Replacement Of Oil Seal 1
Using SST, drive out the oil seal. S ST 09308-00010 Using SST and hammer, tap in a new LH oil seal. SST 09223-15010 Using SST and hammer, tap in a new RH oil seal. SST 09316-60010 09316-00010
inspection of master cylinder
HINT Clean the disassembled parts with compressed air. 1. INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSION. If a problem is found, clean or replace the cylinder. 2. INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLING If either one requires replacement, use the parts from the cylinder kit. 3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
Replacement Requirements
In the following cases, replace the steering wheel pad, steering wheel or spiral cable. CAUTION For replacement of the steering wheel pad, see page AB-15, REMOVAL AND INSTALLATION and be sure to follow the correct procedure. If the airbag has been deployed. If the steering wheel pad or spiral cable has been found to be faulty in troubleshooting. If the steering wheel pad, steering wheel or spiral cable has been found to be faulty during the check in item 1. - b or 2. - b . If the steering wheel...
General Troubleshooting
Fluid contaminated Torque converter faulty Transaxle faulty Vehicle does not move in any forward range or reverse Valve body or primary regulator faulty AT-13 AT-112 AT-66 AT-43 AT-43 AT-49 AT-44 Shift cable out of adjustment Manual valve and lever faulty Transaxle faulty Harsh engagement into any drive range Throttle cable out of adjustment Valve body or primary regulator faulty Accumulator pistons faulty Transaxle faulty Delayed 1-2, 2-3 or 3-0 D up-shift, or down-shifts from O D-3 or 3-2 and...
TOYOTA MR REPAIR MANUAL volume
NOTE The screen toned sections below are in VOLUME 2 Pub.No.RM179U2 . INTRODUCTION MAINTENANCE ENGINE MECHANICAL EXHAUST SYSTEM TURBOCHARGER SYSTEM EMISSION CONTROL SYSTEMS EFI SYSTEM COOLING SYSTEM LUBRICATION SYSTEM IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM SERVICE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS
Threeway Catalyst Twc System
To reduce HC, CO and NOx emissions, they are oxidized, reduced and converted to nitrogen N2 , carbon dioxide C02 and water H20 by the catalyst.
Installation Of Distributor
2. REMOVE RH ENGINE HOOD SIDE PANEL 3. SET NO.1 CYLINDER TO TDC COMPRESSION Turn the crankshaft clockwise, and position the slit of the intake camshaft as shown. a Install a new O-ring to the housing. b Apply a light coat of engine oil on the O-ring. c Align the cutout portion of the coupling with the groove of the housing. d Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. e Lightly tighten the two hold-down bolts. 5. CONNECT...
Inspection Of Ignition Coil 1
1. DISCONNECT IGNITION COIL CONNECTOR 2. DISCONNECT HIGH-TENSION CORD FROM IGNITION COIL See procedure step 3 on pages IG-16 and 17 Using an ohmmeter, measure the resistance between positive and negative - terminals. Primary coil resistance Cold 0.40 - 0.50 Q If the resistance is not as specified, replace the ignition coil. 4. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between positive and high-tension terminals Secondary coil resistance Cold 10.0 - 14.0 kQ If...
Remove Ignition Coil And Igniter
a Disconnect the ignition coil connector. b Disconnect the igniter connector. c Disconnect the high-tension cord. d Remove the two bolts, the ignition coil and igniter assembly. Disconnect the noise filter. 22. DISCONNECT ENGINE WIRE FROM LUGGAGE COMPARTMENT a Disconnect the following connectors 3 Engine compartment cooling fan relay connector 4 Engine compartment wire connector _Engine Compartment Cooling Fan Relay _Engine Compartment Cooling Fan Relay b Pull out the engine wire from the...
Torque Specifications
Oil pump pulley x Oil pump drive shaft No.1 idler pulley bracket x Cylinder head Timing belt tensioner x Cylinder head Camshaft bearing cap x Cylinder head No.3 timing belt cover x Cylinder head Intake manifold stay x Intake manifold Intake manifold stay x Cylinder block Water by-pass pipe x Water pump cover
Installation Of Lower Arm
a Temporarily install the strut bar to the lower arm with the nuts. b Temporarily install the lower arm to the body with a Connect the lower arm to the ball joint and torque the castle nut. Torque 800 kg-cm 58 ft-lb, 78 N-m 3. TORQUE STRUT BAR TO LOWER ARM Torque 1,150 kg-cm 83 ft-lb, 113 N-m a Install the tires and lower the vehicle. Then rock the vehicle up and down to stabilize suspension. Torque 1,200 kg-cm 87 ft-lb, 118 N m See page SA-24
Location Of Components 1
CENTER AIRBAG SENSOR ASSEMBLY CONNECTORS Electrical Connection Check Mechanism Electrical Connection Check Mechanism
Disassembly Of Differential Case
Using SST, remove the two side bearings. SST 09950-20017 a Place the matchmarks on both the differential case and ring gear. c Using a plastic hammer, tap out the ring gear. a Place the matchmarks on the differential right and left case. b Using a torx wrench, remove the sixteen torx screws. c Using a plastic hammer, tap out the differential left case. d Remove the speedometer drive gear from the differential right case. e Remove the two differential side gears, two side thrust washers,...
Installation Of Thermostat
a Install a new gasket to the thermostat. b Align the jiggle valve of the thermostat with the upper side of thestud bolt, and insert the thermostat in the water pump. HINT The jiggle valve may be set within 5 of either side of the precribed position. Install the water inlet with the two nuts. Torque 3S-GTE 80 kg-cm 69 in.-lb, 7.8 Nm 5S-FE 90 kg-cm 78 in.-lb, 8.8 N m CONNECT OIL DIPSTICK GUIDE TO WATER INLET See step 4 on page LU-22 4. CONNECT RADIATOR HOSE TO WATER INLET 5. FILL WITH ENGINE...
Installation Of Timing Belt
a Align the cutouts of the pulley and shaft, and slide the pulley. b Using SST, install the nut. 2. INSTALL CRANKSHAFT TIMING PULLEY a Align the pulley set key with the key groove of the pulley. b Slide on the timing pulley facing the flange side inward. a Install the pulley with the bolt. Torque 440 kg-cm 32 ft-lb, 43 N-m b Check that the idler pulley moves smoothly. a Apply adhesive to two or three threads of the pivot bolt. Adhesive Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or...
Removal Of Fuel Pressure Regulator 1
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative - terminal cable is disconnected from the battery. 2. REMOVE RH ENGINE HOOD SIDE PANEL 3. w CRUISE CONTROL SYSTEM REMOVE CRUISE CONTROL ACTUATOR See step 11 page EM-182 4. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 5. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR Remove...
Removal Of Radiator Cooling Fans
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative - terminal cable is disconnected from the battery. 2. DISCONNECT FRONT LUGGAGE UNDER COVERS 3. DISCONNECT UPPER RADIATOR SUPPORT SEAL See step 4 on page CO-17 4. DISCONNECT RADIATOR COOLING FAN CONNECTORS 5. REMOVE RADIATOR COOLING FANS Remove the three bolts and cooling fan. Remove the two cooling...
Removal Of Alternator
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative - terminal cable is disconnected from the battery. a Loosen the pivot bolt and adjusting lock bolt. b Loosen the adjusting bolt, and disconnect the drive belt from the alternator. a Disconnect the alternator connector. b Remove the nut, and disconnect the alternator wire. c Remove the pivot bolt,...
Low Temperature Below C F 1
1. TURN IGNITION SWITCH ON If not, check the cooling fan relays and water temperature switch, and check for a separated connector or severed wire between the cooling fan relay and water temperature switch. 2. DISCONNECT WATER TEMPERATURE SWITCH CONNECTOR If hot, check the fan main relay, cooling fan relays, cooling fan and fuses, and check for a short circuit between the cooling fan relay and water temperature switch. 3. CONNECT WATER TEMPERATURE SWITCH CONNECTOR
Installation Of Lateral Control Rod
1. ASSEMBLE ENGINE LATERAL CONTROL ROD Assemble the parts in the correct direction as shown. Torque 250 kg-cm 18 ft-lb, 25 N-m 2. INSTALL ENGINE LATERAL CONTROL ROD a Install the No.1 bracket to the control rod. Torque 500 kg-cm 36 ft-lb, 49 Nm b Install the control rod in place and torque the No.1 bracket installation bolts. Torque 360 kg-cm 26 ft-lb, 35 N m c Install and torque the No.2 bracket installation bolt. Torque 740 kg-cm 54 ft-lb, 73 Nm 3. INSTALL LH ENGINE MOUNTING STAY Torque No.2...
Compression Check
HINT If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. Allow the engine to warm up to normal operating temperature. DISCONNECT SOLENOID RESISTOR CONNECTOR 3. DISCONNECT COLD START INJECTOR CONNECTOR 4. DISCONNECT DISTRIBUTOR CONNECTOR 5. REMOVE SPARK PLUGS See page IG-6 or 11 6. CHECK CYLINDER COMPRESSION PRESSURE a Insert a compression gauge into the spark plug hole. c While cranking the engine, measure the compression pressure. HINT...
d Brake booster vacuum hose from intake manifold CONNECT GROUND STRAP CONNECTOR
34. INSTALL AIR CLEANER CAP See step 40 on pages EM-179 35. INSTALL CRUISE CONTROL ACTUATOR w CRUISE CONTROL SYSTEM AND ACCELERATOR LINKAGE See step 36 on pages EM-178 36. INSTALL ACCELERATOR CABLE, AND ADJUST IT 37. INSTALL SUSPENSION UPPER BRACE See step 41 on page EM-179 38. FILL ENGINE WITH COOLANT See page CO-7 13.6 liters 14.4 US qts, 12.0 Imp. qts 39. START ENGINE AND CHECK FOR LEAKS See steps 9 to 13 on pages IG-17 and 18 41. INSTALL ENGINE HOOD SIDE PANELS 42. INSTALL ENGINE UNDER...
Components Rbz
Cylinder End Stopper g T-v Oil Seal kg-cm ft-lb, N m J Specified torque m Apply Molybdenum Disulphide Lithium Base Grease Apply Power Steering Fluid EH
Symptom High Engine Speed No Drop
HINT 5S-FE Disconnecting the battery will cause the idling speed date in the ISC to be returned to the initial idling speed, causing the idling speed to rise above 750 rpm USA M T, CANADA A T , 700 rpm USA A T , 850 rpm CANADA M T . Should this happen, either carry out a driving test, including stop-go several times at a speed above 10km h, or start the engine, idle for 30 seconds and then turn the engine off repeatedly. By doing this, idle date will be stored in the ISC and the idle rpm will...
Installation Of Alternator
a Mount the alternator on the alternator brackets with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet. b Connect the alternator connector. c Connect the alternator wire with the nut. Adjust the drive belt tension. See step 3 on page CH-3 Drive belt tension New belt 120 20 lb Used belt 104 20 lb 3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 4. PERFORM ON-VEHICLE INSPECTION See steps 5 to 7 on pages CH-4 and 5
Removal Of Injectors 1
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative - terminal cable is disconnected from the battery. 2. REMOVE ENGINE HOOD SIDE PANELS 3. REMOVE AIR CLEANER See step 9 on page EM-182 4. w CRUISE CONTROL SYSTEM REMOVE CRUISE CONTROL ACTUATOR See step 11 on page EM-182 5. REMOVE COLD START INJECTOR PIPE See step 3 on page FI-102 6. DISCONNECT BRAKE...
Installation Of Injectors 1
1. INSTALL INJECTORS AND DELIVERY PIPE a Install a new grommet to the injector. b Apply a light coat of gasoline to a new 0-ring and install it to the injector. c While turning the injector left and right, install it to the delivery pipes. Install the four injectors. d Place four new insulators and the two spacers in position on the cylinder head. e Place the four injectors together with the delivery pipe in position on the cylinder head. f Temporarily install the two bolts holding the delivery...
Oil Pressure Check
Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is poor, replace the oil. Oil grade API grade SG, multigrade, fuelefficient and recommended viscosity oil F -20 0 20 40 60 80 100 C -29 -18 -7 4 16 27 38 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE The oil level should be between the L and F marks on the dipstick. If low, check for the leakage and add oil up to F mark. Allow the engine to warm up to normal operating temperature. At idling 0.3 kg...
Oil Pressure Check 1
NOTICE When supplementing the power steering fluid, use TOYOTA POWER STEERING FLUID EH or equivalent which is exclusively for EH PS use. a Using SST, disconnect the pressure line from the PS pump. b Connect the gauge side of the pressure gauge to the PS pump and the valve side to the pressure line. c Bleed the system. Start the engine and turn the steering wheel from lock to lock two or three times. d Check that the fluid level is correct. 2. CHECK THAT FLUID TEMPERATURE IS AT LEAST 40 C 104 F...
Disassembly Of Cylinder Xlf
1. REMOVE DUST BOOT AND SLIDING BUSHING Using a chisel and hammer, tap out the dust boots. 3. REMOVE CYLINDER BOOT SET RING AND CYLINDER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot. Using SST, turn the piston counterclockwise and remove it. Using a screwdriver, remove the piston seal. a Set SST onto the adjusting bolt, and lightly tighten it with a 14 mm socket. To insure safety, always use SST as there is a possibility of the spring flying out, causing injury...
Output Of Diagnostic Codes
To obtain an output of diagnostic codes, proceed as follows a Battery voltage 11 V or more b Throttle valve fully closed throttle position sensor IDL points closed c Transmission in neutral position e Engine at normal operating temperature 2. Turn the ignition switch to ON. Do not start the engine. 3. Using SST, connect terminals TE1 and E1 of the check connector. 0.25 Second 3S-GTE 0.26 Second 5S-FE 4. Read the diagnostic code as indicated by the number of flashes of the CHECK engine warning...
Replacement Of Front Axle Hub Bolt
Remove the brake caliper from the steering knuckle and suspend it with a wire. Align the matchmarks, and install the rotor disc to the axle hub. a Align the disc brake dust cover cutting portion and axle hub bolt. b Using SST, remove the axle hub bolt. SST 09628-10011 a Install a new hub bolt from the backing plate side. b Install the suitable plate washer and nut. c Tighten the nut, while holding the axle hub. Align the matchmarks and install the rotor disc to the axle hub. 6. INSTALL DISC...
Inspection And Adjustment Of Valve Clearance Sfe
HINT Inspect and adjust the valve clearance when the engine is cold. 1. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS See page IG-11 2. REMOVE CYLINDER HEAD COVER See step 32 on page EM-104 3. SET N0.1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with timing mark 0 of the No.1 timing belt cover. b Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No.4 are tight. If not, turn the crankshaft one revolution 360 and align the mark...
Assembly Of Cylinder Head
Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. a Using SST, push in a new oil seal. SST 09201-41020 HINT The intake valve oil seal is brown and the exhaust valve oil seal is black. HINT Install the valve spring, facing the white painted mark upward. c Using SST, compress the valve spring and place the two keepers around the valve stem. d Using a plastic-faced...
Troubleshooting Gxo
Battery cables loose, corroded or worm
Components Iko
kg-cm ft-lb, N m Specified torque Non-reusable part
Torque Specifications Contd
LH engine hanger x Cylinder head 12 mm head bolt Catalytic converter x Turbine outlet elbow Catalytic converter stay x Catalytic converter RH front engine hanger x Cylinder head Rear oil seal retainer x Cylinder block RH engine mounting bracket x Cylinder block LH engine mounting bracket x Transaxle Rear engine mounting bracket x Transaxle 14 mm head bolt LH engine mounting insulator x LH engine mounting bracket RH engine mounting insulator x RH engine mounting bracket RH engine mounting stay x...
Disassembly Of Cylinder Block 1
Remove the six bolts, retainer and gasket. 2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.160 - 0.312 mm Maximum thrust clearance 0.35 mm 0.0138 in. If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. 3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Using a punch or numbering stamp, place the...
Onvehicle Inspection Oiy
INSPECT RESISTANCE OF COLD START INJECTOR a Disconnect the cold start injector connector. b Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the cold start injector. c Reconnect the cold start injector connector. REMOVAL OF COLD START INJECTOR 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the...
Onvehicle Inspection 1
INSPECT RESISTANCE OF COLD START INJECTOR See steps 1 to 8, 10 and 11 on pages FI-135 and 136 b Disconnect the cold start injector connector. c Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the cold start injector. d Reconnect the cold start injector connector. e Reinstall the throttle body. See steps 2, 3 and 5 to 12 on page FI-138 and 139
Front Airbag Sensor 1
1. Never reuse the front airbag sensors involved in a collision when the airbag has deployed. Replace both the left and right airbag sensors. 2. Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. 3. The front airbag sensor set bolts and nuts have been anti-rust treated. When the sensor is removed, always replace the set bolt and nut with new ones. 4. The front airbag sensor is equipped with an electrical connection check mechanism. Be sure to...
Inspection Of Input Shaft Component Parts 1
b Turn the ring and push it in to check the braking action. c Measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance 0.6 mm 0.024 in. If the clearance is less than the limit, replace the synchronizer ring. 2. MEASURE CLEARANCE OF NO. 2 SHIFT FORK AND HUB SLEEVE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance 1.0 mm 0.039 in. If the clearance exceeds the limit, replace the shift fork or hub sleeve....
Inspection Of Jet
1. INSPECT JET BY BLOWING AIR FROM EACH SIDE EXHAUST GAS RECIRCULATION EGR SYSTEM To reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature. Pressure in the EGR Valve Pressure Chamber Remarks When the throttle valve is positioned above the E port, the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the EGR gas, even if the exhaust pressure is...
Exhaust Gas Recirculation Egr System
Pressure in the EGR Valve Pressure Chamber Positioned between E port and R port Pressure increase- Modulator closes- EGR valve opens- Pressure drops -EGR valve close- -Modulator opens- -1 when the throttle valve is positioned above R port, the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the exhaust gas, even if the exhaust pressure is insufficiently low. If terminals TE1 and E1 of check connector are connected, the VSV switches ON.
Onvehicle Inspection Ber
Engine at normal operating temperature b Disconnect the ISC valve connector. c Check the engine rpm. Engine rpm 1,000 rpm or more d Reconnect the ISC valve connector. e Check that they return to the idle speed. Idle speed 800 50 rpm If the rpm operation is not as specified, check the ISC valve, wiring and ECU. a Disconnect the ISC valve connector. b Using an ohmmeter, measure the resistance between terminal B and other terminals RSC, RSO . If resistance is not as specified, replace the ISC...
Disassembly Of Front Axle Hub
a Clamp the steering knuckle in a soft jaw vice. b Using a screwdriver and hammer, remove the hub bearing cap. a Clamp the axle hub in soft jaw vice. HINT Close vice until it holds hub bolt. Do not tighten further. b Using a hammer and chisel, loosen the staked part of the nut and remove the lock nut. NOTICE Take care to not scratch the serrations of speed sensor rotor. a Remove the disc brake dust cover. b Using SST, remove the axle hub from the steering knuckle. a Using snap ring pliers,...
Front Airbag Sensor
1. Never reuse the front airbag sensors involved in a collision when the airbag has deployed. Replace both the left and right airbag sensors. 2. Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. 3. The front airbag sensor set bolts and nuts have been anti-rust treated. When the sensor is removed, always replace the set bolts and nuts with new ones. 4. The front airbag sensor is equipped with an electrical connection check mechanism. Be sure to...