Inspection

INSPECT RELAY (FAN NO. 1, FAN NO. 3) (a) Check the resistance of the relay. Standard (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (a) Check the resistance of the relay. Standard (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. -20 0 20 40 60 80 100 (-4) (32) (68) (104) (140) (176) (212) -20 0 20 40 60 80 100 (-4) (32) (68) (104) (140) (176) (212) 3. INSPECT ENGINE COOLANT...

Add Engine Coolant

(a) Tighten the radiator drain plug. (b) Add engine coolant into the radiator until it overflows. Capacity 6.2 liters (6.6 US qts, 5.4 Imp. qts) Use of improper coolants may damage the engine cooling system. Use Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed...

Adjust Front Door Panel Subassy Lh

(a) Using SST, adjust the door by loosening the body side hinge bolts. Forward rearward and vertically. (b) Tighten the bolts after adjustment. Torque 26 N m (265 kgf cm, 19 ft Ibf) (c) Adjust the door by loosening the door side hinge bolts. Horizontally and vertically. (d) Tighten the bolts after adjustment. Torque 26 N m (265 kgf cm, 19 ft Ibf) (e) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer. (f) Tighten the...

Basic Inspection

(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS (1) Unless stated, all resistance is measured at an ambient temperature of 20 C (68 ). Resistances measured may be outside the specifications if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, then press the lock claw and separate the...

Be careful not to damage the inside of the cylinder body

(e) Install the push rod to the cylinder body. (f) Install the boot to the cylinder body. 8. INSTALL CLUTCH RELEASE CYLINDER ASSY (a) Install the clutch release cylinder assy with the 2 bolts. Torque 12 N m (120 kgf cm, 9 ft Ibf) Install the clutch accumulator assy with the 2 nuts and the bolt. Torque 12 N m (120 kgf cm, 9 ft Ibf) Install the flexible hose bracket No.2 with the 2 bolts. Torque Bolt A 12 N m (120 kgf cm, 9 ft Ibf) Bolt B 39 N m (398 kgf cm, 29 ft Ibf) CONNECT CLUTCH RELEASE...

Bleeding

If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. NOTICE Wash off the brake fluid immediately if it comes into contact with a painted surface. 1. FILL RESERVOIR WITH BRAKE FLUID Fluid SAE J1703 or FMVSS No. 116 DOT3 If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Remove the air cleaner assembly with hose. (b) Disconnect the brake lines from the master...

Caulk Lock Plate

(a) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 Do not tap the areas protruding around the pipes, brackets or tank ribs. The points shown in the illustration and oil cooler near here cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. (b) Check the lock plate height (H)...

Check Air Tightness In Fuel Tank And Filler Pipe

(a) Disconnect the vent line hose from the fuel tank (see page 11-52). (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If malfunctions, damage or other problems are found, replace (g) Reconnect the vent line hose...

Clutch Pedal Subassy Replacement

REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE PAGE 71-16) 2. REMOVE COMBINATION METER ASSEMBLY (SEE PAGE 71-29) 3. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-16) 4. REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-16) 5. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN (a) Disconnect the clutch start switch clamp and connector. (b) Remove the bolt, 2 nuts and clutch pedal assy. 7. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING (a) Using a small screwdriver, remove the...

Clutch Unit Overhaul

REMOVE MANUAL TRANSAXLE ASSY (SEE PAGE 41-11) 2. REMOVE CLUTCH RELEASE FORK BOOT 3. REMOVE CLUTCH RELEASE BEARING ASSY 4. REMOVE CLUTCH RELEASE FORK SUB-ASSY 5. REMOVE RELEASE BEARING HUB CLIP (a) Remove the release fork support from the manual transaxle assy. (a) Place the matchmarks on the clutch cover assy with the one on the flywheel sub-assy. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the set bolts and pull off the clutch cover assy. NOTICE...

Do not use plain water alone

(c) Pour coolant into the radiator reservoir tank until the coolant reaches the full line. (e) Start the engine and run the engine for 10 seconds. (f) Remove the radiator cap after 10 seconds. Pour coolant if the coolant level is lower. (g) Repeat (d) to (f) until the coolant level remains the same from steps (d) to (f). HINT Perform the procedures above before the engine warms up. A warmed up engine causes the thermostat valve to open, and the air inside of the engine circulates between the...

Electronic Control

(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL (1) Before performing electronic work, disconnect the battery negative (-) terminal cable beforehand to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting and installing the terminal cable, turn the ignition switch and lighting switch OFF and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. Remove the battery cable from battery post. (3) Clock...

Fluid temperature to D to

(a) Park the vehicle on a level surface and set the parking brake. (b) With the engine idling and the brake pedal depressed, shift the lever into all positions from the P to the L position, and return to the P position. (c) Pull out the dipstick and wipe it clean. (d) Push it back fully into the pipe. (e) Pull it out and check that the fluid level is within the HOT range. If there are leaks, it is necessary to repair or replace O-rings, FIPGs, oil seals, plugs or other parts. AUTOMATIC...

Front No Speaker Assy Replacement

REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY (See page 75-8) 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75-8) 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (See page 75-8) 4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH (See page 75-8) (b) Remove the 4 screws and front No.1 speaker assy. (a) Install the front No.1 speaker assy with the 4 screws. NOTICE Install them in the order shown in the illustration.

Glossary Of Sae And Toyota Terms

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 2 Total Diagnosis Communication Link (TDCL) 3 OBD II Diagnostic Connector Engine ECU (Electronic Control Unit) Coolant Temperature, Water Temperature (THW) Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable...

Inspect Charcoal Canister Assy

(a) Visually check the charcoal canister for cracks or damage. If cracks or damage is found, replace the charcoal canister assy. (b) Check the charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf cm2, 0.06 psi) into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister. (2) While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf cm2, 0.06 psi) into the vent port,...

Inspect Engine Coolant Temperature Sensor

(a) Measure the resistance between each terminal. Standard If the result is not as specified, replace the sensor. NOTICE If checking the engine coolant temperature sensor in the water, keep the terminals dry. After the check, wipe the sensor dry. If the result is not as specified, replace the sensor. NOTICE If checking the engine coolant temperature sensor in the water, keep the terminals dry. After the check, wipe the sensor dry.

Inspect Torque Converter Clutch Assy

Sample showing minimum amount of powders in ATF Install SST into the inner race of the one-way clutch. 09350-32014 (09351-32010) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. 09350-32014 (09351-32020) With the torque converter clutch setting up on its side, check that the one-way clutch locks when it is turned counterclockwise, and rotates smoothly clockwise. If necessary, clean the converter and retest the one-way clutch. Replace the...

Install Crankshaft

(a) Apply engine oil to upper bearing and install the crankshaft on the cylinder block. (b) Apply engine oil to the lower bearing. (c) Examine the front marks and install the bearing caps on the cylinder block. (d) Apply a light coat of engine oil on the threads and under the bearing cap bolts. (e) Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque 20 N m (204 kgf cm, 15 ft Ibf) (f) Mark the front of the bearing cap bolts with paint....

Install Floor Shift Parking Lock Cable Assy

(a) Turn the ignition switch to ACC or ON. (b) Connect the cable to the upper bracket. (d) Insert the slide cap into the through hole and install. (1) Shift the shift lever to P position and turn the ignition switch to LOCK position. (TMC made) (2) Shift the shift lever to N position and turn the ignition switch to ACC position. (TMMK made) (3) Set the accessory tool to the shift lock control unit assy.

Install the pad support plates in the correct position and direction

< i Disc brake grease F50334 < i Disc brake grease F50334 34. INSTALL ANTI SQUEAL SHIM KIT FRONT NOTICE When replacing worn pads, the anti-squeal shims must be replaced together with the pads. Install the shims and pad wear indicator plates in the correct position and direction. (a) Apply disc brake grease to the anti-squeal shims as shown in the illustration. (b) Install the anti-squeal shims on each pad as shown in the illustration. (c) Install the pad wear indicator plates to each pad....

Maintain at to inHg to inAq for over seconds

If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (h) Disconnect the battery's positive (+) and negative (-) leads from the VSV for EVAP terminals. (i) Reconnect the VSV for EVAP connector. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Connect a pressure gauge to the EVAP service port on the purge line. (I) Disconnect the VSV for CCV connector, (m) Connect the battery's...

Minutes after the pressure is added the gauge should still read over to in Aq

If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (o) Disconnect the battery's positive (+) and negative (-) leads from the VSV for CCV terminals, (p) Reconnect the VSV for CCV connector, (q)...

Never disassemble the curtain shield airbag assembly

(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which is very dangerous. (3) Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93 C (200 F), without high humidity and away from electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2...

Never use a backup power source battery or other avoid erasing system memory The backup power source may power the SRS

(3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly front seat airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected before further use of the vehicle (See pages 60-27, 60-40, 60-53, 60-47 and 61-7). (4) Never use SRS parts from another vehicle. When replacing parts, use new parts. (5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during...

Not Using Hand Held Tester Inspect Evap System Line

(a) Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. (b) Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. (c) Disconnect the VSV for EVAP connector. (d) Connect the battery's positive (+) and negative (-) leads to the VSV for EVAP terminals. (f) Check the vacuum while the engine is idling. Standard

Oneway clutch is free or locked in both directions Fine powders exceeding the sample limit is identified in ATF See the

The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch (c) Replace the ATF in the torque converter clutch. (1) If the ATF is discolored and or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. AUTOMATIC TRANSMISSION TRANS - TORQUE CONVERTER CLUTCH AND DRIVE Clean and check the oil cooler and oil pipe line. (1) If the torque...

Onvehicle Inspection

(a) Connect the hand-held tester to the DLC3. (b) Start the engine and run it at idle. (c) Select the ACTIVE TEST mode on the hand-held tester. HINT Please refer to the hand-held tester operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay ON, check the actuator motor operation noise. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d) Wth the motor relay ON, check that the pedal does not...

Precaution

Hat and safety shoes must be worn. Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. When working with 2 or more persons, be sure to check safety in one another. When working with the engine running, pay attention to the providing ventilation for exhaust fumes in the workshop. f working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to...

Problem Symptoms Table

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. 4. Rear brake shoe clearance (Out of adjustment) 6. Booster push rod (Out of adjustment) 2. Parking brake pedal travel (Out of adjustment) 4. Rear brake shoe clearance (Out of adjustment) 5. Parking brake shoe clearance (Out of adjustment) 6. Pad or lining (Cracked or distorted) 9. Anchor, tension or...

Radiator Assy Mzfemzfe Onvehicle Cleaning

(a) If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard 2,942 to 4,903 kPa (30 to 50 kg cm2, 427 to 711 psi) 4,903 to 7,845 kPa (50 to 80 kg cm2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components.

Registration

The garage door opener is built in the map lamp assy. When transmitter codes for garage door, gate, entry gate, door lock, home lighting system or security system are registered with the garage door opener, be sure to register them again whenever replacing the map lamp assy. After the map lamp assy has been replaced, register transmitter codes with the garage door opener (Registration mode). While the transmitter code for a system (garage, door, gate, etc.) is being registered, the system may...

Removal And Installation Of Fuel Control Parts

(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Work in a place with good air ventilation and without any ignition sources, such as a welder, grinder, drill, electric motor or stove. (2) Never work in a place such as a pit or near a pit because vaporized fuel will collect in those places. (b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting operation. (2) To prevent static electricity, install a ground on the fuel changer, vehicle and...

Remove Stud Bolt

CLEAN CYLINDER BLOCK SUB-ASSY NOTICE If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45 C (113> F) or less. 16. INSPECT CYLINDER BLOCK FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. (a)...

Remove Water Outlet

(a) Disconnect the radiator hose inlet. Disconnect the ECT sensor connector. Remove the clamp. Remove the 2 bolts, 2 nuts and 2 washers. Lock the hose clamp as shown in the illustration. Then remove the water outlet together with the water bypass hose No. 1. Remove the 2 gaskets from the 2 cylinder heads.

Replacement

REMOVE ENGINE COVER SUB-ASSY N0.1 (SEE PAGE 14-29) or (SEE PAGE 14-164) 3. REMOVE AIR CLEANER ASSY (SEE PAGE 14-29) or (SEE PAGE 14-164) 4. REMOVE AIR CLEANER HOSE N0.1 (SEE PAGE 14-29) or (SEE PAGE 14-164) 5. REMOVE INTAKE AIR RESONATOR SUB-ASSY (SEE PAGE 14-29) or (SEE PAGE 14-164) 6. REMOVE ENGINE UNDER COVER LH 7. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (a) Remove the nut from the control shaft lever. (b) Disconnect the control cable from the control shaft lever. (c) Remove the clip and...

Some fluid will remain in the oil pan Remove all pan bolts and carefully remove the oil pan assembly

(b) Remove the 2 magnets from the oil pan. (1) Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the pan and on the magnets to see the type of wear which might be found in the transaxle. Steel (magnetic) bearing, gear and plate wear Brass (non-magnetic) bearing wear

Symptom Confirmation

If a DTC was displayed in the initial DTC check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (see page 01-32). TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). The most difficult case in troubleshooting is when no problem symptoms occur. In...

Three Bond or equivalent

(c) Install the oil pan and a new gasket with the 18 bolts to the transaxle case. Torque 7.8 N m (80 kgf cm, 69 in. Ibf) NOTICE Apply seal packing to the bolts and tighten them within 10 minutes of application. 9. ADD AUTOMATIC TRANSAXLE FLUID Fluid type ATF type T-IV Capacity 3.5 liters (3.7 US qts, 3.1 Imp. qts) 10. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2) 11. INSTALL ENGINE UNDER COVER LH

To mm to in

INSPECT INNER COMPRESSION SPRING (a) Using a vernier caliper, measure the free length of the valve spring. If the free length is not as specified, replace the valve spring. (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation 1.6 mm (0.063 in.) If the deviation is greater than the maximum, replace the valve spring. (a) Using a vernier caliper, measure the valve overall length. Specified overall length 101.21 to 101.71 mm (3.9846 to 4.0043 in.) If the overall...

Torque N m kgf cm ft

(7) Install the stop lamp switch assy. (8) Connect the connector to the stop lamp switch assy. (9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off. (10) After installation, push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.), check that stop lamp lights up. (11) Install the instrument panel insert sub-assy lower LH and instrument panel finish panel sub-assy lower.

V

No. 1 Bearing Cap Camshaft Bearing No. 1 Camshaft Timing Sprocket Camshaft Bearing No. 2-r V-. Camshaft Timing Sprocket Camshaft Bearing No. 2-r V-. Nm (kgfcm, ft Ibf) Specified torque 1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-26) 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE FRONT FENDER APRON SEAL RH 7. DRAIN ENGINE COOLANT (See page 16-27) 8. DRAIN AUTOMATIC TRANSAXLE FLUID 10. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See...

Valve Clearance Mzfemzfe Adjustment

DRAIN ENGINE COOLANT (See page 16-27) 2. REMOVE FRONT FENDER APRON SEAL RH (a) Using a socket hexagon wrench 5, remove the 3 nuts. 5. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W FRONT SUSPENSION BRACE UPPER CENTER) 6. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 7. REMOVE EMISSION CONTROL VALVE SET (a) Disconnect the 2 VSV connectors. (b) Remove the wire harness clamp. (c) Disconnect the fuel vapor feed hose No. 1. (d) Disconnect the fuel vapor feed hose No. 2. (e) Disconnect the 2 vacuum hoses. (g)...

Vibration Method When vibration seems to be the major cause

(1) Apply slight vibration with a finger to the part of the sensor considered to be the cause of the problem and check whether or not the malfunction occurs. ing strong vibration to relays may open relays. CONNECTORS (1) Slightly shake the connector vertically and horizontally. (1) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly.

Visually Inspect Hoses Connections And Gaskets

(a) Check for cracks, leaks or damage. HINT Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. If necessary, replace any damage parts.

When rotating the torque converter clutch do not push it by excessive force

(g) Using vernier calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in step (a). Standard A + 1 mm (0.04 in.) or more 21. INSTALL AUTOMATIC TRANSAXLE ASSY (a) Install the automatic transaxle to the engine with the 8 bolts. Bolt A 64 N m (653 kgf cm, 47 ft Ibf) Bolt B 44 N m (449 kgf cm, 32 ft Ibf) Bolt C 46 N m (470 kgf cm, 34 ft Ibf) (b) Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter...

When testing a goldplated female terminal always use a goldplated male terminal

(3) Checking the contact pressure of the terminal Prepare a spare male terminal. Insert it into a female terminal, and check for good tension when inserting and after full engagement. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any dirt on the terminal, clean the contact point using an air gun or shop rag. Never polish the contact point using a sandpaper as the platings may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is...

TMMK Made

Only in the case of reusing the shift lock control unit assy. (b) Using a screwdriver, unlock the claw of the lock key of automatic adjustment part. (c) Insert the lever pin into the hole in the floor shift parking lock cable. At this time, the shift lever should be in P position and the ignition key should be set to LOCK position. (TMC Made) At this time, the shift lever should be in N position and the ignition key should be set to ACC position. (TMMK Made) (e) Remove the accessory tool....

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 Electronically Modulated Suspension Total Information System For Vehicle Development TOYOTA Motor Manufacturing Kentucky, Inc. Warm Up Three-way Catalytic Converter Warm Up Oxidation Catalytic Converter

Inspect Valve Seats

(a) Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve face against the valve seat. (c) Check the valve face and valve seat according to the following procedure. (1) If blue appears 360 around the valve face, the valve face is concentric. If not, replace the valve. (2) If blue appears 360 round the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the...

Thermostat Mzfemzfe Replacement

DRAIN ENGINE COOLANT (See page 16-27) 2. REMOVE AIR CLEANER INLET ASSY 3. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 5. REMOVE AIR CLEANER INLET NO.1 6. DISCONNECT RADIATOR HOSE OUTLET 7. REMOVE WATER INLET PIPE (a) Remove the bolt and inlet pipe. (a) Install a new gasket to the thermostat. (b) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. The jiggle valve may be set within 15 of either side of the prescribed position. Torque 8 N m...

Connect test leads to the connectors backside The connectors should not be disconnected from the ECM

Voltage between the terminals of the ECM is kept constant regardless of the voltage of the A F sensor. (b) Connect the hand-held tester to the DLC3. (c) Select DATA MONITOR. Then select A FS B1 S1, A FS B2 S1 and 02S B1 S2 to display the monitors. (d) Warm up the A F sensor with the engine speed at 2,500 rpm for approximately 2 minutes. (e) Keep the engine speed at 2,500 rpm and confirm that the displays of A FS B1 S1 and A FS B2 S1 are as shown in the illustration. The illustration may differ...

Check Throttle Body

(a) Listen to the throttle control motor operating sounds. (1) Turn the ignition switch ON. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure no friction noise comes from the motor. If friction noise exists, replace the throttle body. (b) Check the throttle position sensor. (1) Connect the hand-held tester or OBD II scan tool to the DLC3. (2) Turn the ignition switch ON. (3) Check that the check engine warning light does not light up. (4)...

Remove Cylinder Boot

(a) Using a screwdriver, remove the set ring and disc cylinder boot. (a) Place a piece of cloth or similar, between the piston and the disc brake cylinder. (b) Use compressed air to remove the piston from the disc brake cylinder. Do not place your fingers in front of the piston when using compressed air. NOTICE (a) Using a screwdriver, remove the piston seal from the brake cylinder. NOTICE Do not damage the inner cylinder and the cylinder groove. 15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP 16....

Exhaust A B C mm in

Select a new shim with a thickness as close as possible to the calculated values. Measured valve clearance 0.45 mm (0.0177 in.) 0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) 0.25 mm (0.0098 in.) (Measured - Specification Excess clearance) Used shim measurement 2.80 mm (0.1102 in.) 0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) 3.05 mm (0.1201 in.) (Excess clearance + Used shim Ideal new shim) Closest new shim 3.05 mm (0.1201 in.) Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.),...

Check Camshaft Timing Oil Control Valve Assy

Oil Control Valve For Toyota Tacoma 2006

(a) Connect the hand-held tester or OBD II scan tool to the DLC3. (b) Turn the ignition switch ON. (c) Start the engine and warm it up. (d) Select the VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the hand-held tester. Standard If the result is not as specified, replace the OCV assy. 4. CHECK MASS AIR FLOW METER (MAF meter) NOTICE Perform the MAF meter inspection by following the procedures below. Only replace the MAF meter when both the LONG FT 1 value...

Maintain at to inHg to in Aq for over seconds

Guru Pressure Gauge

If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (i) Disconnect the hand-held tester from the DLC3. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Connect a pressure gauge to the EVAP service port on the purge line. (I) Connect the hand-held tester to the DLC3. (n) Turn the hand-held tester main switch ON. (o) Use the ACTIVE TEST mode on the hand-held tester to

Power Point Socket Assy Replacement

REMOVE SHIFT LEVER KNOB SUB-ASSY (M T TRANSAXLE) (See page 71-16) 2. REMOVE CONSOLE PANEL UPPER REAR(See page 71-16) 3. REMOVE INSTRUMENT PANEL CUP HOLDER (W O ASHTRAY)(See page 71-16) 4. REMOVE FRONT ASH RECEPTACLE ASSY (W ASHTRAY)(See page 71-16) 5. REMOVE CONSOLE PANEL SUB-ASSY UPPER(See page 71-16) (a) Turn the socket in the circumference direction as shown in the illustration, disengage the claw between the socket and the power pint socket cover, and push out the socket to the room side....

Speed Sensor Front Lh Replacement

Replace the RH side by the same procedures with LH side. 2. REMOVE FRONT FENDER LINER LH a Disconnect the speed sensor connector and clamp. b Remove the 2 clamp bolts holding the sensor harness and clamp from the body and shock absorber. c Remove the bolt and speed sensor FR LH. NOTICE Do not stick and foreign matter on the sensor tip. a Install the speed sensor FR LH with the bolt. Torque 8.0 N m 82 kgf cm, 71 in. Ibf NOTICE b Install the sensor harness clamps with the 2 bolts A and B to the...

Remove Knock Sensor Mzfe Engine Type

a Disconnect the 2 knock sensor connectors. b Remove the 2 nuts and 2 knock sensors. 11. INSTALL KNOCK SENSOR 1MZ-FE ENGINE TYPE a Using SST, install the 2 knock sensors. SST 09249-63010, 09816-30010 Torque 39 N m 398 kgf cm, 29 ft Ibf b Connect the 2 knock sensors. 12. INSTALL KNOCK SENSOR 3MZ-FE ENGINE TYPE a Install the 2 knock sensors with the 2 nuts, as shown in the illustration. Torque 20 N m 199 kgf cm, 14 ft Ibf b Connect the 2 knock sensor connectors. a Install 2 new gaskets to the 2...

Partial Engine Assy Azfefrom July Components

Vane Pump Assy Transverse Engine Engine Mounting Bracket Vane Pump Assy Transverse Engine Engine Mounting Bracket Frame Suspension Member Brace Rear RH Frame Suspension Member Brace Rear RH Frame Suspension Member Brace Rear LH Frame Suspension Member Brace Rear LH o N m kgfcm, ft-Ibf Specified torque Vane Pump Assy Transverse Engine Engine Mounting Bracket Frame Suspension Member Brace Rear LH Nm kgfcm, ft lbf Specified torque Intake Manifold Runner Valve Assy A Gasket N m kgf cm, ft-lbf gt...

Perform the torque with the lower limit value of the torque tolerance

4 Some seal lock agents harden slowly. You may have to wait for the seal lock agent to harden. 1 When necessary, use a sealer on gaskets to prevent leaks. 1 Carefully follow all the specifications for tightening torques. Always use a torque wrench. 1 When replacing fuses, be sure that the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. Medium Current Fuse and High Current Fuse Equal Amperage Rating 1 The removal and installation methods of...

Check Short Circuit

If the wire harness is ground shorted Fig. 5 , locate the section by conducting a resistance check with the body ground below . b Check the resistance with the body ground. 1 Disconnect connectors A and C and measure the resistance between terminals 1 and 2 of connector A and the body ground. Resistance 10 kil or higher Measure the resistance while lightly shaking the wire harness vertically and horizontally. Fig. 6 Between terminal 1 of connector A and body ground Below 1 Q Between terminal 2...

Ventilation Valve Subassy Mzfemzfe Replacement

REMOVE VENTILATION VALVE SUB-ASSY a Disconnect the PCV hose from the PCV valve. 2. INSTALL VENTILATION VALVE SUB-ASSY 1 Apply adhesive to 2 or 3 threads. Adhesive Part No. 08833-00070, THREE BOND 1324 or equivalent 2 Reinstall the PCV valve. Torque 19 N m 193 kgf cm, 14 ft Ibf b Connect the PCV hose to the PCV valve.

Vehicle Identification And Serial Numbers

a The vehicle identification number is stamped on the vehicle identification number plate and certification label, as shown in the illustration. A Vehicle Identification Number Plate B Certification Label a World manufacture identifier is used to distinguish between TMC and TMMK made vehicles. The first 3 digits and letters of the vehicle identification number shows the world manufacturer identifier. 3. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER a The engine serial number is stamped on...

Remove Rear Door Glass Run Lh

Rav4 Door Torx Bolt

REMOVE REAR DOOR WEATHERSTRIP LH a Using a screwdriver, remove the door weatherstrip. HINT Tape the screwdriver tip before use. 9. REMOVE REAR DOOR BELT MOULDING ASSY LH See page 76-13 10. REMOVE REAR DOOR WINDOW FRAME SUB-ASSY REAR LOWER LH b Remove the 2 bolts and window frame rear lower. 11. REMOVE REAR DOOR QUARTER WINDOW GLASS LH a Remove the quarter window glass. 12. REMOVE REAR DOOR GLASS SUB-ASSY LH HINT Insert a shop rag inside the door panel to prevent scratching the glass. b Tilt...

Disconnect Steering Intermediate Shaft Assy

2004 Toyota Sienna Magnetic Relay

b Place matchmarks on the steering intermediate shaft and control valve shaft. c Remove the bolt and disconnect the steering intermediate shaft. d To prevent the steering wheel from rotating, fix the wheel If the steering wheel is not fixed, the spiral cable will be damaged. 49. REMOVE GENERATOR ASSY See page 19-42 50. REMOVE GENERATOR BRACKET NO.2 51. REMOVE GENERATOR BELT ADJUSTING BAR a Remove the 2 bolts, 2 nuts and the adjusting bar. 52. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH a Remove...

Adjust Valve Clearance

Cams Valve Corolla 1997

a Turn the camshaft so that the cam lobe faces upward. b Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. c Using SST A , press down the valve lifter and place SST B between the camshaft and valve lifter. Remove SST A . SST 09248-55040 09248-05410, 09248-05420 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...

Install Clutch Pedal Bush

Clutch Pedal Circuit Diagram

a Apply MP grease to both side of 2 new bushes. b Install the 2 bushes to the clutch pedal sub-assy. a Install the clutch pedal sub-assy to the clutch pedal support with the bolt and nut. Torque 37 N m 375 kgf cm, 27 ft Ibf Install the bolt from the right side of the vehicle. b Install the clutch pedal spring. 22. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING a Apply MP grease to the contact surface of the bush and spring. b Install the compression spring. c Using needle nose pliers,...

Knock Sensor Mzfemzfe Replacement

Knock Sensor Toyota Carina

DISCHARGE FUEL SYSTEM PRESSURE See page11-26 2. DRAIN ENGINE COOLANT See page 16-27 3. REMOVE V-BANK COVER SUB-ASSY See page 10-18 4. REMOVE AIR CLEANER CAP SUB-ASSY See page 10-18 5. REMOVE EMISSION CONTROL VALVE SET See page 11-38 6. REMOVE INTAKE AIR SURGE TANK See page 11-38 1 Remove the fuel pipe clamp. 2 Pinch the tube connector and then pull out the fuel pipe No. 1. Check the connector for dirt, mud or other contamination. Clean if necessary. Be sure to keep the tube connector, pipe...

Front Differential Oil Seal Ue Replacement

REMOVE ENGINE UNDER COVER LH 4. DRAIN AUTOMATIC TRANSAXLE FLUID a Remove the drain plug and gasket, and drain the ATF. b Install a new gasket and the drain plug. Torque 49 N m 500 kgf cm, 36 ft Ibf 5. REMOVE FRONT DRIVE SHAFT ASSY RH SEE PAGE 30-8 6. REMOVE FRONT DRIVE SHAFT ASSY LH SEE PAGE 30-8 SST 09520-01010, 09520-24010 09520-32040 7. REMOVE TRANSAXLE HOUSING OIL SEAL a Using SST, pull out the oil seal. SST 09308-00010 8. REMOVE DIFFERENTIAL SIDE BEARING...

Install Front Axle Inboard Joint Boot Lh No Clamp

1999 Toyota Camry Front Axle Boot

1 Using pliers, install the inboard joint boot LH No.2 clamp, as shown in the illustration. Install new inboard joint boot clamps. 1 Hold the drive shaft lightly in a soft vise. 2 Install 2 new inboard joint boot clamps to the boot. 3 Place SST onto the inboard joint boot LH No.2 clamp. 4 Tighten the SST so that the inboard joint boot LH No.2 clamp is pinched. 5 Using SST, measure the clearance of the inboard joint boot LH No.2 clamp. SST 09240-00020 Clearance 1.9 mm 0.075 in. or less NOTICE...

Charcoal Canister Assy Mzfemzfe Replacement

Toyota Charcoal Canister Removal Hose

REMOVE FUEL TANK ASSY See page 11-52 a Disconnect the fuel tank vent hose. 1 Push the connector deep into the charcoal canister assy to release the locking tab. b Disconnect the VSV connector for CCV. c Disconnect the fuel emission hose. d Disconnect the air inlet line hose. e Remove the 2 bolts and charcoal canister. 3. INSTALL CHARCOAL CANISTER ASSY Torque 39.2 N m 400 kgf cm, 29 in. Ibf 4. INSTALL FUEL TANK ASSY See page 11-52

Remove Front Door Trim Board Subassy Lh

2004 Sienna Sliding Door Handle Torx

d Using a screwdriver, remove the trim board. HINT Tape the screwdriver tip before use. e Remove the inside handle then disconnect the 2 cables from the door lock. 5. REMOVE FRONT DOOR SERVICE HOLE COVER LH a Disconnect each connector and remove the service hole cover. NOTICE Remove the remaining tape on the body side. 6. REMOVE FRONT NO.1 SPEAKER ASSY b Remove the 4 bolts and front No.1 speaker. 7. REMOVE FRONT DOOR GLASS SUB-ASSY LH Insert a shop rag inside the door panel to prevent...

Water Pump Assy Azfefrom July Replacement

Where Water Pump 2006 Camery

DRAIN ENGINE COOLANT See page 16-6 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE ENGINE MOVING CONTROL ROD W BRACKET See page 14-29 5. REMOVE ENGINE MOUNTING STAY NO.2 RH See page 14-29 6. REMOVE ENGINE MOUNTING BRACKET NO.2 RH See page 14-29 7. REMOVE FAN AND GENERATOR V BELT See page 14-5 8. REMOVE GENERATOR ASSY See page 19-17 a Using SST, remove the 4 bolts and pump pulley. SST 09960-10010 09962-01000, 09963-00700 b Disconnect the crankshaft position sensor wire harness clamp. a Remove...

Disconnect Transmission Wire

Shift Solenoid Toyota Rav4 Location

a Disconnect the 7 shift solenoid valve connectors. b Remove the bolt and lock plate, and disconnect the ATF temperature sensor. 5. REMOVE VALVE BODY OIL STRAINER ASSY a Remove the 3 bolts and oil strainer. NOTICE Be careful that some fluid will come out of the oil strainer. b Remove the O-ring from the oil strainer. 6. REMOVE TRANSMISSION VALVE BODY ASSY a Support the valve body assy and remove the 17 bolts and Be careful not to drop the check ball, spring and accumulator piston. b Remove the...

Do not apply heat directly to the parts in the ECU

Ikz Ecu Diagnostic Code Diagram

WATER SPRINKLING METHOD When the malfunction seems to occur on a rainy day or in high-humidity. a Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by applying water spray onto the front of the radiator. Never apply water directly onto the electronic components. If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or...

Window Glass Antenna Wire Repair

INSPECT WINDOW GLASS ANTENNA WIRE NOTICE When cleaning the glass, use a soft, dry cloth, and wiper the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown in the illustration. a Inspect the continuity, at the center of each antenna wire, as shown in the...

Skid Control Sensor Replacement

Skid Control Sensor Sst 09520 00031

Replace the RH side by the same procedure with LH side. 1. REMOVE REAR WHEEL 2. DISCONNECT SKID CONTROL SENSOR WIRE a Disconnect the connector from the skid control sensor. 3. REMOVE REAR DISC BRAKE CALIPER ASSY LH See page 32-44 5. REMOVE REAR AXLE HUB amp BEARING ASSY LH a Remove the 4 bolts and rear axle hub amp bearing assy. a Mount the rear axle hub in a soft jaw vise. NOTICE Replace the axle hub assembly if it is dropped or a strong shock is given to it. b Using a pin punch and hammer,...

Inspect Charcoal Canister Assy Pzev

Canister Assy Charcoal Rav4

a Visually check the charcoal canister for cracks or damage. b Inspect the charcoal canister operation. 1 While holding the purge port closed, blow air 0.39 kPa, 4.0 gf cm2, 0.06 psi into the vent port, and check that air flows from the air line port. 2 While holding the air line port closed, blow air 0.39 kPa, 4.0 gf cm2, 0.06 psi into the vent port, and check that air flows from the purge port. 3 While holding the air line port closed, apply vacuum 3.43 kPa, 25.7 gf cm2, 1.01 psi to the vent...

Inspect Vacuum Switching Valve Assy For Evap

a Check the VSV for open circuit. 1 Measure the resistance. If the resistance is not as specified, replace the VSV assy. 1 Check that air does not flow from the port as shown in the illustration. 2 Apply battery positive voltage across the terminals. 3 Check that air flows from the port as shown in the illustration. If the result is not as specified, replace the VSV assy.

Check Pedal Free Play

Camry Stop Lamp Switch

a Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. b Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown. Pedal free play 1 - 6 mm 0.04 - 0.24 in. If incorrect, check the stop lamp switch assy clearance. If the clearance is OK, then troubleshoot the brake system. Stop lamp switch clearance 0.5 - 2.5 mm 0.020 - 0.098 in.

Bleed Brake Line

a Connect the vinyl tube to the brake caliper. b Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. c At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. d Repeat b and c until all the air in the fluid has been bled out. e Tighten the bleeder plug completely. Torque 8.3 N m 85 kgf cm, 74 in. Ibf f Repeat the above procedure to bleed the air out of the brake line for each wheel. 4. BLEED BRAKE ACTUATOR ASSY...

Remove Rear Disc Brake Anti Squeal Shim

a Remove the 2 anti-squeal shims and pad wear indicator from each of 2 brake pads. Remove the 2 pad wear indicator plates from each of 2 brake pads. Remove the pad wear indicator plate from inner pad. 8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE a Remove the rear disc brake pad support plate No.1. 9. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE a Remove the rear disc brake pad support plate No.2.

Do not remove the radiator cap while the engine and radiator are still hot Pressurized hot engine coolant and steam may

Radiator And Engine Plugs Camry

b Drain engine coolant by loosening the radiator drain plug and the engine's water drain plug. HINT Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. c Tighten the cylinder block drain cock plugs. Torque 13 N m 130 kgf cm, 10 ft Ibf

Install Front Axle Hub Subassy Lh

Nut Hub Remove Disc Toyota Rav

a Using SST and a press, install the front axle hub sub-assy LH. SST 09608-32010, 09950-60020 09951-00790 , 09950-70010 09951-07100 18. INSTALL FRONT AXLE HUB LH HOLE SNAP RING a Using snap ring pliers, install a new front axle hub LH hole snap ring. 19. FRONT WHEEL BEARING DUST DEFLECTOR NO.1 LH a Using SST and a hammer, install the bearing dust deflector No.1 LH. SST 09316-60011 09316-00011, 09316-00031 , 09608-32010 Align the hole for the speed sensor in the bearing dust deflector No.1 LH...

Inspect Vribbed Belt

Compression Gauge 95506

a Using a belt tension gauge, check the belt tension. Belt tension gauge DENSO BTG-20 95506-00020 Borroughs No. BT-33-73F Drive belt tension Cooler compressor to crankshaft pulley Cooler compressor to crankshaft pulley After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crankshaft pulley. New belt is a belt which has been used less than 5 minutes on a running...

Install Parkneutral Position Switch Assy

a Install the park neutral position switch to the manual valve shaft. b Temporarily install the 2 bolts. c Place a new lock plate and tighten the nut. Torque 6.9 N m 70 kgf cm, 61 in. Ibf d Temporarily install the control shaft lever. e Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. f Remove the control shaft lever. g Align the groove with neutral basic line. h Hold the switch in position and tighten the 2 bolts. Torque 5.4 N m 55 kgf cm, 48 in. Ibf i Using a...

Install Release Bearing Hub Clip

a Install the release bearing hub clip to the release bearing assy. 18. INSTALL CLUTCH RELEASE FORK SUB-ASSY a Apply release hub grease to the release fork and release bearing assy contact, release fork and push rod contact and release fork pivot points. Part No. 08887-01806, RELEASE HUB GREASE or equivalent b Install the release fork to the release bearing assy. 19. INSTALL CLUTCH RELEASE BEARING ASSY a Apply the clutch spline grease to the input shaft spline. Sealant Part No. 08887-01706,...

Inspect Evap System Line

a Warm up and stop the engine. 1 Warm up the engine to normal operating temperature. b Install a vacuum gauge EVAP control system test equipment vacuum gauge to the EVAP service port on the purge line. c Connect the hand-held tester to the DLC3. e Turn the hand-held tester main switch ON. f Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for EVAP. g Check the vacuum while the engine is idling. Standard

Knock Sensor Azfe Replacement

Sensores Camry 2002

DRAIN ENGINE COOLANT See page 16-6 2. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 3. REMOVE THROTTLE BODY ASSY See page 10-6 a Remove the 5 bolts, 2 nuts, intake manifold and gasket. a Disconnect the knock sensor connector. b Remove the nut and knock sensor. a Install the knock sensor with the nut. Torque 20 N m 204 kgf cm, 15 ft Ibf b Connect the knock sensor connector. a Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque 30 N m 306 kgf cm, 22 ft Ibf 8....

Steering Sensor Replacement

SEPARATE BATTERY NEGATIVE TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO.2 5. REMOVE STEERING WHEEL COVER LOWER NO.2 4 SPOKE STEERING WHEEL ASSY 6. REMOVE STEERING WHEEL COVER LOWER NO.3 3 SPOKE STEERING WHEEL ASSY 7. REMOVE HORN BUTTON ASSY See page 60-25 8. REMOVE STEERING WHEEL ASSY See page 50-9 or 50-21 SST 09950-50013 09951-05010, 09952-05010, 09953-05020, 09954-05021 9. REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 71-16 10. REMOVE...

Adjust Hood Subassy

a Loosen the hood side hinge bolts. b Adjust the clearance so that it will be in the standard value, by moving the hood. c Tighten the hood side hinge bolts after adjustment. Torque 26 Nm 265 kgfcm, 19 ft Ibf d Adjust the height of the hood front end by the cushion gum. The cushion gum goes up and down by turning it. e Using a screwdriver, remove the hood lock release lever cover. Tape the screwdriver tip before use. NOTICE Removing the protector damages the clips inside the protector, and...

Push rod play at pedal top mm in

e Adjust the pedal free play and push rod play. 1 Remove the instrument panel sub-assy upper. 2 Remove the instrument panel insert sub-assy lower LH. 4 Loosen the lock nut and turn the push rod until the free play and push rod play are correct. 6 After adjusting the pedal free play, check the pedal height. 8 Install the instrument panel insert sub-assy lower LH. 9 Install the instrument panel sub-assy upper. f Check the clutch release point. 1 Pull the parking brake lever and install wheel...

Front Brake Components

Lithium Soap Base Glycol Grease

Front Disc Brake Cylinder Mounting LH Front Disc Brake Cylinder Mounting LH Nm kgfcm, ft lbf Specified torque Non-reusable part Lithium soap base glycol grease Disc brake grease Cylinder Boot Front Disc Brake Cylinder Slide Pin No.2 Nm kgfcm, ft lbf Specified torque Front Disc Brake Pad Wear Pad Support Plate No.2 Indicator Plate Front Disc Brake Pad Support Plate No.1 Non-reusable part Lithium soap base glycol grease Disc brake grease

Remove Air Cleaner Cap Subassy

a Disconnet the MAF meter connector. b Disconnect the VSV connector. c Remove the ventilation hose No. 2. d Disconnect the emission tube No. 1 fuel hose. e Disconnec the vacuum hoses. f Remove the fuel vapor feed hose from the 2 hose clamps. g Loosen the air cleaner hose clamp bolt, and then remove the intake air resonator.

Remove Front Wheel Bearing Dust Deflector Lh No Wo

Dust Cover Drive Shaft Bearing

a Mount the front drive outboard joint shaft assy LH in a soft jaw vise. b Using a screwdriver and a hammer, remove the front wheel bearing dust deflector LH No.2. 24. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING a Using a screwdriver, remove the hole snap ring. 25. REMOVE FRONT DRIVE SHAFT DUST COVER LH a Using SST and a press, remove the front drive shaft dust cover LH. Be careful not to drop the inboard joint assy. 26. REMOVE FRONT DRIVE SHAFT DUST COVER RH a Using a press, remove the front...

Front Axle Hub Subassy Lh From July Replacement

Use the same procedures for the RH side and LH side. The Procedures listed below are for the LH side. 2. REMOVE FRONT AXLE HUB LH NUT SEE PAGE 30-8 SST 09930-00010 3. DISCONNECT SPEED SENSOR FRONT LH W ABS SEE PAGE 30-8 4. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH a Remove the 2 bolts and separate the front disc brake caliper assy LH from the steering knuckle LH. NOTICE Use a string or other device to keep the brake caliper from hanging down by the flexible hose. 6. SEPARATE TIE ROD ASSY LH...

Inspect Valve Clearance

a Turn the crankshaft pulley, and align the timing notch with timing mark 0 of the No. 1 timing belt cover. b Check that the valve lifters on the No. 1 timing belt cover IN and EX are both loose. If not, turn the crankshaft 1 revolution 360- and align the mark as above. c Check the valves indicated in the illustration on the left. 1 Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance Cold 0.15 to 0.25 mm 0.006 to 0.010 in. 0.25 to 0.35 mm 0.010 to...

Inspect Fuel Cutoff Valve And Fill Check Valve

a Disconnect the vent line hose from the fuel tank see page 11-52 . b Connect the pressure gauge to the fuel tank. c Fill the fuel tank with fuel until full. d Apply pressure of 4 kPa 41 gf cm2, 0.58 psi to the vent port of the fuel tank. It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. e Remove the fuel tank cap, and check that pressure drops. If pressure does not drop,...