Recomended Tools Kcl
MANUAL TRANSAXLE ASSY FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY C59 SHIFT amp SELECT LEVER SHAFT ASSY C59 09043-20060 Socket Hexagon Wrench 6 FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT 09043-20060 Socket Hexagon Wrench 6 09905-00012 Snap Ring No.1 Expander
Front Differential Oil Seal Replacement
1. DRAIN MANUAL TRANSAXLE OIL Torque 39.2 Nm 400 kgfcm, 29 ftlbf 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 6. REMOVE FRONT DRIVE SHAFT ASSY LH See page 30-6 SST 09520-01010, 09520-24010 09520-32040 7. REMOVE FRONT DRIVE SHAFT ASSY RH See page 30-6 SST 09520-01010, 09520-24010 09520-32040 a Using SST, remove the transaxle case oil seal. SST 09308-00010 9. REMOVE TRANSMISSION CASE OIL SEAL a Using SST, remove the transmission case oil seal. SST 09308-00010 a Coat a new oil...
Check Battery Terminals Fusible Link And Fuses
a Check that the battery terminals are not loose or corroded. b Check the fusible link, H-fuses and fuses for continuity. a Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
Power Steering 1
Fluid pressure at idle speed with valve closed 7,300 - 7,S00 kPa 75 - S0 kgf cm2, 1,067 - 1,13S psi 0.27 N m 2.S kgf cm, 2.4 in. lbf or less Vane pump shaft and vane pump housing oil clearance 0.021 - 0.043 mm 0.000S - 0.0017 in. 0.07 mm 0.002S in. Clearance between the rotor groove and plate Total preload Tie rod rotating torque 0.49 - 3.43 Nm 5.0 - 35 kgfcm, 4.34 - 30.3S in.lbf Total preload Control valve rotating torque 1.0 - 1.S Nm 10 - 1S kgfcm, S.6 - 15.7 in.lbf _SERVICE SPECIFICATIONS -...
Inspect Synchronizer Ring Set No
a Coat the 2nd gear cone with gear oil. Check the braking effect of the synchronizer ring set No.2 b Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Standard clearance 0.7 - 1.3 mm 0.0276 - 0.0512 in. If the clearance is out of specification, replace the synchronizer ring set No.2.
Inspect Skid Control Sensor
Disconnect the skid control sensor connector. Measure resistance between terminals 1 and 2 of the skid control sensor connector. OK Measure resistance between each of terminals 1 and 2 of skid control sensor connector and body ground. OK Check the speed sensor signal last See page 05-297 .
These tests must be performed within to seconds to prevent burnout of the coil
1 Remove the nut, then disconnect the lead wire from terminal C. 2 Connect the battery to the starter repair service kil as shown in the illustration. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the starter repair service kit. 1 Disconnect the negative - lead from terminal C with the lead wire disconnected from terminal C. Check that the clutch pinion gear remains extended. If the clutch pinion gear returns, replace the starter repair...
Remove Floor Shift Cable Transmission Control Select
a Remove the clip and washer, separate the top of the select cable from the transaxle. b Remove the clip, separate the select cable from the control cable bracket. d Using a screwdriver, release the cable outer spring. e Turn the lock, separate the select cable from the shift lever retainer. MANUAL TRANSMISSION TRANSAXLE - FLOOR SHIFT CABLE TRANSMISSION CONTROL 41-13 f Separate the end of the select cable from the shift lever assy. g Remove the 2 bolts and retainer from the floor. h Pull out...
Components Ykb
Front Disc Brake Cylinder Sliding Pin Front Disc Brake Cylinder Sliding Pin Anti-squeal Shim No.1 l Indicator Plate Front Disc Brake Cylinder Mounting LH Front Disc Brake Cylinder Mounting LH Anti-squeal Shim No.1 l Indicator Plate lt gt Front Disc Brake Pad Support Plate lt gt Front Disc Brake Pad Support Plate N m kgf cm, ftlbf Specified torque Non-reusable part Lithium soap base glycol grease N lt 3 i Disc brake grease
Replacement Tgk
1. REMOVE CONSOLE BOX SUB-ASSY REAR See page 71-10 2. REMOVE PARKING BRAKE LEVER SUB-ASSY See page 33-4 3. REMOVE EXHAUST PIPE ASSY FRONT See page 15-2 4. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 a Remove the 3 nuts and front floor insulator No.1. 5. REMOVE FRONT FLOOR HEAT INSULATOR NO.2 a Remove the 2 nuts and front floor insulator No.2. 6. REMOVE PARKING BRAKE CABLE ASSY NO.1 a Disconnect the parking brake cable assy No.1 from the equalizer and remove the parking brake cable assy No.1. 7....
If necessary replace the antisqueal shim kit when replacing the brake pad
a Apply disc brake grease to each anti-squeal shim No.1. b Install anti-squeal shims on each pad. c Install the pad wear indicator plate facing upward, and install each pad. Front Disc Brake Pad Wear Indicator Plate
Sst Fll
09023-12700 Union Nut Wrench 17mm 09223-50010 Crankshaft Front Oil Seal FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY C59 09309-12020 5th Driven Gear Replacer 09309-36010 Transmission Rear Bearing 09309-36100 Transmission Bearing Replacer 09316 60011 Transmission amp Transfer Bearing MANUAL TRANSAXLE ASSY C59 INPUT SHAFT ASSY C59 OUTPUT SHAFT ASSY C59 lt H gt j gg gl 09350-32014 TOYOTA Automatic Transmission 09351-32120 Overdrive Bearing Replacer 09520-01010 Drive Shaft Remover Attachment...
Manual Transaxle Assy C Components
Input Shaft Rear Bearing Hole Snap Ring N m kgf cm, ft lbf I Specified torque Input Shaft Rear Bearing Hole Snap Ring N m kgf cm, ft lbf I Specified torque Input Shaft Snap Ring Transmission Clutch Hub No 3 Restrict Pin Assy Oil Receiver Pipe No. 1 MTM 1 Manual Transmission Case Cover Sub-assy O Gasket Manual Transmission Filler Plug O Gasket Manual Transmission Filler Plug 1 Manual Transmission Case Cover Sub-assy Nm kgfcm, ftlbf Specified torque
Inspect Disc Runout
a Temporarily fasten the disc with hub nuts. Torque 103 Nm 1,050 kgfcm, 76 ftlbf b Using a dial indicator, measure the disc runout 10 mm 0.39 in. away from the outer edge of the disc. Maximum disc runout 0.05 mm 0.0020 in. c If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout See page 30-2 . If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a On-car brake lathe.
Preparation Mgt
09520-00031 Rear Axle Shaft Puller 09520-01010 Drive Shaft Remover Attachment 09520-24010 Differential Side Gear Shaft 09521-24010 Rear Axle Shaft Puller 09527-10011 Rear Axle Shaft Bearing Remover 09527-17011 Rear Axle Shaft Bearing Remover 09608-16042 Front Hub Bearing Adjusting Tool 09608-32010 Steering Knuckle Oil Seal Replacer 09608-32010 Steering Knuckle Oil Seal Replacer REAR AXLE LH HUB BOLT FRONT AXLE LH HUB BOLT FRONT DRIVE SHAFT FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT FRONT...
Terms
Automatic Disconnecting Differential Engine Control And Measurement System Electronic Throttle Control System-intelligent High Intensity Discharge Head Lamp Load Sensing Proportioning And Bypass Valve Throttle Body Electronic Fuel Injection TOYOTA Electronic Modulated Suspension Total Information System For Vehicle Development TOYOTA Motor Manufacturing Kentucky, Inc. Warm Up Three-way Catalytic Converter Warm Up Oxidation Catalytic Converter
Install Input Shaft Rear Radial Ball Bearing
a Using SST and a press, install the input shaft rear radial ball bearing to the input shaft. SST 09636-20010 b Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm 0.0039 in. . Snap ring thickness b Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm 0.0039 in. . Snap ring thickness c Using a brass bar and a hammer, tap in the snap...
Replacement Xek
2. REMOVE FRONT AXLE HUB LH NUT See page 30-6 SST 09930-00010 3. SEPARATE FRONT STABILIZER LINK ASSY LH See page 30-6 4. SEPARATE SPEED SENSOR FRONT LH W ABS See page 30-6 5. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH a Remove the 2 bolts, separate the brake caliper assy LH from the steering knuckle. 7. SEPARATE TIE ROD END SUB-ASSY LH See page 30-6 8. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH See page 30-6 a Using a plastic hammer, separate the front drive shaft Be careful not to...
Overhaul 1
2. REMOVE SPARE WHEEL COVER ASSY 3. REMOVE REAR FLOOR FINISH PLATE See page 76-21 4. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH See page 76-21 5. REMOVE REAR SHOCK ABSORBER WITH COIL SPRING a Support the rear axle beam with jack. c Remove the nut, washer and shock absorber. 6. REMOVE SHOCK ABSORBER ASSY REAR LH a Using SST, compress the coil spring. Do not use an impact wrench. It will damage the SST. b Using a 6 mm hexagon wrench to hold the piston rod, remove the nut. c Remove the support...
Inspect Skid Control Ecu Connectorgnd Terminal Continuity 1
a Measure resistance between terminal GND 1, 23 of skid control ECU harness side connector and body ground. OK REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK AND REPLACE BRAKE ACTUATOR ASSY See page 05-306 DIAGNOSTICS - ABS WITH EBD SYSTEM April, 2003 _057UK-04
Replacement
1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE ENGINE UNDER COVER RH a Disconnect the starter connector. c Remove the nut, then disconnect the starter wire. d Remove the 2 bolts, then remove the starter. 4. INSTALL STARTER ASSY Torque 37 Nm 378 kgfcm, 27 ftlbf for bolt 9.8 Nm 100 kgfcm, 7 ftlbf for nut 5. INSTALL ENGINE UNDER COVER RH 6. CONNECT BATTERY NEGATIVE TERMINAL Torque 5.4 Nm 55 kgfcm, 48 in.lbf
Inspect Camber Caster And Steering Axis Inclination
a Install the camber-caster-kingpin gauge or position vehicle on wheel alignment tester. b Inspect the camber, caster and steering axis inclination. Camber, caster and steering axis inclination -0 32' 45' -0.53 0.75 45' 0.75 or less -0 22' 45' -0.37 0.75 45' 0.75 or less 2 50' 45' 2.83 0.75 45' 0.75 or less 2 43' 45' 2.72 0.75 45' 0.75 or less 11 21' 45' 11.35 0.75 45' 0.75 or less 10 59'' 45' 10.98 0.75 45' 0.75 or less If the caster and steering axis inclination are not within the specified...
Overhaul Bpf
1. REMOVE MANUAL TRANSAXLE ASSY See page 41-17 2. REMOVE CLUTCH RELEASE FORK SUB-ASSY a Remove the clutch release fork with clutch release bearing from the transaxle assy. 3. REMOVE CLUTCH RELEASE BEARING ASSY a Remove the clutch release bearing assy from the clutch release fork. a Remove the release fork support from the transaxle assy. 5. REMOVE RELEASE BEARING HUB CLIP 6. REMOVE CLUTCH RELEASE FORK BOOT a Align the matchmarks on the clutch cover assy with the one on the flywheel sub-assy. b...
Adjust Differential Side Bearing Rreload
a Coat the differential case assy with gear oil, install it to the transaxle case. b Install the manual transmission case with 16 bolts. Torque 29.4 Nm 300 kgfcm, 22 ftlbf c Using SST and a torque wrench, turn the differential case assy to the right and left 2 or 3 times to allow the bearings to settle. d Using SST and a torque wrench, measure the preload. SST 09564-32011 Preload at starting New bearing 0.78 - 1.57 Nm 8 - 16 kgfcm, 6.9 - 13.9 in.lbf If the preload is out of specification,...
Front Drive Shaft Components
Front Axle Inboard Joint Boot LH Clamp Front Drive Inner Shaft Inner LH Shaft Snap Ring Front Axle Inboard Joint Boot LH Clamp Front Axle Inboard Joint Boot LH No.2 Clamp Front Axle Inboard Joint Sub-assy LH Front Axle Inboard Joint Sub-assy LH _DRIVE SHAFT PROPELLER SHAFT - FRONT DRIVE SHAFT_
Do not overtighten the SST
g Using SST, adjust the clearance of the damper setting clamp. SST 09240-00020 09242-00150 Clearance 1.5 mm 0.059 in. or less 25. INSTALL FRONT AXLE INBOARD JOINT SUB-ASSY LH Before installing the boot, wrap the spline of the drive shaft with vinyl tape to prevent the boot from being damaged. a Install new parts to the outboard joint shaft assy in the following order. 1 Inboard joint boot LH clamp 3 Inboard joint boot LH No.2 clamp b Using a snap ring expander, install a new inner LH shafl...
Overhaul Yni
1. DRAIN MANUAL TRANSAXLE OIL M T TRANSAXLE Torque 39.2 Nm 400 kgfcm, 29 ftlbf 2. DRAIN AUTOMATIC TRANSAXLE FLUID A T TRANSAXLE Torque 17.5 Nm 178 kgfcm, 13 ftlbf 4. REMOVE ENGINE UNDER COVER LH a Using SST and a hammer, unstake the staked part of the hub LH nut. SST 09930-00010 b While applying the brakes, remove the hub LH nut. NOTICE Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged. 6. SEPARATE FRONT STABILIZER LINK ASSY LH a Remove the nut,...
Inspect Skid Control Ecu Connectorig Terminal Voltage
a Check the voltage condition output from the ECU displayed on the hand-held tester. OK IN CASE OF NOT USING HAND-HELD TESTER a Disconnect the skid control ECU connector. b Turn the ignition switch to ON. c Measure voltage between terminals IG1 3 and GND 1, 23 of skid control ECU harness side connector.
Install Front Suspension Crossmember Subassy Lh At Position
a Lift the front suspension crossmember sub-assy up with a transmission jack. b Insert SST to the base hole of the RH side crossmember and RH side of the vehicle. c Tighten the bolt temporarily in the order A and B. d Insert SST to the base hole of the LH side of crossmember and LH side of the vehicle. e Tighten the bolt temporarily in the order A and B. f Insert SST to the base hole of the RH side of crossmember and RH side of the vehicle. g Then tighten the bolt A and B by the specified...
Ignition System
Cold and Hot in these sentences express the temperature of the coils themselves. Cold is from -10oC 14 F to 50oC 122 F and Hot is from 50oC 122 F to 100oC 212 F . 1. INSPECT IGNITION COIL WITH IGNITER AND SPARK TEST If DTC is indicated, carry out troubleshooting in accordance with the procedure on the following DTC. b Check that the spark occurs. 1 Remove the ignition coils with igniter . 2 Using a 16 mm 0.63 in plug wrench, remove the spark plugs. 3 Install the spark plugs to each ignition...
Definition Of Terms
Description of what the ECM monitors and how it detects malfunctions monitoring purpose and its details . Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value s exceeds the malfunction threshold s . The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored...
Remove Parking Brake Lever Subassy
a Disconnect the parking brake switch connector from the parking brake switch. b Remove the lock nut and adjusting nut from the parking brake cable assy No.1. d Using a screwdriver, raise the pick on the parking brake lever, and remove the parking brake cable assy No.1 from the parking brake lever. e Remove the parking brake lever from the body.
Install Parking Brake Lever Subassy
a Install the parking brake cable assy No.1 to the parking brake lever, temporarily tighten the adjusting nut and lock nut. b Using a screwdriver, fix the parking brake cable No.1 to the pick. c Install the parking brake lever with the 2 bolts. Torque 12.5 Nm 130 kgfcm, 9 ftlbf d Connect the parking brake switch connector to the parking brake switch.
Replacement Kad
2. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH See page 30-17 Using SST and a hammer handle or an equivalent, remove the LH hub bolt. SST 09628-10011 a Install a washer and nut to a new LH hub bolt as shown in the illustllation. b Using a hammer handle or an equivalent to hold the hub sub-assy LH, install the LH hub bolt by tightening the nut. 7. INSTALL FRONT DISC BRAKE CALIPER ASSY LH See page 30-17 Torque 103 Nm 1,050 kgfcm, 76 ftlbf
Floor Shift Assy Atm Components
Floor Shift Cable Transmission Control Shift Floor Shift Cable Transmission Control Shift Nm kgfcm, ftlbf Specified torque Shift Lever Knob Button Shift Lock Release Button Cover Shift Lever Knob Button Shift Lock Release Button Cover Precoated part p h Apply MP grease
Remove Brake Master Cylinder Subassy
a Disconnect the brake fluid level switch connector from master cylinder reservoir sub-assy. Slide the clip and disconnect the clutch reservoir tube No.1 from master cylinder reservoir sub-assy. c Using SST, disconnect the 2 brake tubes from the master cylinder. d Using SST, disconnect the 2 or 3 brake tubes from the No.1 way. e Remove the 2 nuts, and pull out the master cylinder, No.' way and vacuum check valve bracket.
Precheck
a Release the parking brake lever. b Check the warning lights. When the ignition switch is turned ON, check that the ABS warning light and brake warning light goes on for 3 sec. When the parking brake is applied or the level of the brake fluid is low, the brake warning light is lit. If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit See page 05-332 or 05-335 or brake warning light circuit See page 05-338 . c In case of not using hand-held...
Inspection Procedure Jnc
Start the inspection from step 1 in case of using the hand-held tester and start from step 2 in case of not using the hand-held tester. 1 READ VALUE OF HAND-HELD TESTER FRONT SPEED SENSOR a Select the DATALIST mode on the hand-held tester. b Check that there is no difference between the speed value output from the speed sensor displayed by the hand-held tester and the speed value displayed by the speedometer when driving the vehicle. OK There is almost no difference in the displayed speed...
Remove St Gear Thrust Washer
a Remove the 1st gear thrust washer from the output shaft 14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL a Remove the 1st gear thrust washer pin or ball from the output shaft. a Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear. NOTICE Using a waste to prevent the synchromesh shifting key and spring from being scattered. a Using a dial indicator and 2 V-blocks, measure the shaft runout. Maximum runout 0.015 mm 0.0006 in. If the runout exceeds the...
Overhaul Pkq
When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disul fide lithium base grease See page 51-15 . 2. DISCONNECT BATTERY NEGATIVE TERMINAL 4. REMOVE HORN BUTTON ASSY See page 50-8 5. REMOVE STEERING WHEEL ASSY See page 50-8 SST 09950-50013 09951-05010, 09952-05010, 09953-05020, 09954-05021 7. REMOVE ENGINE UNDER COVER LH 8. REMOVE ENGINE UNDER COVER RH 9. DISCONNECT TIE ROD END SUB-ASSY LH a Remove the cotter pin and nut. b Using SST, disconnect tie...
Install Flywheel Housing Under Cover
40. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET a Install the engine mounting bracket RR and 3 bolts to the automatic transaxle. Torque 64 Nm 652 kgfcm, 47 ftlbf 41. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET a Install the engine mounting bracket FR and 2 bolts to the automatic transaxle. Torque 64 Nm 652 kgfcm, 47 ftlbf 42. INSTALL ENGINE MOUNTING MEMBER SUB-ASSY CENTER a Install the dynamic damper, member sub-assy center with engine mounting insulator FR and 4 bolts. Torque Bolt...
Components Ccw
Bleeder Plug 8.3 85, 74 in.lbf Bleeder Plug Cap Cylinder Cup Piston r-r Parking Brake Shoe Lever Sub-assy r-r Parking Brake Shoe Lever Sub-assy Shoe Hold-down Spring Rear Brake Automatic Adjust Lever LH N m kgfcm, ftlbf Specified torque Lithium soap base glycol grease High temperature grease
Front Differential Oil Seal Atm Replacement
2. REMOVE ENGINE UNDER COVER RH 3. REMOVE ENGINE UNDER COVER LH 4. DRAIN AUTOMATIC TRANSAXLE FLUID a Remove the drain plug, gasket and drain ATF. b Install a new gasket and drain plug. Torque 17.5 Nm 178 kgfcm, 13 ftlbf 5. REMOVE FRONT DRIVE SHAFT ASSY RH See page 30-6 6. REMOVE FRONT DRIVE SHAFT ASSY LH See page 30-6 7. REMOVE TRANSAXLE HOUSING OIL SEAL RH a Using SST, pull out the oil seal. SST 09308-00010 8. REMOVE TRANSAXLE CASE OIL SEAL LH a Using SST, pull out the oil seal. SST...
Remove Shift Detent Ball
a Using a hexagon wrench, remove the 2 shift detent bal plugs from the manual transmission case. b Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case. c Using a hexagon wrench, remove the shift detent bal plug from the transaxle case. d Using a magnetic finger, remove the seat, spring and shifl detent ball from the transaxle case.
Overhaul Dyi
2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD If the airbag connector is disconnected with the ignition switch being at ON, DTCs will be recorded. a Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. b Pull out the horn button assy from the steering wheel. c Using a screwdriver, release the lock part of each airbag connector and disconnect the 2 airbag connectors. When...
Adjust Rear Drum Brake Shoe Clearance
a Temporarily install the hub nuts. b Remove the hole plug, and turn the adjuster and expand the shoe until the drum locks. c Using a screwdriver, back off the adjuster 8 notches. 26. FILL RESERVOIR WITH BRAKE FLUID 27. BLEED MASTER CYLINDER See page 32-4 SST 09023-00100 28. BLEED BRAKE LINE See page 32-4 29. CHECK FLUID LEVEL IN RESERVOIR 32. INSPECT PARKING BRAKE LEVER TRAVEL See page 33-2 33. ADJUST PARKING BRAKE LEVER TRAVEL See page 33-2