolts and disconnect the No.2 timing belt cover. (d) Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. (e) Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (f) Wipe off any splattered gasoline. (g) Connect the TOYOTA hand-held tester to the DLC3. (h) Reconnect the negative (-) terminal cable to the battery. (i) Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high. replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections - Fuel pump - Fuel filter - Fuel pressure regulator (k) Disconnect the TOYOTA hand-held tester from the DLC3. Page 4007 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Page 3108 Vehicle Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 437 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1004 (l) Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) (m)Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator. and plug the hose end. (o) Measure the fuel pressure at idle. Fuel pressure 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm. 21 psi) or more If pressure is not as specified. check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (s) Remove the other union bolt. 3 gaskets and fuel pipe from the delivery pipes. (t) Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 2873 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2052 CHART 21 Page 3458 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3574 Glossary Of Term And Symbols (Part 1 Of 2) Page 1618 Page 1739 Thermostat: Pressure, Vacuum and Temperature Specifications Valve Opening Temperature .......................................................................................................................................................... 80 - 84° C (176 - 183° F) Page 2630 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 1376 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 340 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3994 Glossary Of Term And Symbols (Part 1 Of 2) Page 2281 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4482 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2221 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 607 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1239 Part numbers remain the same. Wheel Weight Part Numbers Repair Procedure On vehicles produced before the production change reduce the clamp width on Toyota wheel weights. Warranty Information Page 731 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2779 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 4916 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection ABS ACTUATOR INSPECTION 1. Inspect battery positive voltage. Battery positive voltage: 10-14 Volts. 2. Disconnect connectors. Disconnect Connector (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3. Connect actuator checker Special Service Tool (SST) to actuator. Sub-Wire Harness C And Sub-Wire Harness E (a) Connect the actuator checker (SST) to the actuator, control relay and body side wire harnesses through the sub - wire harnesses C and E (SST), as shown. SST 09990-00150, 09990-00200,09990-00210 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (-) terminal. Connect the black cable of the sub-wire harnesses to the battery negative (-) terminal or body ground. (c) Place the "SHEET L" (SST) on the actuator checker. SST 09990 - 00370 4. Inspect brake actuator operation. (a) Start the engine, and run it at idle. Page 2204 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3215 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2389 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1500 Intake Manifold: Testing and Inspection INSPECTION Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and intake air connector for warpage. Maximum warpage: 0.10 mm (0.0039 inch) If warpage is greater than the maximum, replace the intake manifold. Page 357 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2284 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 444 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 571 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4871 (c) Using a screwdriver, remove the C-washer and bellcrank No.3 from the backing plate with parking brake cable No.2. (d) Remove the parking brake bellcrank and dust cover with the 2 bolts. Torque: 13 Nm (9 ft. lbs.) (e) Remove the bellcrank boot from the bellcrank bracket. (f) Remove the C-washer and pin. (g) Remove the parking brake bellcrank from the bellcrank bracket. INSTALLATION Installation is in the reverse order of removal, noting the following: Adjust bellcrank. See: Adjustments - Check operation of automatic adjusting mechanism. See: Adjustments - Check clearance between brake shoes and drum. Specifications Gear Sensor/Switch: Specifications 4WD-position Switch ........................................................................................................................... ................................................... 37 N.m (27 ft. lbs.) L4 Position Switch ............................................. ...................................................................................................................................... 37 N.m (27 ft. lbs.) Neutral Position Switch ................................................................................................................ ........................................................... 37 N.m (27 ft. lbs.) Page 2703 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1979 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Door Lock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3373 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3068 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 1641 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 2453 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 64 Inspection Procedure / Diagnosis Circuit (2 Of 2) INSPECTION PROCEDURE ECU Power Source Circuit ECU POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc.. When terminal GND and the cruise control ECU case are grounded. ECU Power Source Circuit WIRING DIAGRAM Page 1655 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Electrical Specifications Air Flow Meter/Sensor: Electrical Specifications Measure Terminals THA - E2 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 230 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3545 Ignition Coil: Testing and Inspection IGNITION COIL INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS AND IGNITION COIL CONNECTORS FROM IGNITION COILS 3. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (-) terminals. Primary coil resistance Cold: 0.67 - 1.05 Ohms Hot: 0.85 - 1.23 Ohms If the resistance is not as specified, replace the ignition coil. 4. REMOVE IGNITION COILS 5. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and high-tension terminals. Secondary coil resistance: Cold: 9.3 - 16.0 K ohms Hot: 11.7 - 18.8 K ohms If the resistance is not as specified, replace the ignition coil. 6. REINSTALL IGNITION COILS 7. RECONNECT IGNITION COIL CONNECTORS AND HIGH-TENSION CORDS 8. REINSTALL AIR CLEANER HOSE Page 1861 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1386 Valve Guide: Testing and Inspection 1. Using a caliper gauge, measure the inside diameter of the guide busing. Bushing inside diameter: 6.010 - 6.030 mm (0.2366 - 0.2374 inch) 2. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake: 5.970 - 5.985 mm (0.2350 - 0.2356 inch) Exhaust: 5.965 - 5.980 mm (0.2348 - 0.2354 inch) 3. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake: 0.025 - 0.060 mm (0.0010 - 0.0024 inch) Exhaust: 0.030 - 0.065 mm (0.0012 - 0.0026 inch) maximum oil clearance: Intake: 0.08 mm (0.0031 inch) Exhaust: 0.10 mm (0.0039 inch) If the clearance is greater than the maximum, replace the valve and guide bushing. Page 4932 Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. NOTE: Tape the screwdriver tip before use. Torque 10 Nm (7 ft. lbs.) 5. Remove 2 pistons and springs. Remove Snap Ring With Snap Ring Pliers (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. NOTE: Tape the screwdriver tip before use. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. CAUTION: If pulled out and install at an angle, there is a possibility that the cylinder bore could be damaged. REASSEMBLY CAUTION: Be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the blocks until the No. 2 piston drops out of the cylinder. NOTE: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch). INSPECTION NOTE: Clean the disassembled parts with compressed air. 1. Inspect cylinder bore for rust or scoring. 2. Inspect cylinder for wear or damage. If necessary, clean or replace the cylinder. REASSEMBLY Page 3907 Electronically Controlled Transmission And A/T Indicator-Connectors Service Specifications Valve Body: Specifications Service Specifications Keys Drivetrain - Revised Rear Axle Oil Seal/Installation Seals and Gaskets: Technical Service Bulletins Drivetrain - Revised Rear Axle Oil Seal/Installation DRIVELINE & DIFFERENTIAL DL002-03 August 6, 2003 Title: REAR AXLE SEAL DESIGN CHANGE Models: '01 - '02 Sequoia, '95 - '02 Tacoma & '00 - '02 Tundra Introduction The rear axle seal lip design has been changed from a flat face type to an angled face type. A different SST seal driver is required to install the seal properly and prevent damaging the oil seal during the installation process. NOTE: Use of SST part number 09951-00610 (Replacer 6-4) as listed in the Repair Manual to install the newly designed rear axle seal can damage the seal assembly causing it to leak. Repair Manual update on Technical Information System (TIS) is in process. Applicable Vehicles ^ 2001 - 2002 model year Sequoia vehicles. ^ 1995 - 2002 model year Tacoma vehicles. ^ 2000 - 2002 model year Tundra vehicles. Parts Information Required SSTs NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Required Tools & Material Warranty Information Identification Procedure Description and Operation Fillpipe Restrictor: Description and Operation Fillpipe Restrictor The fillpipe restrictor is used to prevent leaded fuel from being added to the fuel tank. The gasoline pump for unleaded fuel has a smaller nozzle. The fillpipe restrictor will only allow the unleaded type nozzle to be inserted into the fuel tank. Page 1110 @ Compressor 7.2 ft/lbf (9.8 N.m, 100 Kgf/cm) @ Evaporator 24 ft/lbf (32.3 N.m, 330 Kgf/cm) CAUTION: Maintain clearance between the suction hose and other parts. A. 4 Cylinder (L4) engine models: a. Remove original suction hose. b. Install new suction hose. B. 6 Cylinder (V6) engine models: a. Remove original suction hose. b. Route the new suction hose around the power steering hose to install. 3. Perform Gas Charge and Leak Check procedures as explained in the A/C Installation Manual. Page 4244 b. Using SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) and a press, remove the bearing from the steering knuckle. ASSEMBLY 1. Install new bearing. a. Using SST 09527-17011, 09950-60020 (09951-00910) and a press, install a new bearing to the steering knuckle. b. Using snap ring pliers, install the snap ring. 2. Install new oil seal (Outside). a. Using SST 09223-15030, 09527-17011 and a plastic hammer, install a new oil seal (outside). b. Coat MP grease to the oil seal lip. 3. Install axle hub to steering knuckle. a. Install the brake dust cover to the steering knuckle with the 4 bolts. Torque to 18 Nm (13 ft. lbs.) b. Using SST 09649-17010 and a press, install the axle hub to the steering knuckle. 4. Install ABS speed sensor rotor/spacer. Page 649 CHART 5 CHART 6 Page 188 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1682 Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY 1. Check that there is no continuity between terminals with the switch OFF (float up). 2. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 4782 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Actuator Components REMOVAL 1. Disconnect brake lines. Disconnect Brake Lines Page 2483 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2391 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4033 Springs / Upper Valve Body Page 146 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3902 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4049 RETAINERS, PIN, STOPPER, CHECK BALLS AND STRAINER LOCATION 1. RETAINER, STOPPER AND PIN Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts: Torque: 1st Pass ............................................................................................................................................... ...................................... 61 Nm (45 ft. lbs.) 2nd Pass ......................................................................... ................................................................................................................................ + 90° Main Bearing Clearance: Standard: No. 1: Standard ................................................................................................................................................ 0.020 0.038 mm (0.0008 - 0.0015 inch) U/S 0.25 ................................................................................................................................................ 0.019 0.059 mm (0.0007 - 0.0023 inch) Others: STD ....................................................................................................................................................... 0.024 - 0.042 mm (0.0009 - 0.0017 inch) U/S ................................................................................................................................................. 0.250.023 - 0.063 mm (0.0009 - 0.0025 inch) Maximum clearance ........................................................................................................................................................... 0.08 mm (0.0031 inch) If replacing the cylinder block subassembly, the bearing standard clearance will be: No. 1 ...................................................................................................................................................... 0.010 - 0.049 mm (0.0004 - 0.0020 inch) Others .................................................................................................................................................... 0.014 - 0.053 mm (0.0006 - 0.0021 inch) Bearing Size Codes Page 3798 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. Locations One Touch 2-4 Selector System Page 2551 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 860 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 659 CHART 20 Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3682 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2429 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1962 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1509 Crankshaft Main Bearing Seal: Service and Repair NOTE: There are 2 methods (A and B) to replace the oil seal which are as follows: A. If rear oil seal retainer is removed from cylinder block. 1. Using a screwdriver and a hammer, tap out the oil seal. 2. Using Special Service Tool (SST) Oil Seal & Bearing Replacer # 09223 - 15030, Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap in a new oil seal until its surface is flush with the oil seal retainer edge. 3. Apply Multipurpose (MP) grease to the oil seal lip. B. If rear oil seal retainer is installed to cylinder block. 1. Using a knife, cut off the oil seal lip. 2. Using a screwdriver, pry out the oil seal. CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip. 3. Apply MP grease to a new oil seal lip. 4. Using SST Oil Seal & Bearing Replacer # 09223 - 15030, Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. Locations Starter Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2641 Malfunction Indicator Lamp: Testing and Inspection Check the MIL (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter. (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system Page 1699 5. When using the radiator cap tester, tilt it more than 30 degrees. 6. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Page 2523 Glossary Of Term And Symbols (Part 1 Of 2) Testing and Inspection Shift Interlock Control Module: Testing and Inspection Shift Lock ECU, Harness Side: Floor Shift Floor Shift: Inspect shift lock control ECU. Using a voltmeter, measure the voltage at terminal. HINT: Do not disconnect the ECU connector. Page 4910 Brake Proportioning/Combination Valve: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove valve bracket. (a) Remove the nut, bolt and plate washers. (b) Remove the 2 nuts, and remove the valve bracket and set plate from the valve body. 2. Disconnect spring from valve. Using pliers, remove the clip, and remove the spring from the valve. 3. Remove shackles No.1 and No.2. (a) Remove the nut and bolt, and then remove the load sensing spring and 2 plate washers. (b) Loosen the 2 nuts, and remove the shackle No.1 from the shackle No.2. 4. Disassemble load sensing spring. Disassembly the these parts: 4 Bushings. - 2 Collars. - 2 Rubber plates. - Load sensing valve boot. - Load sensing spring boot. INSPECTION Page 759 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3466 Page 1452 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................... SH Energy Conserving II, SJ Energy Conserving, or ILAC Multigrade Above 0° F (-18°C) .................................. .............................................................................................................................................................. ... 10W-30 All Temperatures ................................................................................................................ .......................................................................................... 5w-30 Page 3704 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 4288 Companion Flange: Specifications Rear TIGHTENING SPECIFICATIONS Flange Nuts ......................................................................................................................................... .............................................. 196 Nm (145 ft. lbs.) Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1895 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3750 Electronically Controlled Transmission And A/T Indicator-Connectors Page 3339 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 518 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2068 * Warranty application is limited to correction of a problem based upon a customer's complaint. Page 1139 Fluid - A/T: Technical Service Bulletins A/T - Fluid Type T-IV Replaces Type T-II TRANSMISSION & CLUTCH TC003-98 June 19, 1998 Title: AUTOMATIC TRANSMISSION FLUID TYPE T-IV Models: ALL MODELS Introduction The introduction of Automatic Transmission Fluid type T-IV makes type T-II obsolete. Use type T-IV for all applications that specify ATF type T-II. Affected Vehicles ^ All vehicles with Automatic Transmissions specified to use ATF Types T-II or T-IV. Parts Information Warranty Information Page 2525 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 3633 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4817 Brake Caliper: Service and Repair Disassembly and Reassembly Front Brake Components (4WD) DISASSEMBLY 1. Remove cylinder boot set rings and boots. Using a screwdriver, remove the 4 cylinder boot set rings and 4 boots from the caliper. Page 4318 HINT: When replacing the rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration. Page 4591 Page 3489 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 3160 EGR Valve: Testing and Inspection INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the EGR valve. Page 2757 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 1599 6. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) 7. REINSTALL SPARK PLUGS Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 8. REINSTALL IGNITION COILS 9. RECONNECT HIGH-TENSION CORDS Page 1802 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2780 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 3858 Forward Clutch Page 2653 Engine Bank Identification Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential TYPE.................................................................................................................................................... ........................................................................ GL-5* CAPACITY Front .............................................. .............................................................................................................................................................. .. 1.10L (1.16 Qt) With A.D.D [1] .......................................................................................................... ................................................................................... 1.15L (1.22 Qt) VISCOSITY Below -18° C (0° F) ......................................................................................................................................................... ............................... 80W, 80W-90 Above -18° C (0° F) ...................................................................... ..................................................................................................................................... 90 With A.D.D .............................................................................................................................................................. ................................................. 75W-90 [1] Automatic Disconnecting Differential Rear Differential Rear Differential Fluid Capacity* 4WD Extra Long Model: 2.05L (2.17 Qt) w/ Differential Lock Short Model: 2.65L (2.80 Qt) w/ Differential Lock Extra Long Model: 2.95L (3.18 Qt) w/o Differential Lock: 2.55L (2.69 Qt) Fluid level should be less than 0.20 in (5mm) below the fill plug. *Capacities are approximate Page 3751 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1 Of 3) Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 2352 Adjusting Shim Selection Chart (Exhaust) Page 1815 Standard Values Of ECM Terminals Chart 2 Of 2 Page 2279 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 749 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1484 Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING SWITCH 1. Disconnect the connector from the switch. 2. Check that there is continuity between terminal and ground with the engine stopped. 3. Check that there is no continuity between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2547 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 4610 K: 2.00-2.05 mm (0.0787-0.0807 inch) L: 2.05-2.10 mm (0.0807-0.0827 inch) Page 1589 Page 3857 First and Reverse Brake Page 345 INSPECTION PROCEDURE Page 3036 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2655 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 2867 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Fuel - Idle Speed Increased by Replacement ECM Engine Control Module: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Specifications Ignition Cable: Specifications Maximum Resistance per Cord 25 K ohms Page 3504 Page 2975 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 55 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 1951 Glossary Of Term And Symbols (Part 1 Of 2) Page 688 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3275 Page 1391 4. Hand-lap the valve and valve seat with an abrasive compound. 5. After hand-lapping, clean the valve and valve seat. Component Tests and General Diagnostics Knock Sensor: Component Tests and General Diagnostics KNOCK SENSOR INSPECTION 1. REMOVE KNOCK SENSORS See: Service and Repair 2. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Page 3733 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 22) Parts Location Parts Location Page 763 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 3732 Locations-J/B No.1 Left Kick Panel (Fig 20) Page 2415 Page 19 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Component Tests and General Diagnostics Camshaft Position Sensor: Component Tests and General Diagnostics CAMSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 2. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. 3. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR Page 4321 Yoke: Bearing With drill mark: With color mark (Red) No drill mark: No color mark 5. Install spider bearings. a. Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. d. Using SST 09332-25010, install new bearings on the spider. e. Using SST, adjust both bearings so that the snap ring grooves are at Maximum and equal widths. DANA 6. Install snap rings. a. Install 2 new snap rings of equal thickness which will allow 0-0.05 mm (0-0.0020 inch) axial play. HINT: Do not reuse the snap rings. Color: Thickness Green: 1.384 mm (0.0545 inch) Red: 1.435 mm (0.0565 inch) Black: 1.486 mm (0.0585 inch) Copper: 1.511 mm (0.0595 inch) Silver: 1.537 mm (0.0605 inch) Yellow: 1.588 mm (0.0625 inch) Blue: 1.638 mm (0.0645 inch) Front Differential Pinion Seal Seals and Gaskets: Service and Repair Front Differential Pinion Seal REPLACEMENT 1. REMOVE UNDER COVER 2. REMOVE FRONT PROPELLER SHAFT 3. REMOVE COMPANION FLANGE a. Using a chisel and hammer, unstake the nut. b. Using SST to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) Fuel - Idle Speed Increased by Replacement ECM Idle Speed: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 442 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4129 b. Using SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) and a press, remove the plate washer and outer race from the differential carrier. 15. Remove ring gear. a. Place matchmarks on the ring gear and differential case. b. Using a screwdriver, unstake the lock plates. c. Remove the 10 bolts and 5 lock plates. d. Using a plastic hammer, tap on the ring gear to separate it from the differential case. 16. Remove side bearings. Using SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), remove the side bearings from the differential case. HINT: Fix the claws of SST to the notch in the differential case. 17. Disassemble differential case assembly. a. Using a pin punch and a hammer, remove the straight pin. b. Remove these parts from the differential case: ^ Pinion shaft. ^ 2 pinion gears. ^ 2 pinion gear thrust washers. ^ 2 side gears. ^ 2 side gear thrust washers. Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3612 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 195 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 747 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2776 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2111 Page 200 Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 2844 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2098 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3932 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2285 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 2406 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1714 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1305 Connecting Rod: Specifications Connecting Rod Nut Connecting Rod Nut Torque: 1st Pass ............................................................................................................................................... ......................... 25 N-m (250 kgf-cm, 18 ft-lbf) 2nd Pass .................................................................... ........................................................................................................................................... + 90° Page 1901 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 3465 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1881 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3014 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 1644 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2501 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Direct Clutch Direct Clutch Page 3393 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 643 Page 507 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 2118 Glossary Of Term And Symbols (Part 1 Of 2) Page 3853 First and Reverse Brake Page 4723 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagnostic Trouble Code Tests and Associated Procedures Idle Speed/Throttle Actuator - Electronic: Diagnostic Trouble Code Tests and Associated Procedures DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed and a VSV for idle up control is also added (for air conditioning). DETECTING CONDITION WIRING DIAGRAM Step 1 Page 582 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4216 7. 3RZ-FE, 5VZ-FE W/ Diff. lock: REMOVE FRONT BEARING OUTER RACE AND OIL STORAGE RING a. Using SST, remove the front bearing outer race. SST 09308-00010 b. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE BEARING SPACER a. 3RZ-FE, 5VZ-FE w/o Diff. lock: Remove the 2 washers. b. Remove the bearing spacer. 9. INSTALL NEW BEARING SPACER a. Install a new bearing spacer. b. 3RZ-FE, 5VZ-FE w/o Diff. lock: Install the 2 washers. 10. 3RZ-FE, 5VZ-FE w/ Diff. lock: INSTALL OIL STORAGE RING AND FRONT BEARING OUTER RACE a. Using SST and a hammer, install a new oil storage ring. SST 09316-60011 (09316-00011, 09316-00021) b. Using SST and a hammer, install the front bearing outer race. SST 09316-60011 (09316-00011, 09316-00021) 11. INSTALL FRONT BEARING a. Place the front bearing. b. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: Place the oil slinger. c. Using SST and the companion flange, install the front bearing then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 12. INSTALL NEW OIL SEAL Page 609 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 176 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 4569 3. Remove oil pump plate. a. Using a Torx socket wrench, unscrew the 3 Torx screws. (Torx socket wrench (T30 09042-00010). Torque: 7.4 N.m (65 inch lbs.) b. Remove the oil pump plate. 4. Remove drive rotor and driven rotor. INSTALLATION HINT: Apply gear oil to the both rotors. INSPECTION 1. Inspect driven rotor body clearance. Push the driven rotor to one side of the body. Using a feeler gauge, measure the clearance. Standard Clearance: 0.09-0.16 mm (0.0035-0.0063 inch) Maximum Clearance: 0.16 mm (0.0063 inch) If the clearance exceeds the Maximum, replace the drive rotor, driven rotor or pump body. 2. Inspect both rotor tips clearance. Using a feeler gauge, measure the clearance between both rotor tips. Standard Clearance: 0.05-0.15 mm (0.0020-0.0059 inch) Maximum Clearance: 0.15 mm (0.0059 inch) If the clearance exceeds the Maximum, replace the drive rotor, driven rotor or pump body. 3. Inspect both rotors side clearance. Using a steel straight edge and feeler gauge, measure the clearance between the rotors and straight edge. Standard Clearance: 0.03-0.10 mm (0.0012-0.0039 inch) Maximum Clearance: 0.10 mm (0.0039 inch) Service Specifications Camshaft Gear/Sprocket: Specifications Service Specifications DIMENSIONS Free Distance .............................................................................................................................................................. 18.2 - 18.8 mm (0.712 -0.740 inch) Gear Backlash: STD ............................................................................................................................................................. 0.020 - 0.200 mm (0.0008 - 0.0079 inch) Maximum ............................................................................ ..................................................................................................... 0.30 mm (0.0188 inch) Page 3544 Page 796 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Wheels - Aluminum Weight Retention Improvement Wheels: Technical Service Bulletins Wheels - Aluminum Weight Retention Improvement SUSPENSION SU001-98 May 29, 1998 Title: ALUMINUM WHEEL WEIGHT RETENTION IMPROVEMENT Models: '97 4Runner & Tacoma Introduction A groove has been added to both the inner and outer wheel flanges to improve wheel weight retention on 1997 4Runner and Tacoma vehicles. NOTE: If wheel identification is necessary, break the tire bead from the aluminum wheel and inspect the wheel flange for the added groove. Production Change Information ^ 1997 4Runners starting with the following VINs: JT3GM84R * V0010422 JT3GN86R * V0029236 JT3GN87R * V0029236 JT3HM84R * V0020616 JT3HM84R * V9002018 JT3HN86R * V0079293 JT3HN87R * V0079293 ^ 1997 Tacomas starting with the following VINs: 4TANL42N * VZ258665 4TAVL52N * VZ258598 4TAVN52N * VZ258534 4TAPM62N * VZ258494 4TAPN62N * VZ258175 4TAWM72N * VZ258616 4TAWN72N * VZ258593 4TAWN74N * VZ258593 Parts Information Page 429 Backup Lamp Switch: Testing and Inspection BACK-UP LIGHT SWITCH INSPECTION INSPECT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Disassembly Connecting Rod: Service and Repair Disassembly 1. Using a small screwdriver, pry out the 2 snap rings. 2. Gradually heat the piston to about 60° C (140° F). 3. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. NOTE: ^ The piston and pin are a matched set. ^ Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Page 150 Standard Values Of ECM Terminals Chart 1 Of 2 Page 2568 Standard Values Of ECM Terminals Chart 1 Of 2 Page 3117 Catalytic Converter: Service and Repair CATALYTIC CONVERTER REPLACEMENT Installation is in the reverse order of removal. REMOVE CENTER EXHAUST PIPE Remove the 4 bolts, TWC joint retainer. center exhaust pipe and 2 gasket. Torque: 62 N.m (632 kgf.cm. 40 ft.lbf) INSTALLATION HINT: Place 2 new gaskets on the front exhaust and tail pipes. and temporarily install the center exhaust pipe. Page 4670 Location Of Splice Points (Fig 36) System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The Electronically Controlled Transmission, however, electrically controls the governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the Engine Control Module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the Engine Control Module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the Engine Coolant Temp. Sensor to TERMINAL THW of the Engine Control Module and also the input signals to TERMINAL SP2+ of the Engine Control Module from the Vehicle Speed Sensor devoted to the Electronically Controlled Transmission. Current is then output to the Electronically Controlled Transmission Solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the Engine Control Module --> TERMINAL 1 of the Electronically Controlled Transmission solenoid --> GROUND, and from TERMINAL S2 of the Engine Control Module --> TERMINAL 2 of the Electronically Controlled Transmission solenoid --> GROUND. and continuity to Solenoid No.1 and No.2 causes the shift. For 3rd speed. there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 Solenoid. 2. LOCK-UP OPERATION When the Engine Control Module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the Engine Control Module --> TERMINAL 3 of the Electronically Controlled Transmission Solenoid --> GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop Light SW ON) when driving in lock-up condition, a signal is input to TERMINAL BK of the Engine Control Module, the Engine Control Module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ^ O/D Main SW ON When the O/D main SW is turned ON, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module Page 3299 (l) Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) (m)Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator. and plug the hose end. (o) Measure the fuel pressure at idle. Fuel pressure 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm. 21 psi) or more If pressure is not as specified. check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (s) Remove the other union bolt. 3 gaskets and fuel pipe from the delivery pipes. (t) Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 496 Specifications Fill Plug: Specifications Fill Plug ................................................................................................................................................ ................................................... 37 N.m (27 ft. lbs.) Page 3792 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 2584 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3660 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3847 Case: Specifications Service Specifications TRANSMISSION CASE Transmission Case Bushing, Maximum ........................................................................................................................................... 38.19 mm (1.5035 inch) Page 1955 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Page 4395 Extension Housing: Service and Repair 1. Remove reverse restrict pin. a. Using a Torx socket wrench (T40), remove the screw plug. b. Using a pin punch and hammer, drive out the slotted spring pin. c. Remove the reverse restrict pin. 2. Inspect reverse restrict pin. Turn and push the reverse restrict pin by hand. Check for smooth operation. 3. Install reverse restrict pin. a. Install the reverse restrict pin to the extension houseing or transfer adaptor. b. Using a pin punch and hammer, drive in the slotted spring pin, as shown. c. Apply sealant to the plug threads. Sealant: THREE BOND 1344, LOCTITE 242 or equivalent. d. Using a Torx socket wrench (T40), install and torque the screw plug. Torque: 19 N.m (14 ft. lbs.) Page 439 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1459 Engine Oil: Testing and Inspection Oil Quality Check 1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the oil quality is visibly poor, replace it. 2. Oil grade: API grade SH, Energy-Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration. SAE 5W-30 being the preferred engine oil. Page 296 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 1070 (e) Install the timing belt in this order: (1) LH camshaft timing pulley. (2) No. 2 idler pulley. (3) RH camshaft timing pulley. (4) Water pump pulley. (5) Crankshaft timing pulley. (6) No. 1 idler pulley. 8. Set timing belt tensioner. (a) Using a press, slowly press in the push rod using 981 - 9,807 N (200 - 2,205 lbs.) of pressure. (b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (c) Release the press. (d) Install the dust boot to the tensioner. 9. Install timing belt tensioner. (a) Temporarily install the tensioner with the 2 bolts. (b) Alternately tighten the 2 bolts. Torque: 27 Nm (20 ft. lbs.) Remove the 1.27 mm hexagon wrench from the tensioner. 10. Check valve timing. Page 3212 Glossary Of Term And Symbols (Part 1 Of 2) Page 4182 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 448 Stop Light Switch Circuit Page 4331 Flex Plate: Specifications Service Specifications SERVICE SPECIFICATIONS Drive Plate Runout: Maximum ............................................................................................................................................. .................................... 0.20 mm (0.0079 inch) Page 3459 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 4567 Page 3289 Fuel Pressure Regulator: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 3665 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 383 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 811 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3174 5. REINSTALL PCV VALVE Specifications Output Shaft: Specifications OUTPUT SHAFT Thrust Play .............................................................................................................. ................................................. 0.27 - 0.86 mm (0.0106 - 0.0339 inch) Page 583 Glossary Of Term And Symbols (Part 1 Of 2) Page 2924 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 1371 Adjusting Shim Selection Chart (Exhaust) Page 537 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2673 CHART 15 Page 994 RZN171L Camber: .............................................................................................................................. ..................................................... 0° 20' ± 45' (0.33° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 45' ± 45' (1.75° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less VZN170L Camber: ............................................................................................................................... .................................................... 0° 20' ± 45' (0.33° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 45' ± 45' (1.75° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less 3. inspect camber, caster and steering axis inclination. If the steering axis inclination is not within the specification, after camber and caster have correctly adjusted, recheck the steering knuckle front wheel for bearing or looseness. Measuring Point Reference 4. Inspect toe-in. If the toe-in is not within the specification, adjust the rack ends. (A + B) = 0° 12' ± 12' (0.02° ± 0.02°) (C - D) = 2 ± 2 mm (0.08 ± 0.08 inch) 5. Adjust camber and caster. a. Loosen the front and/or rear adjusting cam nuts. b. Adjust the camber and caster by front and/or rear adjusting cams. HINT: Try to adjust the camber and caster to the center value. c. Torque the front and/or rear adjusting cam nuts. Torque to 130 Nm (96 ft. lbs.) 6. Adjust toe-in and wheel angle. Tie rod end length left-right error: Less than 1.5 mm (0.059 inch) HINT: First, check or adjust the lengths of the tie rod ends, then adjust the toe-in. a. Remove the boot clamps. b. Loosen the rack end lock nuts. Page 3610 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4239 Axle Shaft: Application and ID Joint Color ID: Outboard .............................................................................................................................................. ............................................................... Black Inboard ................................................................................................................................................ ............................................................. Yellow Page 1852 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 2822 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 606 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4870 (a) Using Special Service Tool (SST) # 09703 - 30010, disconnect the return spring. (b) Using SST, remove the shoe hold-down spring, cups and pin. SST 09718 - 00010 (c) Disconnect the anchor spring from the rear shoe and remove the rear shoe. (d) Remove the anchor spring from the front shoe. 4. Remove front shoe. (a) Using SST, remove the shoe hold-down spring, cups and pin. SST 09718 - 00010 (b) Remove the return spring from the front shoe. (c) Disconnect the parking brake cable No.1 from the parking brake bellcrank No.3. (d) Remove the front shoe with adjuster. (e) Disconnect the parking brake cable from the front shoe. 5. Remove adjuster from front shoe. (a) Remove the adjusting lever spring. (b) Remove the adjuster. 6. Remove automatic adjusting lever and parking brake lever. Remove E-Ring And C-Washer (a) Remove the E-ring. (b) Remove the automatic adjusting lever. (c) Remove the C-washer. (d) Remove the parking brake lever. 7. Remove and disassemble parking brake bellcrank. (a) Remove the clip and disconnect the parking brake cable. (b) Remove the tension spring. Removal and Installation Radiator: Service and Repair Removal and Installation REMOVAL 1. Drain engine coolant. 2. Remove front bumper filler. 3. Remove radiator grille. (a) Remove the 4 screws and clearance lights. A/T - Fluid Interchangeability Fluid - A/T: Technical Service Bulletins A/T - Fluid Interchangeability TRANSMISSION & CLUTCH TC003-99 Title: AUTOMATIC TRANSMISSION FLUIDS Models: All Models May 21, 1999 REVISION NOTICE: The information contained in this TSB updates TC003-98 dated June 19, 1998. Introduction Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify ATF Type T-II. Please refer to the following table for the interchangeability between each ATF. Affected Vehicles ^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV. NOTICE: With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed. Parts Information SIZE NEW PART NUMBER PART NAME 4 Liter 08886-01705 ATF Type T-IV Warranty Information Page 3608 Ignition Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2229 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3411 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4761 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2045 CHART 12 CHART 13 Page 1348 (c) Position the piston rings so that the ring ends are as shown. CAUTION: Do not align the end gaps. 3. Install bearings. (a) Align the bearing claw with the groove of the connecting rod or connecting cap. (b) Install the bearings in the connecting rod and connecting rod cap. Page 1281 (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 inch) Maximum backlash: 0.30 mm (0.0188 inch) If the backlash is greater than the maximum, replace the camshafts. Page 4774 Electronic Brake Control Module: Testing and Inspection NOTE: - Tools Required: - TOYOTA hand-held tester, or equivalent. - TOYOTA break-out-box, or equivalent. Connect Hand-Held Tester And Break-Out-Box 1. Hook up the hand-held tester and break-out-box to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. NOTE: Hand-held tester has a "Snapshot" function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the hand-held tester/break-out-box operator's manual for further details. Page 4052 RETAINERS, CLIP, CHECK BALLS, STRAINERS, SPRINGS AND VALVES AND LOCATION 1. RETAINER AND CLIP Page 3898 operation causes gear shift when the conditions for overdrive are met. ^ O/D Main SW OFF When the O/D main SW is turned to OFF, the current flowing through the O/D OFF indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the Engine Control Module and Engine Control Module operation prevents shift into overdrive. 5. A/T OIL TEMP. WARNING When the A/T Oil Temp. Sensor affixed to the transmission case detects that the fluid temp. is 150°C (302°F) or more, the Engine Control Module operates and the current flowing through the GAUGE fuse flows to the A/T Oil Temp. warning light --> TERMINAL OIL-W of the Engine Control Module --> Ground, so that the warning light lights up, informing that the Oil Temp. is high. When the Oil Temp. drops to 120°C (248°F) or less, the Engine Control Module stops operating and the warning light goes out. Page 3606 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1545 (e) Install the timing belt in this order: (1) LH camshaft timing pulley. (2) No. 2 idler pulley. (3) RH camshaft timing pulley. (4) Water pump pulley. (5) Crankshaft timing pulley. (6) No. 1 idler pulley. 8. Set timing belt tensioner. (a) Using a press, slowly press in the push rod using 981 - 9,807 N (200 - 2,205 lbs.) of pressure. (b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (c) Release the press. (d) Install the dust boot to the tensioner. 9. Install timing belt tensioner. (a) Temporarily install the tensioner with the 2 bolts. (b) Alternately tighten the 2 bolts. Torque: 27 Nm (20 ft. lbs.) Remove the 1.27 mm hexagon wrench from the tensioner. 10. Check valve timing. Locations One Touch 2-4 Selector System Page 3806 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 4783 Using Special Service Tool (SST) # 09023 - 00100, disconnect the 5 brake lines from the Anti-Lock Brake System (ABS) actuator. Torque: 15 Nm (11 ft. lbs.) 2. Disconnect connectors. Disconnect the 2 connectors from the actuator. 3. Remove control relay from actuator bracket. 4. Remove ABS actuator. (a) Remove the 2 bolts, 2 nuts and ABS actuator assembly. Torque: 19 Nm (14 ft. lbs.) (b) Remove the bolt and connector clamp. (c) Remove the 3 nuts and ABS actuator from the actuator bracket. Torque: 5.4 Nm (48 inch lbs.) (d) Remove the 3 holders and cushions from the ABS actuator. INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system. Refer to Brakes. See: Brake Bleeding/Service and Repair Check for leaks. Page 2112 Throttle Position Sensor: Description and Operation CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ~ 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. Page 2504 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1002 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 4609 4. Insert high and low clutch hub onto clutch sleeve. a. Install the clutch hub and 3 shifting keys onto the clutch sleeve. b. Install the-2-shifting key springs under the shifting keys. NOTICE: Install the key springs positioned so that their end gaps are not in line. 5. Install high and low clutch hub assembly. Using SST 09316-60011 (09316-00011) and a hammer, drive in a new key retainer. NOTICE: Be careful not to deform or damage the key retainer. b. Using a press, install the high and low clutch hub assembly. 6. Install snap ring. Select a snap ring that will allow minimum axial play and install it to the shaft. A: 2.10-2.15 mm (0.0827-0.0846 inch) B: 2.15-2.20 mm (0.0846-0.0866 inch) C: 2.20-2.25 mm (0.0866-0.0886 inch) D: 2.25-2.30 mm (0.0886-0.0906 inch) E: 2.30-2.35 mm (0.0906-0.0925 inch) F: 2.35-2.40 mm (0.0925-0.0945 inch) G: 2.40-2.45 mm (0.0945-0.0965 inch) H: 2.45-2.50 mm (0.0965-0.0984 inch) J: 2.50-2.55 mm (0.0984-0.1004 inch) Page 2260 Crankshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Locations Page 2998 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 718 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3686 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 375 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2061 Page 3518 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 4378 Counter Gear: Application and ID Counter Gear Snap Ring Thickness, Front Mark A ................................................................................................................................................. ............... 2.00-2.05 mm (0.0787-0.0807 inch) Mark B ........................................................................ ........................................................................................ 2.05-2.10 mm (0.0807-0.0827 inch) Mark C .............................................................................................................................................................. .. 2.10-2.15 mm (0.0827-0.0846 inch) Mark D ..................................................................................... ........................................................................... 2.15-2.20 mm (0.0846-0.0866 inch) Mark E ............ .................................................................................................................................................... 2.20-2.25 mm (0.0866-0.0886 inch) Mark F ........................................................................................ ......................................................................... 2.25-2.30 mm (0.0886-0.0906 inch) Counter Gear Snap Ring Thickness, Rear Mark A ................................................................................................................................................. ............... 2.80-2.85 mm (0.1102-0.1122 inch) Mark B ........................................................................ ........................................................................................ 2.85-2.90 mm (0.1122-0.1142 inch) Mark C .............................................................................................................................................................. .. 2.90-2i95 mm (0.1142-0.1161 inch) Mark D ..................................................................................... ........................................................................... 2.95-3.00 mm (0.1161-0.1181 inch) Mark E ............ .................................................................................................................................................... 3.00-3.05 mm (0.1181-0.1201 inch) Mark F ........................................................................................ ......................................................................... 3.05-3.10 mm (0.1201-0.1220 inch) Mark G ............. ................................................................................................................................................... 3.10-3.15 mm (0.1220-0.1240 inch) Page 3409 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Page 4734 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 3181 EGR Temperature Sensor: Testing and Inspection EGR GAS TEMPERATURE SENSOR INSPECTION Except Model No. VZN17O - 4wd Long Wheel Base 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: At 50°C (122°F): 84 - 97 K ohms At 100°C (212°F): 11 - 16 K ohms At 150°C (302°F): 2 - 4 K ohms If the resistance is not as specified. replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) Page 2599 Idle Speed/Throttle Actuator - Electronic: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION IAC VALVE REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws. IAC valve and gasket. INSTALLATION HINT: Place a new gasket on the throttle body. IAC VALVE INSTALLATION Installation is in the reverse order of removal. Page 25 Power Door Lock Relay: Testing and Inspection Integration Relay Inspection INSPECT INTEGRATION RELAY OPERATION Key-Off Power Window Signal: HINT: When the relay circuit is as specified, inspect the key-off power window signal. 1. Connect the connector to the relay. 2. Connect the positive (+) lead from the voltmeter to terminal 5 and the negative (-) lead to terminal 11. 3. Close the door with ignition switch turned to LOCK or ACC, check that the meter needle indicates battery positive voltage. 4. Open the door. check that the meter needle indicates 0.0V. 5. Turn the ignition switch ON, check that the meter needle indicate battery positive voltage again. If operation is not as specified, replace the relay. Page 4174 13. Inspect tooth contact between ring gear and drive pinion. a. Coat 3 or 4 teeth at three different position on the ring gear with red lead. b. Hold the companion flange firmly and rotate the ring gear in both directions. c. Inspect the teeth pattern. If the teeth are not contacting properly, use the following chart to select a proper washer for correction. Washer thickness (Mark and Thickness): 87 1.87 mm (0.0736 inch) 88 1.88 mm (0.0740 inch) 89 1.89 mm (0.0744 inch) 90 1.90 mm (0.0748 inch) 91 1.91 mm (0.0752 inch) 92 1.92 mm (0.0756 inch) 93 1.93 mm (0.0760 inch) 94 1.94 mm (0.0764 inch) 95 1.95 mm (0.0768 inch) 96 1.96 mm (0.0772 inch) 97 1.97 mm (0.0776 inch) 98 1.98 mm (0.0780 inch) 99 1.99 mm (0.0783 inch) 00 2.00 mm (0.0787 inch) 01 2.01 mm (0.0791 inch) 02 2.02 mm (0.0795 inch) 03 2.03 mm (0.0799 inch) 04 2.04 mm (0.0803 inch) Page 2450 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 2207 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 700 Oxygen Sensor: Description and Operation Sensor Cut-Away Reference CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2458 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2409 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Service and Repair Solenoid: Service and Repair 1. Remove A.D.D. switch. 2. Remove sleeve fork pin. a. Using a hexagon wrench, remove the screw plug. b. Using a pin punch and a hammer, remove the pin through the hole of clutch case cover. 3. Separate actuator from clutch case cover and remove sleeve fork. Using a hexagon wrench, remove the screw plug. b. Remove the spring seat, spring and steel ball. c. Remove the 2 bolts and actuator from the clutch case cover. d. Separate the actuator from the clutch case cover and remove the sleeve fork. e. Remove the O-ring from the actuator. 4. Install sleeve fork and actuator into clutch case cover. a. Install a new O-ring to the actuator. b. Coat the O-ring with MP grease. c. Place the sleeve fork and install the actuator to the clutch case cover. d. Torque the 2 bolts. Torque to 21 Nm (15 ft. lbs.) e. Install the steel ball, spring and spring seat. f. Coat the threads of screw plug with FIPG. FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. g. Using a hexagon wrench, install the screw plug. Torque to 13 Nm (9 ft. lbs.) 5. Install sleeve fork pin. a. Using a pin punch and a hammer, install the pin through the hole of clutch case cover. b. Coat the threads of screw plug with FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. c. Using a hexagon wrench, install the screw plug. Torque to 20 Nm (14 ft. lbs.) 6. Install A.D.D. switch. Install a new gasket and indicator switch. Torque to 40 Nm (30 ft. lbs.) Page 2353 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T-Thickness of used shim A-Measured valve clearance N-Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. INSTALL CYLINDER HEAD COVERS 7. INSTALL INTAKE AIR CONNECTOR Page 2099 Glossary Of Term And Symbols (Part 1 Of 2) Page 3107 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Replacement Clutch Master Cylinder: Service and Repair Replacement REMOVAL 1. Draw out fluid with syringe. 2. Disconnect clutch line. Using Special Service Tool (SST) 09023-00100, disconnect the line. use a container to catch the fluid. Torque: 15 N.m (132 inch lbs.) 3. Remove clip and clevis pin. 4. Remove mounting nuts and pull out master cylinder. Torque: 13 N.m (108 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed system and adjust clutch pedal. Page 698 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 4489 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4122 Maximum vertical runout: 0.09 mm (0.0035 inch) Maximum lateral runout: 0.09 mm (0.0035 inch) If the runout is not within the specification, replace the companion flange. 2. Check ring gear runout. Using a dial indicator, measure the ring gear runout. Maximum runout: 0.05 mm (0.0020 inch) If the runout is not within the specification, replace the ring gear. 3. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. 4. Check tooth contact between ring gear and drive pinion. 5. Check side gear backlash. Measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch) Page 1748 Locations Page 1995 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 453 Inspection Procedure / Stop Light Switch Circuit (4 Of 4) INSPECTION PROCEDURE Page 2259 Page 1465 Oil Cooler: Testing and Inspection INSPECTION Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. Page 3416 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 663 Page 4611 Output Shaft: Service and Repair Without Automatic Disconnecting Differential NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair." DISASSEMBLY Page 3456 Power Window A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left side: Right side: If continuity is not as specified, replace the switch. Specifications Clutch Master Cylinder: Specifications SERVICE SPECIFICATIONS Slotted Spring Pin Protrusion ............................................................................................................................................ 1.5-3.5 mm (0.059-0.138 inch) TORQUE SPECIFICATIONS Master Cylinder Installation Nut .................................................................................................................................................... 13 N.m (108 inch lbs.) Page 285 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1065 16. Remove starter wire bracket and No. 1 timing belt cover. (a) Remove the 2 bolts and starter wire bracket. (b) Remove the 4 bolts and timing belt cover. 17. Remove timing belt guide. 18. Set No. 1 cylinder at Top Dead Center (TDC)/compression. (a) Temporarily install the crankshaft pulley bolt to the crankshaft. (b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. CAUTION: Always turn the crankshaft clockwise. (c) Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). (d) Remove the crankshaft pulley bolt. 19. If reusing timing belt, check installation marks on timing belt. Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 20. Remove timing belt tensioner. Page 504 Camshaft Position Sensor: Mechanical Specifications Cam Sensor to Cylinder Head 69 in.lb Page 2490 Step 2 TOYOTA hand-held tester Step 1 Step 2 OBD II scan tool (excluding TOYOTA hand-held tester) Page 4346 Junction Block And Wire Harness Connector Page 2621 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 788 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 2390 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 18 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 3211 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 3446 Throttle Body: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION THROTTLE BODY REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT THESE CABLES: (a) w/ Cruise control: Cruise control actuator cable (b) Accelerator cable (c) A/T: Throttle cable 3. REMOVE AIR CLEANER HOSE 4. DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 5. DISCONNECT IAC VALVE CONNECTOR 6. REMOVE THROTTLE BODY Page 2550 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2408 Brake Signal: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2416 Brake Signal: Description and Operation CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed. (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.) Page 588 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. Disconnect Connector Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1756 Catalytic Converter: Testing and Inspection EXHAUST PIPE ASSEMBLY INSPECTION 1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE. THREE - WAY CATALYTIC CONVERTER INSPECTION CHECK FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts the three-way catalytic converter. repair or replace it. HEAT INSULATOR INSPECTION 1. CHECK HEAT INSULATOR FOR DAMAGE 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR Page 2242 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Sensor to Oil Pump 69 in.lb Page 3960 Page 4442 Reverse Idler Gear: Service and Repair Bearing Replacement If necessary, replace counter gear front bearing. a. Using a snap ring expander, remove the snap ring. b. Using SST 09950-00020 and a press, remove the bearing. c. Replace the side race. d. Using a socket wrench and press, install a new bearing and side race. Specifications Pinion Gear: Specifications SERVICE SPECIFICATIONS Preload (At Starting) ....................................................................................................................................................... 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) TIGHTENING SPECIFICATIONS Pinion Nut [1] ....................................................................................................................................... ........................... 223 Nm (165 ft. lbs.) Maximum [1]: Tighten in 13 Nm (9 ft. lbs.) increments (a little at a time until the specified preload is reached). Page 3645 Camshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CAMSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection PCV VALVE INSPECTION 1. REMOVE PCV VALVE (a) Disconnect the PCV hose from the PCV valve. (b) Remove the PCV valve. 2. INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION (a) Blow air into the cylinder head cover side and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. (b) Blow air into the air intake chamber side and check that air passes through with difficulty. (c) Blow air into the air intake chamber side when lift up the inside valve and check that there is a strong resistance to air flow. If operation is not as specified, replace the PCV valve. 4. REMOVE CLEAN HOSE FROM PCV VALVE Page 493 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2916 Engine Bank Identification Page 3388 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 1051 Adjusting Shim Selection Chart (Intake) Page 2031 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 714 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2002 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagrams Page 2619 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2689 Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2338 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Page 3256 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop Resistance Per Injector Approx. 13.8 ohms Injection Volume 3.4 - 4.2 cu in. Per 15 seconds Difference Between Injectors 0.31 or less Leakage Rate Per Injector 1 drop or less per Minute Page 4659 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Ground Points Ground Points Page 2184 Finding A Short Circuit a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test light comes ON. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) d. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. e. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 218 Locations-J/B No.1 Left Kick Panel (Fig 20) Details Page 2222 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2054 Page 4040 Lower Valve Body / Strainer, Spring and Valve Page 3946 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 2384 Glossary Of Term And Symbols (Part 1 Of 2) Page 1574 Fuel Pressure Release: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH FUEL PRESSURE LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Put a container under the connection. (4) Slowly loosen the connection. (5) Disconnect the connection. (6) Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use 2 new gaskets. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare nut and tighten the flare nut by hand. Page 2903 Knock Sensor: Description and Operation CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 3351 Idle Speed/Throttle Actuator - Electronic: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION IAC VALVE REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws. IAC valve and gasket. INSTALLATION HINT: Place a new gasket on the throttle body. IAC VALVE INSTALLATION Installation is in the reverse order of removal. Specifications Timing Belt: Specifications Timing Belt Replacement Interval 60,000 miles (96,000 km) Page 2037 O2S Application Table O2S Failure Threshold Charts Page 4484 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 1922 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications ECT sensor to Intake Manifold 14 ft.lb Page 1723 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Diagrams Standard Value Of ECU Terminals Page 1181 Power Steering Fluid: Testing and Inspection Fluid Pressure Check 1. Remove air cleaner assembly. Loosen the 3 bolts. 2. Connect SST. a. Disconnect the pressure feed tube from the PS vane pump. b. Connect the SST 09640-10010 (09641-01010, 09641-01030, 09641-01060), as shown. NOTICE: Check that the valve of the SST is in the open position. 3. bleed power steering system. 4. Boost fluid temperature. a. Start the engine and run it at idle. b. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80° C (176° F) 5. Check fluid pressure reading with valve closed. With the engine idling, close the valve of the SST and observe the reading on the SST. Fluid pressure: 8,336 kPa (1,209 psi) Minimum NOTICE: ^ Do not keep the valve closed for more than 10 seconds. ^ Do not let the fluid temperature become too high. Page 1112 Refrigerant Lines Page 2985 Oxygen Sensor: Description and Operation Sensor Cut-Away Reference CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2733 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 13 Inspect Relay Circuit 2. INSPECT RELAY CIRCUIT Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 4931 Components DISASSEMBLY 1. Remove reservoir. (a) Remove the set screw and pull out the reservoir. Torque: 1.7 Nm (16 inch lbs.) (b) Remove the cap and strainer from the reservoir. 2. Remove 2 grommets. 3. Place cylinder in vise. 4. Remove piston stopper bolt. Page 3413 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Service and Repair Solenoid: Service and Repair 1. Remove A.D.D. switch. 2. Remove sleeve fork pin. a. Using a hexagon wrench, remove the screw plug. b. Using a pin punch and a hammer, remove the pin through the hole of clutch case cover. 3. Separate actuator from clutch case cover and remove sleeve fork. Using a hexagon wrench, remove the screw plug. b. Remove the spring seat, spring and steel ball. c. Remove the 2 bolts and actuator from the clutch case cover. d. Separate the actuator from the clutch case cover and remove the sleeve fork. e. Remove the O-ring from the actuator. 4. Install sleeve fork and actuator into clutch case cover. a. Install a new O-ring to the actuator. b. Coat the O-ring with MP grease. c. Place the sleeve fork and install the actuator to the clutch case cover. d. Torque the 2 bolts. Torque to 21 Nm (15 ft. lbs.) e. Install the steel ball, spring and spring seat. f. Coat the threads of screw plug with FIPG. FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. g. Using a hexagon wrench, install the screw plug. Torque to 13 Nm (9 ft. lbs.) 5. Install sleeve fork pin. a. Using a pin punch and a hammer, install the pin through the hole of clutch case cover. b. Coat the threads of screw plug with FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent. c. Using a hexagon wrench, install the screw plug. Torque to 20 Nm (14 ft. lbs.) 6. Install A.D.D. switch. Install a new gasket and indicator switch. Torque to 40 Nm (30 ft. lbs.) Page 2908 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 4047 4. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON TOP OF LOWER VALVE BODY Align each bolt hole and gasket in the valve body. 5. INSTALL 25 BOLTS TO UPPER VALVE BODY HINT: Each bolt length is indicated below. Torque: 6.4 Nm (66 kgf-cm, 56 inch lbs.) Bolt length: Bolt A: 38 mm (1.50 inch) Bolt B: 20 mm (0.79 inch) Bolt C: 28 mm (1.10 inch) 6. INSTALL MANUAL VALVE 7. INSTALL DETENT SPRING Torque: 10 Nm (100 kgf -cm, 7 ft. lbs.) 8. MAKE SURE MANUAL VALVE MOVES SMOOTHLY UPPER VALVE BODY COMPONENTS Page 2278 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3144 EGR Control Solenoid: Mechanical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) VSV Assembly to Intake Manifold 71 in.lb Page 2150 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 615 Knock Sensor: Exploded Views Components For Removal And Installation Part 1 Of 2 Page 1683 Radiator: Testing and Inspection 1. Remove radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. Inspect radiator cap. NOTE: If the radiator cap contaminations, always rinse it with water. Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard opening pressure: 74 - 103 kPa (10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (8.5 psi) NOTE: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. Inspect cooling system for leaks. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (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. 4. Reinstall radiator cap. Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid .............................................................................................................................................. ........................................................ 2.2L (4.6 pints) Page 3594 Components For Removal And Installation Part 2 Of 2 COMPONENTS FOR REMOVAL AND INSTALLATION KNOCK SENSORS REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE INTAKE AIR CONNECTOR 4. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE Page 3220 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2527 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Fuel - Idle Speed Increased by Replacement ECM Engine Control Module: Technical Service Bulletins Fuel - Idle Speed Increased by Replacement ECM ENGINE EG001-98 FEBRUARY 13, 1998 2RZ ECM IDLE SPEED MODELS: '95-'97 TACOMA Introduction Operating logic of 1995-1997 Tacoma ECMs has been revised to improve engine idle smoothness (with transmission in "D" range) by increasing idle speed (A/C "OFF") from 600 RPM to 700 RPM. The change has also narrowed the RPM transition between A/C "OFF" and A/C "ON" engagement. Affected Vehicles 1995-1997 Tacoma 4x2 equipped with 2RZ-FE four cylinder engine and automatic transmission. Part Number Information Production Change Information No production changes have been made. - This change applies only to replacement ECMs available through parts supply. Warranty Information Applicable Warranty: This repair is covered under the Toyota Powertrain Warranty. This warranty Is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in service date. Page 2462 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 769 EGR Temperature Sensor: Mechanical Specifications Note: Except Model VZN170 (Long wheel base 4WD Pickup) EGR Sensor to EGR Valve 14 ft.lb Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY 1. Check that there is no continuity between terminal and the switch body in the ON position (switch pin released/opened door). 2. Check that there is continuity between terminal and the switch body in the OFF position (switch pin pushed in/closed door). If operation is not as specified, replace the switch. A/T - Fluid Interchangeability Fluid - A/T: Technical Service Bulletins A/T - Fluid Interchangeability TRANSMISSION & CLUTCH TC003-99 Title: AUTOMATIC TRANSMISSION FLUIDS Models: All Models May 21, 1999 REVISION NOTICE: The information contained in this TSB updates TC003-98 dated June 19, 1998. Introduction Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify ATF Type T-II. Please refer to the following table for the interchangeability between each ATF. Affected Vehicles ^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV. NOTICE: With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed. Parts Information SIZE NEW PART NUMBER PART NAME 4 Liter 08886-01705 ATF Type T-IV Warranty Information Page 4801 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Specifications Valve Seat: Specifications Refacing Angle .................................................................................................................................... .................................................... 30°, 45°, 60° Contacting Angle ....................................................... ............................................................................................................................................. 45° Contacting Width .................................................................................................................................................... 1.0 1.4 mm (0.039 - 0.055 inch) Page 3640 Page 3392 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 292 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2309 Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 1467 Union bolt: Torque: 59 Nm (43 ft. lbs.) Page 2468 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS FOR REMOVAL AND INSTALLATION ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE 5. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench. remove the ECT sensor and gasket. Page 3962 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 622 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 4013 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 1345 Piston: Service and Repair Disassembly 1. Using a small screwdriver, pry out the 2 snap rings. 2. Gradually heat the piston to about 60° C (140° F). 3. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. NOTE: ^ The piston and pin are a matched set. ^ Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Page 4420 c. Using a dial indicator, check the shaft runout. Maximum Runout: 0.06 mm (0.0024 inch) If the runout exceeds the Maximum, replace the output shaft. 2. Inspect 1st and 3rd gears synchronizer ring. a. Check for wear or damage. b. Check the braking effect of the synchronizer ring. turn the synchronizer ring in one direction while pushing it to the gear cone. check that the ring locks. If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. c. Check again the braking effect of the synchronizer ring. d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum Clearance: 0.8 mm (0.031 inch) If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 3. Inspect 2nd gear synchronizer ring. a. Check for wear or damage. Page 3552 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 516 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2690 CHART 28 Page 3593 Knock Sensor: Service and Repair Components For Removal And Installation Part 1 Of 2 Page 358 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 638 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 2592 Page 1656 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 1291 (i) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 Nm (12 ft. lbs.) B. Exhaust. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Align the timing marks (1 dot mark) of the camshaft drive and driven gears. (c) Place the exhaust camshaft on the cylinder head. (d) Install the 4 bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts. (f) Install and uniformly tighten the 8 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 Nm (12 ft. lbs.) (g) Remove the service bolt. Page 1538 1. Remove engine under cover. 2. Drain engine coolant. 3. Disconnect upper radiator hose. 4. Remove drive belt for Power Steering (PS) pump. 5. w/ A/C: Remove drive belt for A/C compressor. 6. Remove drive belt for generator. 7. Remove No. 2 fan shroud. 8. Remove fan with fluid coupling and fan pulleys. 9. Disconnect PS pump from engine. Testing and Inspection Shift Interlock Solenoid: Testing and Inspection Inspect shift lock solenoid. a. Disconnect the solenoid connector. b. Using an ohmmeter, measure the resistance at each terminal. Standard Resistance 20-28 ohms. If resistance value is not as specified. Replace the solenoid. c. Apply battery positive voltage at each terminal. At this time, confirm that the solenoid operates. If the solenoid does not operate, replace the solenoid. Page 4132 than the maximum, replace the companion flange. Maximum runout: 0.10 mm (0.0039 inch) 2. Check ring gear backlash. Using SST 09564-32011 and a dial indicator, measure the ring gear backlash. If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) 3. Measure drive pinion preload. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) 4. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. If necessary, disassemble and inspect the differential. Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.) Assembly Page 4673 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4862 Brake Drum: Testing and Inspection Fig. 3 Measuring Brake Drum Inside Diameter DRUM DIAMETER 1. Using vernier calipers, measure the inside diameter of the drum. - Standard inside diameter: 295.0 mm (11.614 inch) - Maximum inside diameter: 297.0 mm (11.693 inch) 2. If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. Page 3046 Vehicle Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Page 291 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 1952 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2516 Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Removal and Installation Front Axle Hub / 4WD REMOVAL 1. Remove front wheel. Torque to 110 Nm (83 ft. lbs.) 2. Remove shock absorber. Page 2310 Idle Speed: Adjustments 1. Initial conditions. (a) Engine coolant at normal operating temperature. (b) Air cleaner installed. (c) All pipes and hoses of air induction system connected. (d) All accessories switched OFF. (e) All vacuum lines properly connected. NOTE: All vacuum hoses for Exhaust Gas Recirculation (EGR) systems, etc. should be properly connected. (f) Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged. (g) Ignition timing set correctly. (h) Transmission in neutral position. (i) A/C switch is OFF. 2. Connect TOYOTA hand-held tester or OBD II scan tool or equivalent. 3. Inspect idle speed. (a) Race the engine speed at 2,500 rpm for approximately 90 seconds. (b) Check the idle speed. Idle speed: 700 +/- 50 rpm NOTE: If the idle speed is not as specified, check the Idle Air Control (IAC) valve and air intake system. 4. Disconnect TOYOTA hand-held tester or OBD II scan tool or equivalent. Page 679 Warranty Information Applicable warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. * Warranty application is limited to correction of a problem based upon a customer's complaint. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 534 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 4550 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 4933 Reassembly is in the reverse order of disassembly. CAUTION: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows in EXPLODED VIEW of system. INSTALLATION Installation is in the reverse order of removal. Before installation, adjust length of brake booster push rod. After installation, fill brake reservoir with brake fluid, bleed brake system. See: Brake Bleeding/Service and Repair Check for leaks, check and adjust brake pedal. See: Brake Pedal Assy/Adjustments Page 46 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Ignition Cable: Specifications Maximum Resistance per Cord 25 K ohms Page 3315 Fuel Supply Line: Diagrams CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened parts. Page 3923 Planetary Sun Gear Page 1813 Standard Values Of ECM Terminals Chart 2 Of 2 Page 3486 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 898 Page 2894 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Cold Hot Between Terminals NE+ and NE- 1,630 - 2,740 ohms at 14 - 122 deg F 2,065 - 3,225 ohms at 122 - 212 deg F Page 2130 Page 1983 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2567 Standard Values Of ECM Terminals Chart 2 Of 2 Specifications Exhaust Crossover Pipe: Specifications TIGHTENING SPECIFICATIONS Exhaust Crossover Pipe To Exhaust Manifold................................................................................................................................. 45 Nm (33 ft. lbs.) Page 3630 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 3190 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 3453 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Page 1968 Crankshaft Position Sensor: Service and Repair COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt crankshaft position sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal. Specifications Oil Pick Up/Strainer: Specifications TIGHTENING SPECIFICATIONS Oil Strainer To Cylinder Block .................................................................................................................................................. 7.5 Nm (66 inch lbs.) Page 993 Alignment: Service and Repair Front Front NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to specification. 1. Measure vehicle height. If the vehicle height is not within the specification, try to adjust it by pushing down on or lifting the body. Vehicle height (Front: A - B; Rear: C - D) Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin center. D: Ground clearance of rear axle shaft center. 2. Install camber-caster-kingpin gauge or onto wheel alignment tester. Follow the specific instructions of the equipment manufacturer. RZN161L Camber: .............................................................................................................................. ...................................................... 0°15' ± 45' (0.25° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 35' ± 45' (1.58° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: ............................................................................................................................. .................................... 10° 00' ± 45' (10° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less VZN160L Camber: ............................................................................................................................... .................................................... 0° 15' ± 45' (0.25° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Caster: ................................................................................................................................................. .................................... 1° 35' ± 45' (1.58° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Steering Inclination: .............................................................................................................................................................. 10° 30' ± 45' (10.5° ± 0.75°) Left/Right Error .................................................................................................................................... ........................................... 30' (0.05°) or less Specifications Case: Specifications Front Case To: Control Retainer .................................................................................................................................. ................................................ 18 N.m (13 ft. lbs.) Upper Cover ......................................................... ............................................................................................................................... 18 N.m (13 ft. lbs.) Separator With Oil Strainer ............................................................................................................................................................. 7.5 N.m (69 inch lbs.) Oil Pump Body ................................................................................................. ............................................................................... 7.5 N.m (69 inch lbs.) Rear Case To: Extension Housing ............................................................................................................................... .......................................... 12 N.m (108 inch lbs.) Front Case ............................................................ ................................................................................................................................ 28 N.m (21 ft. lbs.) Locations Main Relay (Computer/Fuel System): Locations Locations-R/B No.2-Engine Compartment Left (USA) (Fig 19) Page 3227 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 2958 CHART 28 Component Tests and General Diagnostics Crankshaft Position Sensor: Component Tests and General Diagnostics CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crank shaft position sensor. Page 1367 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only those valves indicated in the illustration. 1. Using a thickness gauge, measure the clearance between the valve lifter and camshaft. Valve Clearance (Cold): 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Page 1541 Alternately loosen the 2 bolts and remove them, then remove the belt tensioner and dust boot. 21. Remove timing belt. 22. Remove RH camshaft timing pulley. (a) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, loosen the pulley bolt. (b) Remove the bolt, knock pin and camshaft timing pulley with timing belt. 23. Remove LH camshaft timing pulley. (a) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assembly # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, loosen the pulley bolt. (b) Remove the bolt, knock pin and camshaft timing pulley. 24. Remove No. 2 idler pulley. Remove the bolt and No. 2 idler pulley. 25. Remove No. 1 idler pulley. Using a 10 mm hexagon wrench, remove the pivot bolt, No. 1 idler pulley and plate washer. 26. Remove crankshaft timing pulley. NOTE: If the pulley cannot be removed by hand, use SST Puller C Set # 09950 - 50010 (Hanger 150 # 09551 - 05010, Slide Arm # 09552 - Page 604 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 2304 (l) Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) (m)Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator. and plug the hose end. (o) Measure the fuel pressure at idle. Fuel pressure 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm. 21 psi) or more If pressure is not as specified. check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (s) Remove the other union bolt. 3 gaskets and fuel pipe from the delivery pipes. (t) Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 1902 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Specifications Piston: Specifications DIMENSIONS Diameter: STD Mark 1 ............................................................................................................................................... 93.356 - 93.366 mm (3.6754 - 3.6758 inch) Mark 2 ............................................................................................................................................... 93.367 93.376 mm (3.6759 - 3.6762 inch) Mark 3 ............................................................................................................................................... 93.377 93.386 mm (3.6763 - 3.6766 inch) O/S 0.50 .................................................................................................................................................. 93.856 - 93.886 mm (3.6951 - 3.6963 inch) Oil Clearance: STD ............................................................................................................................................................. 0.134 - 0.154 mm (0.0053 - 0.0060 inch) Maximum ............................................................................ ................................................................................................... 0.174 mm (0.0069 inch) Ring Groove Clearance: No. 1 ............................................................................................................................................................ 0.040 - 0.080 mm (0.0016 - 0.0031 inch) No. 2 ............................................................................................................................................................ 0.030 - 0.070 mm (0.0012 - 0.0028 inch) Page 4039 Valve Body: Locations Lower Valve Body Lower Valve Body / Check Balls Lower Valve Body / Retainer and Clip Page 2151 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2055 CHART 23 Page 268 Wheel Speed Sensor: Specifications Mounting Bolt 71 in.lb Page 138 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Testing and Inspection Shift Interlock Switch: Testing and Inspection Inspect shift lock control switch. Inspect that there is continuity between each terminal. If the continuity is not as specified. Replace the switch. Page 1998 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Timing Belt Removal Timing Belt: Service and Repair Timing Belt Removal Page 3364 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT 1. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. 2. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 617 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 359 "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug c. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install Terminal To Connector a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2669 CHART 10 Page 522 Camshaft Position Sensor: Description and Operation CIRCUIT DESCRIPTION The camshaft position sensor, which detects the crankshaft angle signal (G signal), has been installed on the front of right bank cylinder head. The timing rotor has been integrated with the right bank camshaft timing pulley. When the camshafts rotate, the protrusion on the timing rotor and the air gap on the pick up coil change, causing fluctuations, in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the 6 signals and the actual crankshaft angle and the engine speed by the NE signals. Page 893 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 320 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A. Ignition SW ON B. Ignition SW and SW 1 ON C. Ignition SW, SW 1 and Relay ON (SW 2 OFF) b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test a light instead of a voltmeter. Page 2339 Spark Plug: Testing and Inspection SPARK PLUGS INSPECTION 1. DISCONNECT HIGH -TENSION CORDS 2. REMOVE IGNITION COILS 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 4. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 5. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: ND: K16TR11 NGK: BKR5EKB-11 ABS Control (Motor) Relay ABS Main Relay: Description and Operation ABS Control (Motor) Relay Codes 13, 14: ABS Control (Motor) Relay Circuit DTC Chart ABS Control (Motor) Relay Circuit Wiring Diagram Page 862 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2187 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 318 Secondary Locking Device b. Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect Connector Continuity and Resistance Check Continuity And Resistance Check a. Disconnect the battery terminal or wire so there is no voltage between the check points. b. Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check c. Use a Volt/Ohm meter with high impedance (10 K Ohms/Volts minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 77 Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 951 Transmission Speed Sensor: Testing and Inspection Vehicle NO.2 Speed Sensor Inspection Procedure - Remove NO.2 vehicle speed sensor. - Measure resistance between terminals 1 and 2 of NO.2 vehicle speed sensor. Resistance: 560 Ohms to 680 Ohms - Check voltage between terminals 1 and 2 of the NO.2 speed sensor when a magnet is put close to the front end of the NO.2 vehicle speed sensor then taken away quickly. - Voltage is generated intermittenly. Note: The voltages generated is extremely low. Locations Number One Cylinder: Locations Firing Order: 1-2-3-4-5-6 Page 2759 Main Relay (Computer/Fuel System): Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter. check that there is continuity between terminals 1 and 2. If there is no continuity. replace the relay. (b) Check that there is no continuity between terminals and 5. If there is continuity. replace the relay. B. Inspect relay operation (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 4779 Depress MOTOR Switch (b) Turn the selector switch of the actuator checker to "FRONT" position. (c) Push and hold in the MOTOR switch for a few seconds. (d) Depress the brake pedal and hold it until the step (g) is completed. Depress POWER Switch (e) Push the POWER switch, and check that the brake pedal does not go down. CAUTION: Do not keep the POWER switch pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. Depress MOTOR Switch (g) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. (h) Release the brake pedal. Depress MOTOR Switch And Brake Pedal (i) Push and hold in the MOTOR switch for a few seconds. Page 610 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3609 b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Brake Fluid: Specifications Required Brake Fluid SAE DOT3 Page 2023 A/F and 02 Sensor Identification Page 308 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the power source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all system circuit diagram start from the power source, the power source system must be fully understood. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Specifications Throttle Position Sensor: Specifications Between Terminals Measured Resistance At Clearance: 0 mm (0 in.) VTA - E2 0.2 - 5.7 K ohms Throttle Fully Opened VTA - E2 2.0 - 10.2 K ohms At all Times VC - E2 2.5 - 5.9 K ohms Ohmmeter Connection Page 2707 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Resistance 10 - 20 K ohms at -4 deg F 4 - 7 K ohms at 32 deg F 2 - 3 K ohms at 68 deg F 0.9 - 1.3 K ohms at 104 deg F 0.4 - 0.7 K ohms at 140 deg F 0.2 - 0.4 K ohms at 176 deg F Page 2708 The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Wiring Color K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Body). Example: Splice Point The Location of Splice Point I 5 is indicated by the shaded section L: Page No. M: Indicates a shielded cable Shielded Cable N: Indicates a ground point The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Pin Number Of The Connector P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 671 CHART 27 Page 3961 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Service and Repair Heater Control Valve: Service and Repair WATER VALVE REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR REMOVAL HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE INSTALLATION HINT: For installing the control cable, refer to HEATER CONTROL CABLES ADJUSTMENT. See: Heating and Air Conditioning/Air Door/Air Door Cable/Adjustments 3. DISCONNECT WATER HOSE 4. REMOVE WATER VALVE a. Disconnect the water hose from the heater radiator pipe. b. Remove the bolt and the water valve. INSTALLATION HINT: Push the water hose onto the heater radiator pipe as far as the ridge on the pipe. - Install the hose clip in a position as shown. WATER VALVE INSTALLATION Installation is in the reverse order of removal. Mechanical Specifications Thermostat: Mechanical Specifications DIMENSIONS Valve Lift @ 95° C (203° F) .......................................................................................................................................... 8.5 mm (0.335 inch) or more Page 3752 Electronically Controlled Transmission And A/T Indicator (Part 2 Of 3) Page 3950 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector Page 3398 Air Flow Meter/Sensor: Description and Operation System Schematic Sensor Cut-Away CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set temperature. Page 2928 Upper Valve Body Valve Body: Locations Upper Valve Body Upper Valve Body / Retainer, Stopper and Pin Upper Valve Body / Check Balls Page 1724 Page 1308 Connecting Rod: Testing and Inspection Connecting Rod Alignment USING A ROD ALIGNER AND THICKNESS GAUGE, CHECK THE CONNECTING ROD ALIGNMENT 1. Check for bend. Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch) If bend is greater than maximum, replace the connecting rod assembly. 2. Check for twist. Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) If twist is greater than maximum, replace the connecting rod assembly. Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions How To Read Ground Points Ground Points The Ground Point circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source Page 2631 8. REMOVE KNOCK SENSORS Using SST. remove the knock sensor. SST 09817-16011 KNOCK SENSOR INSTALLATION 1. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 N.m (400 kgf.cm. 29 ft.lbf) 2. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 3. REINSTALL INTAKE MANIFOLD ASSEMBLY 4. REINSTALL FUEL PRESSURE REGULATOR 5. REINSTALL HIGH-TENSION CORDS WITH IGNITION COILS 6. REINSTALL INTAKE AIR CONNECTOR 7. REINSTALL AIR CLEANER HOSE 8. REFILL WITH ENGINE COOLANT 9. RECHECK ENGINE COOLANT LEVEL Page 2646 Applicable Vehicles Page 2142 Connector The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is different. F: Indicates related system. G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V V) Outside numerals are pin numbers. Wiring Harness Connector The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this indicates the same type of wiring harness and wiring harness connector. H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). Example: Junction Block J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink R = Red V = Violet W = White Y = Yellow Page 561 Glossary Of Term And Symbols (Part 2 Of 2) Key to Diagram Page 3208 Air Flow Meter/Sensor: Mechanical Specifications MAF Meter to Air Cleaner Cap 61 in.lb Page 2378 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) METER REMOVAL 1. DISCONNECT AIR CLEANER CAP FROM MAF METER 2. REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. Torque: 6.9 N.m (72 kgf.cm, 61 in.lbf) MASS AIR FLOW (MAF) METER INSTALLATION Installation is in the reverse order of removal. Page 3162 (b) Remove the 2 nuts, EGR valve and gasket. Torque: 18.5 N.m (185 kgf.cm, 14 ft.lbf) INSTALLATION HINT: Use a new gasket.