Assembly Of Steering Column

APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (See page SR-7) (a) Install the bearing, thrust collar and spring to the main shaft. (b) Insert the main shaft into the upper column tube. (c) Using SST to compress the main shaft spring, install the snap ring with snap ring pliers. Select the bolt with the plain thread end when the upper column tube mark is 2, and the bolt with the hollow-tipped thread end when the mark is 1. 4. INSTALL MAIN SHAFT WITH UPPER COLUMN TUBE (a) Install the collar to...

Control Relays Inspection Control Relays

Remove the two control relays from the actuator. 2. INSPECT PUMP MOTOR RELAY CONTINUITY (a) Check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 4. (c) Check that there is no continuity between terminals 1 and 4. If continuity is not as specified, replace the relay. 3. INSPECT PUMP MOTOR RELAY OPERATION (a) Apply battery voltage to terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. (c) Check that...

Electronic Control System

Before removing EFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. HINT Always check the diagnosis code before disconnecting the battery terminals. 2. When installing the battery, be especially careful not to incorrectly connect the positive ( + ) and negative (-) cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all EFI parts carefully, especially the...

Inspection Of Diagnosis System

Inspect that the battery voltage is about 12 V. 2. CHECK THAT WARNING LIGHT TURNS ON (a) Turn the ignition switch on. (b) Check that the ABS warning light turns on for 3 seconds. If not, inspect and repair or replace the fuse, bulb and wire harness. (c) Check that the ABS warning light turns off. (d) Turn the ignition switch off. (a) Using SST, connect terminals E1 and Tc, Ts of the check connector. (b) Pull the parking brake lever up, and start the engine. HINT Do not depress the brake pedal....

Inspection Of Cold Start Injector

Toyota Carina Cold Start Valve

INSPECT INJECTION OF COLD START INJECTOR CAUTION Keep injector clear of sparks during the test. a Install SST two unions to the injector and delivery pipe with four new gaskets and the union bolts. b Connect SST hose to the unions. SST 09268-41045 c Connect SST wire to the injector. SST 09842-30050 d Put a container under the injector. e Using SST, connect terminals B and FP of the check connector. f Reconnect the battery negative - cable. g Turn the ignition switch ON. NOTICE Do not start...

Inspection Cleaning And Repair Of Cylinder Head Components

CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK a Turn the crankshaft and bring each piston to top dead center TDC . Using a gasket scraper, remove all the carbon from the piston top surface. b Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. c Using compressed air, blow carbon and oil from the bolt holes. CAUTION Protect your eyes when using high-com-pressed air. Using a gasket scraper, remove all the gasket material from the cylinder block...

Removal Of Component Parts

2002 Toyota Mr2 Parts Shift Lever Switch

REMOVE RELEASE FORK AND BEARING Remove the back-up light switch and gasket. a Remove the retaining bolt and plate. b Pull out the speedometer driven gear. 5. REMOVE SELECTING BELLCRANK ASSEMBLY AND ENGINE MOUNTING BRACKET a Loosen the lock nut as far as the tip of the lock pin. b Using a brass bar and hammer, tap out the lock pin. c Pull out the shift lever with dust boot from shift and select lever shaft. 7. REMOVE NO.1 AND NO.2 LOCK BALL ASSEMBLIES a Loosen the lock nut and remove the No.1...

Assembly Of Differential

Dismantling 1kz Transmission

HINT Coat all of the sliding and rotating surface with ATF before assembly. a Install the thrust washer to the side gear. b Install the side gears with thrust washers, pinion gears and pinion thrust washers into the differential case. c Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case. a Measure the side gear backlash while holding one pinion gear toward the case. If the backlash is out of specification, install the correct b Referring to the...

Toyota Mk2 Mr2 Oil Pressure

Engine Lubrication System Bj4

A fully pressurized, fully filtered lubrication system has been adopted for this engine. A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes through...

Installation Of Component Parts

How Install Slotted Pin Spring

HINT Coat all of the sliding and rotating surface with ATF before assembly. 1. INSTALL AND TORQUE NO. 1 OIL RECEIVER PIPE TO TRANSMISSION CASE Torque 75 kg-cm 65 in.-lb, 7.4 N-m 2. INSTALL TRANSAXLE OIL RECEIVER AND PLATE TO TRANSAXLE CASE a Install and torque the oil receiver. Torque 75 kg-cm 65 in.-lb, 7.4 N-m b Install and torque the plate. Torque 185 kg-cm 13 ft-lb, 18 N-m a Insert No. 2 fork shaft to the transaxle case and align the slotted spring pin hole. b Using a pin punch and hammer,...

Voltage at ECU Wiring Connectors

2015 Corolla Cruise Control Ecu

Throttle valve fully closed Throttle opener must be cancelled first No trouble CHECK engine warning light off and engine running Throttle valve fully closed Throttle opener must be cancelled first J Vacuum Sensor Manifold Absolute Pressure Sensor Intake air temperature 20 C 68 F jn There is no voltage between ECU terminals THA and E2. IG SW ON Check that there is voltage between ECU terminal B or B1 and body ground. IG SW ON Check wiring between ECU terminal E1 and body ground. Check intake air...

Function Of Components

Squib Toyota Tacoma Airbag

The front airbag sensors are mounted inside of the radiator upper support. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit in a collision, the contacts in the sensor make contact, sending a signal to the center airbag sensor assembly. 2. SPIRAL CABLE in COMBINATION SWITCH A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. The inflater and bag of the airbag system are stored in the steering...

Inspection Of Piston And Connecting Rod Assemblies

How Measure Connecting Rods

a Using a gasket scraper, remove the carbon from the piston top. c Using solvent and a brush, thoroughly clean the piston. HINT There are three sizes of the standard piston diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the piston top. a Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23.5 mm 0.925 in. from the piston head. STD Mark 1 86.911 - 86.921 mm 3.4217-3.4221 in. Mark 2 86.921 - 86.931 mm 3.4221 - 3.4225 in. Mark 3 86.931...

Onvehicle Inspection

Avalon Ecm Circuit Check Without Vehicle

INSPECT BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL a Check the specific gravity of each cell. 1.25 - 1.27 when fully charged at 20 C 68 F If not within specification, charge the battery. b Check the electrolyte quantity of each cell. If insufficient, refill with distilled or purified water. 2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES a Check that the battery terminals are not loose or corroded. b Check the fusible links and fuses for continuity. b Check the fusible links and...

Separate Basic Subassembly

REMOVE TRANSMISSION DIPSTICK AND FILLER TUBE a Remove the manual shift lever. b Pry off the lock washer and remove the manual valve shaft nut. c Remove the two bolts and pull out the neutral start switch. a Using the open end wrench, remove the union. b Remove the O-ring from union. 5. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE 6. REMOVE SOLENOID WIRE RETAINING BOLT AND PLATE 7. REMOVE SPEED SENSOR AND SENSOR ROTOR a Remove the retaining plate and pull out the speed sensor. b Remove the...

Installation Of Cylinder Head

Egr Vsv Instal Rav4

Place cylinder head on cylinder block a Place a new cylinder head gasket in position on the cylinder block. NOTICE Be careful of the installation direction. b Place the cylinder head in position on the cylinder head gasket. The cylinder head bolts are tightened in two progressive steps steps b and d . If any cylinder head bolt is broken or deformed, replace it. a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. b Using SST, install and uniformly...

Power Steering

a Check that there is continuity between terminals GND and SGND. b Disconnect the connector and inspect the connector on the wire harness side as shown. Power steering motor brushes installed Power steering motor brushes removed Connect terminals Tc and of check connector Ignition switch ON and spin slowly rear wheel c Inspect the system circuit with the connector connected. Ignition switch ON and engine stopped Ignition switch ON and power steering motor brushes installed Ignition switch ON...

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

Remove Ignition Coil And Igniter

Mr2 Cooling Fan Ecu

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...

Disassembly Of Differential Case

Differential Cases Toyota

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,...

Removal Of Alternator

Carib Power Steering Belt

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,...

Installation Of Injectors

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

Oil Pressure Switch Location 1989 Supra

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...

Inspection And Adjustment Of Valve Clearance

Cylinder Tdc Corolla 2002

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...

Exhaust Gas Recirculation Egr System

1996 Toyota Corolla Egr

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.

Installation Of Timing Belt

Bolt Torque Toyota Tercel

a Align the cutouts of the pulley and shaft, and slide on the pulley. b Using SST, install the nut. 2. INSTALL CRANKSHAFT TIMING PULLEY a Align the timing 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 425 kg-cm 31 ft-lb, 42 Nm HINT Use bolt 35 mm 1.38 in. in length, b Check that the idler pulley moves smoothly. 4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND a Install the pulley with the...

Installation Of Rear Drive Shaft

Mr2 Drive Shaft Seal Installation

INSTALL DRIVE SHAFT BEARING BRACKET AND BEARING BRACKET STAY a Install the bearing bracket to the engine with the two bolts. Torque 650 kg-cm 47 ft-lb, 64 N-m b Install the two bearing bracket stays to the engine and bearing bracket with the two bolts and the nut. Bolt 770 kg-cm 56 ft-lb, 75 N-m Nut 770 kg-cm 56 ft-lb, 75 N-m a Apply the oil seal lip with MP grease. b Using a brass bar and hammer, drive in the drive shaft until it makes contact with the pinion shaft. NOTICE Be careful not to...

91 Mr2 Valve Spring Remover

HINT Arrange the valve lifters and shims in correct order. a Using SST, compress the valve spring and remove the two keepers. b Remove the spring retainer, valve spring, valve and spring seat. HINT Arrange the valves, valve springs, spring seats and spring retainers in correct order. c Using needle-nose pliers, remove the oil seal.

Bleeding Of Power Steering System

CHECK FLUID LEVEL IN RESERVOIR TANK Check the fluid level and add fluid if necessary. Fluid TOYOTA POWER STEERING FLUID EH Part No. 08886-01206 or equivalent HINT Check that the fluid level is within the HOT LEVEL of the dipstick. If the fluid is cold, check that it is within the COLD LEVEL of the dipstick. NOTICE Use only TOYOTA PS fluid EH or equivalent. Otherwise, you may not get expected power assist. 2. START ENGINE AND TURN STEERING WHEEL FROM LOCK TO LOCK THREE OR FOUR TIMES With the...

Cold Engine Operations

Sw20 Engine Coolant Drain Plug

a Remove the timing belt. 3S-GTE See pages EM-26 to 31 5S-FE See pages EM-47 to 52 3S-GTE See pages EM-35 to 41 5S-FE See pages EM-55 to 60 a Visually check the drive belt for excessive wear, frayed cords etc. If necessary, replace the drive belt. HINT Cracks on the ribbed side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. b Using a belt tension gauge, measure the drive belt tension. Nippondenso BTG-20 95506-00020...

Locations of Airbag Components

Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most important source of information when troubleshooting. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery See page AB-24 . 2. Work must be started after approx. 20 seconds or loner from the time the ignition switch is turned to the LOCK position and the negative - terminal cable is disconnected from the battery. The airbag system...

Inspect And Adjust Shift Cable

When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedure. a Remove the No. 1 engine under cover. b Loosen the swivel nut on manual shift lever. c Push the manual shift lever fully toward the right side of the vehicle. d Return the lever...

Inspection And Replacement Of Steering Column

Key Lock Cylinder Corolla E11

Check that the steering lock mechanism operates properly. 2. IF NECESSARY, REPLACE KEY CYLINDER a Place the ignition key at the ACC position. b Push down the stop pin with a thin rod, and pull out the key cylinder. c Make sure the ignition key is at the ACC position. d Install a new key cylinder. 3. IF NECESSARY, REPLACE MAIN SHAFT BUSHING b Using a screwdriver, remove the bushing. c Align the holes of the tube and projections of a new bushing, and insert the bushing in the column tube. Check...

Removal Of Cold Start Injector

Mr2 Cold Start Injector

See steps 1 to 8, 10 and 11 on pages FI-135 and 136 2. DISCONNECT COLD START INJECTOR CONNECTOR 3. REMOVE COLD START INJECTOR PIPE Remove the two union bolts and four gaskets and injector pipe. Put a suitable container or shop towel under the injector pipe. Slowly loosen the union bolt. Remove the two bolts, cold start injector and gasket. Union Bolt funion New Gasket- lt m gt Union Bolt funion New Gasket- lt m gt

Inspection Of Starter Relay

LOCATION In the luggage compartment on the left side. a Using an ohmmeter, check that there is continuity between terminals 1 and 3. b Check that there is no continuity between terminals 2 and 4. If continuity is not as specified, replace the relay. a Apply battery voltage across terminals 1 and 3. b Using an ohmmeter, check that there is continuity between terminals 2 and 4. If operation is not as specified, replace the relay.

Clearing Of Diagnostic Codes

a Turn the ignition switch on. b Using SST, connect terminals Tc and E1 of the check connector. HINT Keep the vehicle stopped vehicle speed 0 km h 0 mph . c Clear the diagnostic codes stored in ECU by depressing the brake pedal 8 or more times within 3 seconds. d Check that the warning light shows the normal code. e Remove the SST from terminals Tc and E1 of the check connector. f Check that the warning light goes off.

Check And Adjustment Of Clutch Pedal

How Release Clutch Pedal

CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet 184-194 mm 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resistance is felt. Push in on the pedal with a finger softly until the resistance begins to increase a little. Push rod play at pedal top 1.0 - 5.0 mm 4. IF NECESSARY,...

Installation Of Distributor

1989 Mr2 Distributor

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 hold-down bolt. f Install the high-tension...

Adjustment Of Valve Timing

1985 Toyota Mr2 Spark Timing Setup

REMOVE NO.2 TIMING BELT COVER See steps 1 to 6 and 9 to 12 on pages EM-26 to 28 2. REMOVE SPARK PLUGS See page IG-7 a Turn the crankshaft pulley, and align its groove with timing mark 0 of the No.1 timing belt cover. NOTICE Always turn the crankshaft clockwise. Check that the timing marks of the camshaft timing pulleys are aligned with the timing mark of the No.3 timing belt cover. If there is more than one timing pulley tooth between the timing marks, realign the timing marks in accordance...

Front Wheel Alignment

1991 Toyota Mr2 Wheel Specs

Measure toe-in with a toe-in gauge in the following procedure. a Bounce the vehicle up and down to stabilize the suspension. b Move the vehicle forward about 5 m 16.4 ft with the front wheel in the straight-ahead position on a level place. c Mark the center of each rear tread and measure the distance between the marks of the right and left tires. d Advance the vehicle until the marks on the rear sides of the tires come to the measuring heights of the gauge on the front side. HINT If the tire...

Mr2 Center Bearing Bracket

Center Bearings Mr2

Drive Shaft Assembly RH Drive Shaft Assembly LH _ Drive Shaft Assembly RH Drive Shaft Assembly LH _ Inboard Joint Sub-assembly Snap Ring kg-cm ft-lb, N m Specified torque Non-reusable part The axle bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the axle bearing, first support it with SST. SST 09570-22010, 09608-16041 09608-02010 After...

Inspection Of Abs Actuator Operation

INSPECT BATTERY VOLTAGE Battery voltage 10 - 14.5 V Disconnect the three connectors from the actuator as shown. A.B.S. Anti-lock Brake System ACTUATOR CHECKER A.B.S. Anti-lock Brake System ACTUATOR CHECKER 3. CONNECT ACTUATOR CHECKER SST TO a Connect the actuator checker SST to the actuator and body side wire harness through the sub-wire harness SST as shown. b Connect the red cable of the checker to the battery positive terminal and black to the negative - terminal. Connect the black cable...

Removal Of Engine

Engine Mounting Insulator Yaris 2007

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. 3. REMOVE ENGINE HOOD SIDE PANELS 5. DRAIN ENGINE COOLANT See page CO-6 6. DRAIN ENGINE OIL See page LU-7 Remove the two bolts, two nuts and upper brace. a Disconnect the intake air temperature sensor connector. b Disconnect the four air cleaner...

Inspection Of Engine Compartment Cooling Fan Components

INSPECT COOLING FAN ECU FOR CIRCUIT Disconnect the cooling fan ECU connector, and check the connector on the wiring harness side as shown in the chart. 2. INSPECT IGNITION MAIN RELAY IGN See page CH-18 3. INSPECT COOLING FAN MAIN RELAY VENT See page CO-23 Check the relay the same way as for the No.1 Cooling Fan Relay. 4. INSPECT ENGINE COMPARTMENT TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Approx. 2.45 kQ at 20 C 68 F Approx. 0.63 kQ at 57.5 C 135.5 F...

Remove Main Bearing Caps And Check Oil Clearance

Schematics Air Cleaner System Mr2 Sw20

a Remove the main bearing cap bolts. b Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers No.3 main bearing cap only . Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. HINT Keep the upper bearing and upper thrust washers together with the cylinder block. d Clean each main journal and bearing. e Check each main...

Replacement Requirements

Auris Service Airbag Replacement

In the following cases, replace the center airbag sensor assembly. NOTICE For replacement of the center airbag sensor assembly, see page AB-19, REMOVAL AND INSTALLATION. If the center airbag sensor assembly has been found to be faulty in troubleshooting. If the center airbag sensor assembly has been found to be faulty during the check in item 2. - b . If the center airbag sensor assembly has been dropped. HINT The airbag system wire harness is integrated with the cowl wire harness assembly and...

Removal Of Starter

1996 Toyota Tacoma Starter Location

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 LH ENGINE HOOD SIDE PANEL 3S-GTE See step 9 on page EM-134 5S-FE See step 9 on page EM-182 b Remove the nut, and disconnect the starter cable. c Remove the nut, and disconnect the starter wire. d Disconnect the starter connector. e Remove...

Bleeding Of Clutch System

HINT If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. NOTICE Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently. Add fluid if necessary. 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. a Slowly pump the clutch pedal several times. b While pressing on the pedal, loosen the...

Inspection Of Circuit Opening Relay

Toyota Circuit Opening Relay

a Using an ohmmeter, check that there is continuity between terminals STA and E1. b Check that there is continuity between terminals B and FC. c Check that there is no continuity between terminals B and FP. If continuity is not as specified, replace the relay. a Apply battery voltage across terminals STA and E1. b Using an ohmmeter, check that there is continuity between terminals B and FP. c Apply battery voltage across terminals B and FC. d Check that there is continuity between terminals B...

Removal Of Timing Belt

Timing Belt Toyota Tercel

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. 3. REMOVE RH ENGINE HOOD SIDE PANEL 4. REMOVE SUSPENSION UPPER BRACE See step 8 on page EM-134 5. REMOVE CRUISE CONTROL ACTUATOR w CRUISE CONTROL SYSTEM AND ACCELERATOR LINKAGE See step 13 on page EM-135 See steps 4, 5 and 7 to 13 on pages TC-20 to...

Installation Of Engine

Toyota Land Cruiser Ignition Igniter

ASSEMBLE ENGINE AND TRANSAXLE M T See pages MT-5 and 6 2. INSTALL STARTER See page ST-17 3. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE a Attach the engine chain hoist to the engine hangers. b Slowly lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH body mounting. c Keep the engine level, and align RH and LH mountings with the body mountings. d Attach the RH mounting insulator to the body, and temporarily install the through...

Installation Of Throttle Body

Avalon Egr Setup

INSTALL ISC VALVE TO THROTTLE BODY See step 1 on page FI-153 a Place a new gasket on the throttle body, facing the protrusion downward. b Install the throttle body with the four bolts. Torque 195 kg-cm 14 ft-lb, 19 N . m HINT Each bolt is indicated in the figure. a Water by-pass hose from water outlet b Water by-pass hose from water by-pass pipe e Two vacuum hoses from EGR vacuum modulator 5. CONNECT THROTTLE POSITION SENSOR CONNECTOR 7. CONNECT ACCELERATOR CABLE, AND ADJUST IT CONNECT...

Removal Of Fuel Pump

Mr2 Sw20 Top Remove

CAUTION Do not smoke or work near an open flame when working on the fuel pump. kg-cm ft-lb, Nm Specified Torque 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 FUEL PUMP CONNECTOR AND FUEL SENDER GAUGE CONNECTOR LH lower instrument finish panel Center instrument finish panel...

Inspection Of Ignition Main Relay

LOCATION In the engine compartment relay box. a Using an ohmmeter, check that there is continuity between terminals 1 and 3. b Check that there is continuity between terminals 2 and 4. c Check that there is no continuity between terminals 4 and 5. If continuity is not as specified, replace the relay. a Apply battery voltage across terminals 1 and 3. b Using an ohmmeter, check that there is no continuity between terminals 2 and 4. c Check that there is continuity between terminals 4 and 5. If...

EHPS Electro Hydraulic Power Steering

Power Steering Module Mr2 Sw20

In conventional and ordinary hydraulically-con-trolled power steering, hydraulic pressure needed for control is generated when the pump is turned by the engine. In the EH PS, the pump is turned by an electric motor. The ECU controls the voltage acting on the pump motor according to the movement of the steering wheel and the vehicle speed. The pump motor speed is changed accordingly to modulate the hydraulic pressure being generated in the pump.

Replacementof Crankshaft Oil Seals

How Replace The Cranksharf Oil Seal

HINT There are two methods A and B to replace the oil seal which are as follows 1. REPLACE CRANKSHAFT FRONT OIL SEAL A. If oil pump is removed from cylinder block a Using a screwdriver and hammer, tap out the oil seal. b Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. c Apply MP grease to the oil seal lip. B. If oil pump is installed to the cylinder block a Using a knife, cut off the oil seal lip. b Using a screwdriver, pry out the oil seal....

B Vacuum sensor hose from intake manifold

How Replace Egr Mr2 Mk1

c A C VSV vacuum hose from intake manifold d A C VSV air hose from ISC valve 12. REMOVE DISTRIBUTOR See pages IG-19 and 20 13. REMOVE FRONT EXHAUST PIPE See step 29 on page EM-187 14. REMOVE EXHAUST MANIFOLD AND CATALYTIC CONVERTER ASSEMBLY a Disconnect the oxygen sensor main connector. Disconnect the sub-oxygen sensor connector. c Remove the six bolts and manifold upper heat insulator. d Remove the two bolts, two nuts and catalytic converter stay. e Remove the six nuts, the exhaust manifold...

Chassis

1989 Toyota Mr2 Tie Rod Frame Mount

a Check the steering wheel freeplay. Maximum steering wheel freeplay 30 mm 1.18 in. With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. b Check the steering linkage for looseness or damage. Check that Tie rod ends do not have excessive play. Dust seals and boots are not damaged. Visually check the steering wheel pad airbag and infla- Use the diagnosis check to check if there are abnormalities. Check that there are no...

Disassembly Of Rear Drive Shaft

Disassembly Tripod Toyota

a Check to see that there is no play in the outboard joint. b Check to see that the inboard joint slides smoothly in the thrust direction. c Check to see that there is no remarkable play in the radial direction of the inboard joint. 2. REMOVE SNAP RING FROM INBOARD JOINT SHAFT Using a screwdriver, pry out the snap ring. a Using a screwdriver, remove the two boot clamps. b Slide the inboard joint boot toward the outboard joint. a Place matchmarks on the inboard joint tulip and tripod. b Remove...

Removal Of Oil Pump

2002 Rav4 Oil Pump Location

HINT When repairing the oil pump, the oil pan and strainer should be removed and cleaned. kg-cm ft-lb, Nm Specified torque kg-cm ft-lb, N m Specified torque kg-cm ft-lb, N m Specified torque 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 dosconnected from the battery. 2. DRAIN ENGINE OIL See page LU-6 4. REMOVE RH ENGINE...

Diagnostic Code Check

Mr2 Output Diagnostic Codes

a Turn the ignition switch to ON. b Using SST, connect terminals Tc and of the check connector. NOTICE Never make a mistake with the terminal connection position as this will cause a malfunction. Read the diagnostic code as indicated by the number of times the P S warning light blinks. The light will blink 2 times per second. Malfunction code indication In the event of a malfunction, the light will blink. The first number of the code No. will equal the first digit of a 2-digit diagnostic code,...

Inspection Of Toyota Variable Induction System T Vis Components

Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and intake manifold for warpage. Maximum warpage 0.20 mm 0.0079 in. If warpage is greater than maximum, replace the T-VIS valve. a With 400 mmhg 15.75 in.Hg, 53.3 kPa of vacuum applied to the actuator, check that the control valve moves smoothly to the fully closed position. b With the vacuum released, check that the control valve fully opens quickly. If operation is not as specified, replace the...

Removal Of Rear Drive Shaft

Mr2 Sw20 Removing Shaft

REMOVE COTTER PIN, LOCK NUT CAP AND BEARING LOCK NUT a Remove the cotter pin and lock nut cap. b With the parking brake engaged, remove the bearing lock nut. 4. LOOSEN SIX BOLTS HOLDING DRIVE SHAFT TO DIFFERENTIAL SIDE GEAR SHAFT OR CENTER DRIVE SHAFT a Place matchmarks on the drive shaft and side gear shaft. b With the parking brake engaged, using SST, loosen the six hexagon bolts. HI NT Do not remove the bolts, finger tighten them not to drop down the drive shaft. Remove the brake caliper...

Spark Test

a Disconnect the high-tension cord from the distributor. b Hold the end about 12.5 mm 0.50 in. from the body of car. c Check if spark occurs while engine is being cranked. HINT To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1-2 seconds at a time. If the spark does not occurs, perform the test as follows I CHECK POWER SUPPLY TO IGNITION COIL AND IGNITER 2. Check that there is battery voltage at Ignition coil positive terminal. Check...

Removal Of Shock Absorber Assembly

Toyota Mr2 Mk2 Rear Coilovers

a Remove the union bolt and two gaskets, and disconnect the brake hose from the disc brake caliper. HINT Drain the brake fluid into a container. b Remove the clip from the brake hose. c Pull off the brake hose from the brake hose bracket. Remove the speed sensor wire harness clamp bracket bolt. Disconnect the stabilizer link from the shock absorber. HINT If the ball joint stud turns together with the nut, use a hexagon wrench 5 mm 0.197 in. to hold the stud. 3. DISCONNECT SHOCK ABSORBER FROM...

Drainage Of Engine Coolant

Engine Coolant Drain Plug

REMOVE REAR FUEL TANK PROTECTOR 2. REMOVE FRONT LUGGAGE UNDER COVERS a Set the heater control lever to hot. CAUTION To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. c Drain the coolant from the radiator cock and engine drain plug engine drain plug are at the rear left of engine block and two radiator pipe plugs. Engine drain plug 3S-GTE 5S-FE Radiator drain plug 250 kg-cm 18...

Inspection And Adjustment Of Valve Clearance Sgte

How Turn The Crank Manually Avalon

HINT Inspect and adjust the valve clearance when the engine is cold. 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 N0.1 AIR INTAKE CONNECTOR See step 4 on page TC-20 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS See page IG-6 4. REMOVE EGR VACUUM MODULATOR AND VSV See step 22 on...

Inspection Of Radiator Cooling Fan Components

INSPECT A C AMPLIFIER FOR CIRCUIT Disconnect the A C amplifier connector, and check the connector on the wiring harness side as shown in the chart on the next page. 2. INSPECT FAN MAIN RELAY FAN MAIN See page CH-18 Check the relay in the same way as the Ignition Main Relay. 3. INSPECT NO.1 COOLING FAN RELAY FAN NO.1 a Using an ohmmeter, check that there is continuity between terminals 1 and 2. b Check that there is continuity between terminals 3 and 4. If continuity is not as specified,...

Assembly Of Cylinder

Sst 09756 00010

APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED BY ARROWS HINT Pack the lithium soap base glycol grease into areas marked A. Tap in the pin to the brake cylinder until the stopper pin extends 25 mm 0.98 in. . 3. INSTALL CABLE SUPPORT BRACKET Torque 475 kg-cm 34 ft-lb, 47 N-m a Using a 24 mm socket wrench and hammer, tap in new parking brake crank boot shown in the figure. b Confirm that the metal plate portion of the parking brake crank boot fits snugly in the cylinder. a Check that...

DAC VSV air hose from No air tube

Egr Vacuum Toyota Engine

REMOVE RH FRONT ENGINE HANGER Remove the three bolts and engine hanger. See steps 4, 5, 7, 8 and 10 to 13 on pages TC-20 to 22 See step 30 and 31 on pages EM-138 and 139 a Remove the four bolts and RH converter stay. b Remove the three bolts and LH converter stay. c Remove the three bolts, two nuts and catalytic converter. Remove the gasket, retainer and cushion. d Remove the five bolts and front heat insulator. e Remove the four bolts and rear heat insulator. See steps 8,11,12 and 18 to 24...

Installation Of Water Pump

1992 Camry Water Pass Pipes

INSTALL THERMOSTAT AND WATER INLET TO WATER PUMP COVER See steps 1 and 2 on page CO-15 2. ASSEMBLE WATER PUMP AND WATER PUMP COVER Install a new gasket and the water pump to the pump cover with the three bolts. Torque 95 kg-cm 82 in.-lb, 9.3 Nm 3. INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY a Install new O-ring and gasket to the water pump cover. b Install a new O-ring to the water by-pass pipe. c Apply soapy water to the O-ring on the water bypass pipe. d Connect the pump cover to the...

Replacement Of Brake Pads

Corolla Brake Anti Squeal

HINT If a squealing noise is made by the front brakes while driving, check the pad wear indicator. If there is evidence of the indicator contacting the rotor disc, the brake pad should be replaced. Remove the wheel and temporarily fasten the rotor disc with the hub nuts. Check the pad thickness through the cylinder inspection hole and replace the pads if it is not within specification. Minimum thickness 1.0 mm 0.039 in. a Remove the installation bolt from the torque plate. b Lift up the brake...

Refill Of Engine Coolant

Mr2 Turbo Coolant Bleed Points

REMOVE FRONT LUGGAGE COMPARTMENT TRIM 3. REMOVE UPPER RADIATOR SUPPORT SEAL a Connect the service hoses to the radiator air drain and heater valve. b Suspend the opposite end to the service hose connected to radiator air drain to the front hood stay. c Suspend the opposite end to the service hose connected to heater valve to the front hood. NOTICE Do not close-off or pinch any of the service a Set the heater control lever to hot. b Open the radiator and heater air drain plugs above three...

Removal Of Radiator

Toyota Rav4 Cooling Fan Sensor

Sensor Connector w A C or Water Temp. amp Switch Connector w o A C Water Temp. Sensor Connector w A C or Water Temp. amp Switch Connector w o A C 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. DRAIN ENGINE COOLANT See page CO-6 Remove the seven clips and support seal. 7. DISCONNECT...

Check And Adjustment Of Parking Brake

Mr2 Handbrake Adjustment

CHECK THAT PARKING BRAKE LEVER TRAVEL IS a Pull the parking brake lever all the way up and down for two or three times. Then return the parking brake lever. b Depress the brake pedal for several times. c Pull the parking brake lever all the way up, and count the notches of lever travel. Parking brake lever travel at 20 kg 44.1 lb, 196 N 5-8 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE a Pull the parking brake lever all the way up and down for two or...

Inspection And Adjustment Of Idle Speed

Egr Toyota 1kz

a Engine at normal operating temperature c All pipes and hoses of air induction system connected HINT All vacuum hoses for EGR systems, etc. should be properly connected. e EFI system wiring connectors fully plugged f All operating accessories switched OFF g Transmission in neutral range 2. CHECK ISC SYSTEM See page FI-151 3. CONNECT TACHOMETER See page IG-21 a Using SST, connect terminals TE1 and E1 of the check connector. HINT Decrease the rpm after the engine maintains a speed of the 1,000...