service repair manual

1. TOYOTA
REPAIR
MANUAL
• MAINTENANCE
• PREPARATION
• SPECIFICATIONS
•DIAGNOSTICS
Pub. No. RM744U1 VOLUME 1

2. NOTE: The screen toned sections below are in VOLUME 2
(Pub. No. RM744U2).
INTRODUCTION
MAINTENANCE
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
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AIR
ALPHABETICAL INDEX If

3. NOTE:ThescreentonedsectionsbelowareinVOLUME1
(Pub. No. RM744U1).
Ill a
ENGINE MECHANICAL
EMISSION CONTROL
SFI
COOLING
LUBRICATION
IGNITION
STARTING
CHARGING
CLUTCH
C56 MANUAL TRANSAXLE
C60 MANUAL TRANSAXLE
U240E AUTOMATIC TRANSAXLE
U341E AUTOMATIC TRANSAXLE
SUSPENSION AND AXLE
BRAKE
STEERING
SUPPLEMENTAL RESTRAINT SYSTEM
BODY ELECTRICAL
BODY
AIR CONDITIONING
ALPHABETICAL INDEX

4. ENGINE MECHANICAL
CO/HC EM-1
COMPRESSION EM-3
VALVE CLEARANCE EM-4
IGNITION TIMING EM-13
IDLE SPEED EM-14
TIMING CHAIN EM-15
CYLINDER HEAD EM-36
ENGINE UNIT EM-70
CYLINDER BLOCK EM-85J
EXHAUST SYSTEM EM-115

5. EM-1
ENGINE MECHANICAL - CO/HC
CO/HC EMOSJ-OS
INSPECTION
HINT:
This check is used only to determine whether or not the idle
CO/HC complies with regulations.
1. INSTALL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) Air pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
CO/HC Meter
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
Complete the measuring with 3 minutes.
HINT:
When doing the 2 mode (idle and 2,500 rpm) test, these mea-
surement order prescribed by the applicable local regulations.

6. EM-2
ENGINE MECHANICAL - CO/HC
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
• Check heated oxygen sensor operation (See page
DI-49).
• See the table below for possible causes, and then
inspect and correct the applicable causes if neces-
sary.
CO HC
Normal High
Problems
Rough idle
Causes
1. Faulty ignitions:
• Incorrect timing
• Fouled, shorted or improperly gapped plugs
• Open or crossed high-tension cords
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
Low High Rough idle
(Fluctuating HC reading)
1. Vacuum leaks:
• PCV hoses
• Intake manifold
• Throttle body
• IAC valve
• Brake booster line
2. Lean mixture causing misfire
High High Rough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:
• Faulty pressure regulator
•Defective ECT sensor
• Defective IAT sensor
• Faulty ECM
• Faulty injectors
• Faulty throttle position sensor

7. EM-3
ENGINE MECHANICAL - COMPRESSION
H037
COMPRESSION EMOSK-05
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE IGNITION COIL (See page IG-6)
3. REMOVE SPARK PLUGS
4. INSPECT CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression]
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1ZZ-FE 1,500 kPa (15.3 kgf/cm2
, 218 psi)
2ZZ-GE 1,400 kPa (14.3 kgf/cm2
,203 psi) or more
Minimum pressure:
1ZZ-FE 1,000 kPa (10.2 kgf/cm2
,145 psi)
2ZZ-GE 1,000 kPa (10.2 kgf/cm2
,145 psi)
Difference between each cylinder:
1ZZ-FE 100 kPa (1.0 kgf/cm2
,15 psi) or less
2ZZ-GE 110 kPa (1.1 kgf/cm2
,16 psi) or less
(e) If the cylinder compression in one more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
• If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
5. REINSTALL SPARK PLUGS
6. INSTALL IGNITION COIL (See page IG-7)

8. EM-4
ENGINE MECHANICAL - VALVE CLEARANCE
VALVECLEARANCE BJlSQ-OI
ADJUSTMENT
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE CYLINDER HEAD COVER
(See page EM-18)
1ZZ-FE:
A01044
2. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark "0" of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
ets are in straight line on the timing chain cover surface
as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
2ZZ-GE:
3. INSPECT VALVE CLEARANCE
(a) Gheck only the valves indicated.
• Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
• Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
1ZZ-FE:
Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.)
2ZZX3E:
Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.35 - 0.45 mm (0.014 - 0.018 in.)

9. ENGINE MECHANICAL - VALVE CLEARANCE
EM-5
1Z2-FE:
2Z2-GE:
Valve Lifter
A10366
A10411
A10412
YA01053
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 2).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
4. 1ZZ-FE:
ADJUSTVALVECLEARANCE
(a) Set the No. 1 cylinder to the TDC/compression (See pro-
cedure in step 2).
(b) Place matchmarks on the timing chain and camshaft tim-
ing sprockets.
(c) Remove the 2 bolts and chain tensioner.
(d) Remove the camshaft and timing sprocket assemblies
(See page EM-42).
(1) 19 camshaft bearing cap bolts
(2) 9 camshaft bearing caps (No. 1 & No. 3)
(3) Exhaust camshaft and timing sprocket assembly
(4) Intake camshaft and timing sprocket assembly
HINT:
When disconnect the timing chain from the camshaft timing
sprocket, holding the timing chain.
(e) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
• Be careful not to drop anything inside the timing
chain cover.
• Do not allowthe chain to come into contactwith water
or dust.
(f) Remove the valve lifters.

10. EM-6
ENGINE MECHANICAL - VALVE CLEARANCE
A01082
(g) Determine the replacement valve lifter size according to
these Formula or Charts:
• Using a micrometer, measure the thickness of the
removed lifter.
• Calculate the thickness of a new lifter so the valve
clearance comes within the specified value.
T. Thickness of used lifter
A Measured valve clearance
N Thickness of new lifter
Intake: N = T + (A - 0.20 mm (0.008 in.))
Exhaust: N = T + (A - 0.30 mm (0.012 in.))
• Select a new lifter with a thickness as close as pos-
sible to the calculated values.
HINT:
Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260
in.).
5. 2ZZ-GE:
ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe of cam-
shaft on the adjusting valve points upward.
SST
(2) Using SST, press down the valve.
(3) Using SST, remove the adjusting shim.
(4) Determine the replacement shim size according to
these Formula or Charts:
Using dial indicator, measure the thickness of
the removed shim.
Calculate the thickness of a new shim so the
valve clearance comes within the specified
value.

11. EM-7
ENGINE MECHANICAL - VALVE CLEARANCE
T. Thickness of used shim
A Measured valve clearance
N Thickness of new shim
Intake: N = T+ (A - 0.20 mm (0.008 in.))
Exhaust: N = T+ (A - 0.40 mm (0.016 in.))
Select a new shim with a thickness as close
as possible to the calculated values.
HINT:
Shim are available in41 size in incrementsof0.020 mm (0.0008
in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).

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13. 1ZZ-FE: Valve Lifter Selection Chart (Intake)
m
^"". Installed lifter thickness
^^^ mm (in )
Measured clearance ^-^^
mm (in.) ^s
*v^
0.000 - 0.030 (0.0000 - 0.001 2)
0.031 -0.050(0.0012-0.0020)
0.051 - 0.070 (0.0020 - 0 0028)
0.071 - 0.090 (0.0028 - 0.0035)
0.081 - 0 1 10 (0.0036 - O.OO43)
0111-0.130(00044-00061)
0.131 -0.149(0.0052-0.0059)
0. 1 50 - 0.250 (0.0059 - 0,0098)
0.251 - 0.270 (0,0099 - 0.0106)
0.271 - 0.2SO (0.0107 - 0.01 1 4)
0.291 -0.310 (0.0115 - 0.0122)
0.311 -0.330 (0,0122 -0.0130)
0.331 -0.350(0.0130-0.0138)
0.351 -0370(0.0138-0,0146)
0.371 - 0.390 (0.0146 - 0.0154)
0.391 - 0.410 (0.0154 - 0.0161)
0.411-0.430(0.0162-0,0169)
0.431 - 0.450 (0.0170 - 0,0177)
0.451 - 0 470 (0.0178 - 0.0185)
0.491 - 0.510 (0.01 93 - 0.0201)
0.51 1 - 0.530 (0.0201 - 0.0209)
0.531-0.550(0.0209-0.0217)
0.351 - 0.570 (0.021 7 - 0.0224)
0.571 - 0.590 (0.0225 - 0.0232]
0.5B1 - 0.610 {0.0233 - 0.0240)
0611 -0.630(0.0241 -0.0248)
0.651 - 0.670 (0.0256 - 0.0264)
0.691 -0,710(0.0272-0.0280)
0,7 1 1 - Q 730 {0.0280 - 0.0287)
0 731 - 0.760 (0.0288 - 0.0295)
0.751 - 0,770 {0.0296 - 0.0303)
0.771 -0.790(0.0304-0.0311)
0.791-0.610(0.0311-0.0319)
0.811 -0.830(0.0319-0.0327)
0,831 - 0.850 (0,0327 - 0.0335)
0.851 - 0.870 (0.0335 - 0.0343)
0.871 - 0.800 {0.0343 - 0.0350)
ft AOI ft oin in n*»Ki niwuii
0.9 1 1 - 0.9X (0.0359 - 0.0366)
a
1
12
14
15
18
20
22
24
26
28
30
32
36
38
40
42
44
46
48
52
06
58
60
62
«4
66
68
70
72
74
74
74
g
S
a
06
14
16
18
20
22
24
26
28
30
32
34
38
40
42
44
46
48
50
54
68
BO
62
64
66
68
70
72
74
74
74
00(0.2008
iri
06
06
16
18
20
22
24
26
28
3D
32
34
36
40
42
44
46
48
SO
52
56
60
62
64
66
68
70
72
74
74
74
20(0.2016
in'
06
08
06
16
20
22
24
26
28
30
32
34
36
38
42
44
46
48
50
52
54
58
62
64
66
66
70
72
74
74
74
40(0.2024
iri
06
06
08
08
20
22
24
28
28
30
32
34
38
38
40
44
46
48
50
62
54
55
60
64
66
68
70
72
74
74
74
a
S
Iri
06
06
06
OB
10
22
24
26
28
30
32
34
36
38
40
42
48
48
50
52
54
58
58
62
86
68
70
72
74
74
74
a
a
0
06
08
06
08
10
12
24
26
28
30
32
34
36
38
40
42
44
48
50
52
64
66
58
50
64
68
70
72
74
7*
74
a
08
06
08
10
12
14
26
28
30
32
34
36
38
40
42
44
46
60
52
54
56
58
60
62
66
70
72
74
74
74
5510(0.2051
06
06
08
10
12
14
16
26
30
32
34
36
38
40
42
44
46
48
62
64
66
SB
60
62
64
SB
72
74
74
74
|
05
06
08
10
12
14
16
28
30
32
34
36
38
40
42
44
45
46
52
54
B6
58
60
62
64
88
72
74
74
74
a
08
08
10
12
14
16
16
30
32
34
36
38
40
42
44
46
48
50
54
56
58
50
62
64
66
70
74
74
5.240(02063
06
08
10
12
14
16
18
30
32
34
36
38
40
42
44
46
46
50
54
56
68
60
62
64
E6
70
74
74
2.
06
10
12
16
18
20
32
34
36
38
40
42
44
46
48
50
52
66
58
60
62
64
66
58
72
74
5.260(0.2071
08
10
12
16
18
20
32
34
36
38
40
42
44
46
48
50
52
56
58
60
52
64
66
68
72
74
5.270(0.2075
10
12
14
18
20
22
34
36
38
40
42
44
46
46
SO
52
54
58
80
62
64
6G
68
70
5.280(0.2079)
10
12
14
18
20
22
34
36
38
40
42
44
46
48
50
62
54
58
60
62
64
66
68
70
a
12
14
16
20
22
24
38
38
40
42
44
46
48
50
52
54
66
60
62
64
66
66
70
72
5.300(0.2087)
12
14
16
20
22
24
38
38
40
42
44
46
48
50
52
54
56
60
62
64
66
68
70
72
5.310(05091)
14
16
18
20
22
24
26
38
40
42
44
46
48
50
52
54
56
58
52
64
66
68
70
72
74
a
1
14
16
18
20
22
24
26
38
40
42
44
48
48
60
52
54
56
SB
62
64
66
68
70
72
74
74
a
I
16
18
20
as
24
26
28
40
42
44
48
48
50
52
54
56
68
60
64
66
68
70
72
74
74
§
zolores
16
18
20
22
24
26
26
40
42
44
46
48
60
52
54
56
58
60
64
66
68
70
72
74
74
S
5.350(0.2
18
20
22
24
28
28
30
42
44
46
48
50
52
54
53
58
60
82
66
68
70
72
74
74
S
5.360(0.2
18
20
22
24
26
28
30
42
44
46
48
50
52
54
56
58
60
62
66
68
70
72
74
74
?
5.370(0.2
20
22
24
28
28
30
32
44
46
46
50
52
64
56
56
80
82
84
68
70
72
74
74
3
a
1
20
22
24
26
28
30
32
44
46
48
50
52
54
5G
58
60
62
64
68
70
72
74
74
S
a
22
24
26
28
30
32
34
46
48
50
62
54
56
58
60
82
64
66
70
72
74
74
if
5.400(0.2
22
24
28
28
30
32
34
46
46
50
52
54
56
58
eo
62
64
66
70
72
74
74
f
5.410(0.2
24
26
26
30
32
34
36
48
50
52
54
56
58
60
62
64
66
6Q
72
74
74
S
5.420(0.2
24
26
28
30
32
34
36
48
50
52
54
56
68
60
62
84
66
68
72
74
74
S
5.430(0.2
26
28
30
32
34
36
38
50
52
54
66
58
60
62
94
66
68
70
74
74
¥
a
1
iri
26
28
30
32
34
36
38
50
52
54
66
58
60
62
64
66
68
70
74
74
?
a
28
30
32
34
36
38
40
52
54
56
68
60
62
84
68
68
70
72
74
S
5.460(0.2
28
30
32
34
36
38
40
52
54
56
58
60
62
64
86
86
70
72
74
S
<M
a
g
iri
30
32
34
36
38
40
42
54
56
56
60
62
84
66
68
70
72
74
in
5.480(0.2
30
32
34
36
38
40
42
54
66
58
60
62
64
66
68
70
72
74
5
5.490(0.2
32
34
36
38
40
42
44
56
58
60
62
64
66
68
70
72
74
Intake vave clearance (Cold):
0.15 - 0.25 mm (0.006 - 0.010 in.)
EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 48 lifter.
8
5.500(0.2
32
34
36
38
40
42
44
56
SB
60
62
64
66
88
70
72
74
8
0
iri
34
36
36
40
42
44
46
58
60
62
64
66
88
70
72
74
74
C f
a i
m i
34 3
36 31
38 4
40 4
42 4
44 4
46 4
58 6
60 6
62 6
64 6
66 6
88 7
70 7
72 ^
74 7
Lifter
No.
06
08
10
12
14
16
18
20
22
24
26
26
5
i a
i 1
6 35
3 38
0 40
I 42
4 44
6 46
8 48
0 60
2 62
4 64
« 66
8 68
0 70
2 72
4 74
4 74
S
a
1
38
40
42
44
46
46
50
62
84
68
68
70
74
5.560(0.2189)
38
40
42
44
48
48
50
62
64
68
68
70
74
5.570(0.2193)
40
42
44
46
48
50
52
64
66
68
70
72
74
5.580(0.2197
40 4
42 4
44 4
46 4
48 51
50 5
52 5
64 6
66 6
68 7
70 7
72 7
74 7
5600(0.2205
2 42
I44
!46
B 48
3 50
i 52
) 54
S 66
8 68
0 70
2 72
4 74
4 74
4
Thickness
5.060(0.1992)
5.080 (0.2000)
5.100(0.2008)
5.120(0.2016)
5.140(0.2024)
5.160(0.2031)
5.180(0.2039)
5.200 (0.2047)
5.220(0.2055)
5.240(0.2063)
5.260(0.2071)
5.280 (0.2079)
2
ap
1,
44 4
46 4,
48 5
60 6
52 5
54 5
56 5
86 7
70 7
72 7
74 7
74 7
Lifter
No.
30
32
34
36
38
40
42
44
46
48
50
52
i a
6 48
8 60
0 52
2 54
4 56
6 58
a 60
0 72
2 74
4 74
4 74
4
a
i
50
62
54
66
58
60
62
74
74
74
5.700(0.2244
52
54
56
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17. EM-12
ENGINE MECHANICAL VALVE CLEARANCE
6. 1ZZ-FE:
REINSTALL CAMSHAFT
(a) Reinstall the valve lifters (See page EM-61).
(b) Align the crankshaft pulley groove with the timing mark "0"
of the timing chain cover.
(c) Hold the timing chain, and place the intake camshaft and
timing sprocket assembly.
(d) Align the matchmarks on the timing chain and camshaft
timing sprocket.
(e) Reinstall the camshaft and timing sprocket assemblies
(Seepage EM-65).
A10387
(f) Check that the point marks of the camshaft timing sprock-
ets are in straight line on the timing chain cover surface
as shown in the illustration.
(g) Check that the matchmarks on the timing chain and cam-
shaft timing sprockets.
(h) Install the chain tensioner (See page EM-25).
(i) Recheck the valve clearance (See procedure in step 3).
(j) Check the valve timing (See page EM-25).
7. REINSTALL CYLINDER HEAD COVER
(See page EM-25)