1. 1998 TOYOTA MOTOR CORPORATION
All rights reserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jul. 21, 1998 01--980721--00
This supplement has been prepared to provide information covering general service repairs for the
Chassis and body of the TOYOTA HILUX which underwent changes in May, 1998.
Applicable models: RZN142, 144, 147, 148, 149, 154, 168, 169, 173, 174, 193 series
LN141, 145, 146, 147, 150, 152, 165, 166, 167, 170, 171, 172, 191 series
S HILUX Chassis and Body Repair Manual RM585E
S 1RZ, 2RZ, 2RZ-
-E Engine Repair Manual RM167E
S 1RZ-
-E Engine Repair Manual RM467E
S 3RZ-
-F, 3RZ-
-FE Engine Repair Manual RM521E
S 2RZ, 2RZ-
-E Engine Repair Manual Supplement RM558E
S 1RZ, 1RZ-
-E, 2RZ-
-FE, 3RZ-
-F, 3RZ-
-FE Engine Repair Manual Supplement RM584E
S 2L, 3L Engine Repair Manual RM520E
S 2L, 2L-
-T, 3L, 5L Engine Repair Manual Supplement RM582E
S 2L, 2L-
-T, 5L Engine Repair Manual Supplement RM647E
S A340E, A340F, A340H Automatic Transmission Repair Manual RM391U
S HILUX Electrical Wiring Diagram EWD307F
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
CAUTION
Pub.No.
Manual Name
Forthe service specifications and repair procedures of the above modelother than those listed in this supple-
ment, refer to the following manuals.
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use toolsspe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
THE MAIN INDEX
RM651E-D Pages From Supplement
TOYOTA MOTOR CORPORATION
Back To Chassis & Body Index
TO MODEL INDEX
FOREWORD
2. INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
SUSPENSION AND AXLE
STEERING
BODY ELECTRICAL
BODY
ALPHABETICAL INDEX
TO MODEL INDEX
RM651E-D
BACK TO MAIN FOREWORD & Chassis & Body Index Pages From Supplement
May 1998
SUPPLEMENT: CHASSIS & BODY:
MAIN INDEX: HILUX.
3. INTRODUCTION
HOW TO USE THIS MANUAL IN--1
. . . . . . . . . . . . .
GENERAL INFORMATION IN--1
. . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION IN--3
. . . . . . . . . .
VEHICLE IDENTIFICATION AND ENGINE
SERIAL NUMBER IN--3
. . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS IN--4
. . . . . . . . . . . . . . . . .
GENERAL INFORMATION IN--4
. . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS IN--8
. .
FOR ALL OF VEHICLES IN--9
. . . . . . . . . . . . . . . . . .
PRECAUTION IN--9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMS IN--15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS USED IN THIS MANUAL IN--15
. . . .
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RM651E-D
BACK TO MAIN INDEX CHAS. & BODY:
4. IN00U-
-23
N17080
Filler Cap
Float
Reservoir Tank
z Grommet
Clip
Slotted Spring Pin
: Specified torque
z Non--reusable part
Cylinder
Piston
Push Rod
Washer
Snap Ring
Boot
z Gasket
Lock Nut
Clevis Pin
Clevis
N∙m (kgf∙cm, ft∙lbf)
12 (120, 9)
15 (155, 11)
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INTRODUCTION HOW TO USE THIS MANUAL
IN-
-1
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con-
tained in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
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CONTINUED
CHAS. & BODY:
5. Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350-
-30020 (09350-
-06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57 — 114 psi) as shown
in the illustration.
IN-
-2
-
-
INTRODUCTION HOW TO USE THIS MANUAL
The procedures are presented in a step--by--step format:
S The illustration shows what to do and where to do it.
S The task heading tells what to do.
S The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section, for quick
reference.
8. CAUTIONS, NOTICES, HINTS:
S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
S NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
S HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N∙m (310 kgf∙cm, 22 ft∙lbf)
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6. B02106
A
B
C
IN02T-
-02
B02107
2RZ-
-FE, 3RZ-
-F & 3RZ-
-FE engines: 2L, 2L-
-T, 3L & 5L engines: 1RZ-
-E engine:
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-
INTRODUCTION IDENTIFICATION INFORMATION
IN-
-3
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the outer sur-
face of the front right side frame. This number is also stamped
on the manufacturer’s plate and certification regulation plate
(G.C.C. countries only), as shown in the illustration.
A: Manufacturer’s Plate
B: Vehicle Identification Number
C: Certification Regulation Plate (G.C.C. countries only)
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
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7. FI1066
IN06S-
-03
Z11554
Seal Lock Adhesive
IN-
-4
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-
INTRODUCTION REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (--)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape themwith a file oroth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings, oil
seals, etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
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8. BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation
Part Name
Symbol
Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FUSE
M--FUSE
H--FUSE
FL
CB
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INTRODUCTION REPAIR INSTRUCTIONS
IN-
-5
(3) Precoated parts are indicated in the component il-
lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of specialservice tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
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9. IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN-
-6
-
-
INTRODUCTION REPAIR INSTRUCTIONS
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN--8).
S Cancel the parking brake on the level place and
shift the transmission in Neutral (or N range).
S When jacking up the front wheels of the vehicle, at
first place stoppers behind the rear wheels.
S When jacking up the rear wheels of the vehicle, at
first place stopper before the front wheels.
S When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
S After the vehicle is jacked up, be sure to support it
on rigid racks. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission--related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
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10. IN0002
Example
-
-
INTRODUCTION REPAIR INSTRUCTIONS
IN-
-7
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C (68˚F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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11. IN0002
Example
-
-
INTRODUCTION REPAIR INSTRUCTIONS
IN-
-7
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C (68˚F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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12. IN02U-
-02
B02108
2WD:
4WD and pre runner:
Front
Front
JACK POSITION
SUPPORT POSITION
Front
Rear
Center of crossmember
Center of rear axle housing
Safety stand
IN-
-8
-
-
INTRODUCTION REPAIR INSTRUCTIONS
VEHICLE LIFT AND SUPPORT LOCATIONS
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13. IN041-
-07
BO4111
Negative Cable
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The HILUX is equipped with an SRS (Supplemental Re-
straint System), such as the driver airbag, front passen-
ger airbag assembly and seat belt pretensioners.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the negative (--) terminal cable from
the battery (See Pub. No. RM585E).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (--) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back--up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (--) terminal cable from the battery, the SRS
may deploy.)
When the negative (--) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, neveruse a back--up powersupply fromanoth-
er battery.
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INTRODUCTION FOR ALL OF VEHICLES
-
- IN-
-9
CHAS. & BODY:
14. R11910
Marks
IN-
-10
-
-
INTRODUCTION FOR ALL OF VEHICLES
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad, front pas-
senger airbag assembly and seat belt pretension-
ers should be inspected (See Pub. No. RM585E).
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be attached to the sensor during re-
pairs.
(6) Never disassemble and repair the airbag sensoras-
sembly, steering wheel pad, front passenger airbag
assembly or seat belt pretensioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly or seat belt pre-
tensioner has been dropped, or if there are cracks,
dents or other defects in the case, bracket or con-
nector, replace them with new ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work is completed, check the SRS warning
light for the supplemental restraint system (See
Pub. No. RM585E).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR--10 of this manual concerning correct steer-
ing wheel installation.
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15. B02387
Example:
Correct Wrong
Z13950
Example:
-
-
INTRODUCTION FOR ALL OF VEHICLES
IN-
-11
(d) STEERING WHEEL PAD (with Airbag)
(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface facing up.
In this case, the twin--lock type connector lock lever
should be in the locked state and care should be
taken to place it so the connector will not be dam-
aged. In addition do not store a steering wheel pad
on top of anotherone. Storing the pad with its metal-
lic surface facing upward may lead to a serious acci-
dent if the airbag inflates for same reason.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the steering wheel
pad and the pad should not be cleaned with deter-
gents of any kind.
(4) Store the steering wheel pad where the ambient
temperature remains below 93˚C (200˚F), without
high humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
steering column near the combination switch con-
nector before starting work.
(6) When disposing of a vehicle or the steering wheel
pad alone, the airbag should be deployed using an
SST before disposal (See Pub. No. RM585E).
Carry out the operation in a safe place away from
electrical noise.
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CHAS. & BODY:
16. Z13952
Example: Correct Wrong
B02404
Example:
IN-
-12
-
-
INTRODUCTION FOR ALL OF VEHICLES
(e) FRONT PASSENGER AIRBAG ASSEMBLY
(1) Always store a removed or new front passenger air-
bag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deploy-
ment direction facing down could cause a serious
accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the front passen-
ger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93˚C (200˚F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) installed on
the assembly before starting work.
(6) When disposing of a vehicle or the airbag assembly
alone, the airbag should be deployed using an SST
before disposal (See Pub. No. RM585E).
Perform the operation in a safe place away from
electrical noise.
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17. -
-
INTRODUCTION FOR ALL OF VEHICLES
IN-
-13
(f) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pre-
tensioner. (This may cause the seat belt pretension-
er to activate, which is very dangerous.)
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner in another
vehicle.
(4) Store the seat belt pretensioner where the ambient
temperature remains below 80˚C (176˚F) and
away from electrical noise without high humidity.
(5) When using electric welding, first disconnect the
connector (yellow color and 2 pins) before starting
work.
(6) When disposing of a vehicle or the seat belt preten-
sioner alone, the seat belt pretensioner should be
activated before disposal (See Pub. No. RM585E).
Perform the operation in a safe place away from
electrical noise.
(7) The seat belt pretensioner is hot after activation, so
let it cool down sufficiently before the disposal.
However never apply water to the seat belt preten-
sioner.
(g) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired deployment of the supplemental re-
straint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (--) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(h) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors in the
system are a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it.
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18. IN-
-14
-
-
INTRODUCTION FOR ALL OF VEHICLES
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING HAND-
-HELD TESTER
CAUTION:
Observe the following items for safety reasons:
S
S
S
S Before using the hand-
-held tester, the hand-
-held tester’s operator manual should be read thor-
oughly.
S
S
S
S Be sure to route all cables securely when driving with the hand-
-held tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
S
S
S
S Two persons are required when test driving with the hand-
-held tester, one person to drive the
vehicle and the other person to operate the hand-
-held tester.
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19. IN0CG-
-01
-
-
INTRODUCTION TERMS
IN-
-15
TERMS
ABBREVIATIONS USED IN THIS MANUAL
Abbreviations Meaning
ABS Anti-
-Lock Brake System
A/C Air Conditioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
BACS Boost Altitude Compensation System
BAT Battery
B/L Bi-
-Level
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CD Compact Disc
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CRS Child Restraint System
CTR Center
DC Direct Current
DIFF. Differential
DIFF. LOCK Differential Lock
DLC Data Link Connector
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECT Electronic Control Transmission
ECU Electronic Control Unit
EDU Electronic Driving Unit
EFI Electronic Fuel Injection
E/G Engine
ELR Emergency Locking Retractor
FF Front-
-Engine Front-
-Wheel-
-Drive
FIPG Formed In Place Gasket
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CONTINUED
CHAS. & BODY:
20. IN-
-16
-
-
INTRODUCTION TERMS
FL Fusible Link
Fr Front
FR Front-
-Engine Rear-
-Wheel-
-Drive
FWD Front-
-Wheel-
-Drive
GND Ground
H/B Hatchback
HI High
HID High Intensity Discharge (Head Lamp)
HT Hard Top
HWS Heated Windshield System
IAC Idle Air Control
IFS Independent Front Suspension
IG Ignition
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
J/B Junction Block
J/C Junction Connector
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left-
-Hand
LHD Left-
-Hand Drive
LO Low
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Fuel Injection
MPX Multiplex Communication System
M/T Manual Transmission
N Neutral
No. Number
O2S Oxygen Sensor
O/D Overdrive
OPT Option
P & BV Proportioning And Bypass Valve
PCS Power Control System
PKB Parking Brake
PPS Progressive Power Steering
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CONTINUED
CHAS. & BODY:
21. -
-
INTRODUCTION TERMS
IN-
-17
PS Power Steering
PTO Power Take-
-Off
RAM Random Access Memory
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH Right-
-Hand
RHD Right-
-Hand Drive
RLY Relay
ROM Read Only Memory
Rr Rear
RR Rear-
-Engine Rear-
-Wheel Drive
RWD Rear-
-Wheel Drive
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SPEC Specification
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TDC Top Dead Center
TEMP. Temperature
TEMS TOYOTA Electronic Modulated Suspension
T/M Transmission
TMC TOYOTA Motor Corporation
TRC Traction Control System
U/D Underdrive
VENT Ventilator
VIN Vehicle Identification Number
VSC Vehicle Skid Control Vehicle Stability Control
w/ With
WGN Wagon
W/H Wire Harness
w/o Without
1st First
2nd Second
2WD Two Wheel Drive Vehicle (4x2)
4WD Four Wheel Drive Vehicle (4x4)
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22. PREPARATION
SUSPENSION AND AXLE PP--1
. . . . . . . . . . . . . . . .
STEERING PP--2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY ELECTRICAL PP--4
. . . . . . . . . . . . . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
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23. PP1XT-
-01
-
-
PREPARATION SUSPENSION AND AXLE
PP-
-1
SUSPENSION AND AXLE
EQUIPMENT
Dial indicator
Torque wrench
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26. PP090-
-03
PP-
-4
-
-
PREPARATION BODY ELECTRICAL
BODY ELECTRICAL
RECOMMENDED TOOLS
09082-
-00050 TOYOTA Electrical Tester Set.
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28. SERVICE SPECIFICATIONS
STANDARD BOLT SS--1
. . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION AND AXLE SS--4
. . . . . . . . . . . . . . . .
STEERING SS--19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY SS--20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
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29. SS0ZS-
-01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess Bolt
Stud Bolt Weld Bolt
Class
4T
5T
6T
7T
8T
9T
10T
11T
No Mark
w/ Washer
No Mark No Mark
w/ Washer
-
-
SERVICE SPECIFICATIONS STANDARD BOLT
SS-
-1
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
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31. SS0ZU-
-01
6N
8N
10N
11N
12N
B06432
Nut Type
Present Standard
Hexagon Nut Cold Forging Nut Cutting Processed Nut
Class
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11N
12N
Old Standard Hexagon Nut
No Mark (w/ Washer)
No Mark
*
No Mark (w/ Washer) No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
-
-
SERVICE SPECIFICATIONS STANDARD BOLT
SS-
-3
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
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32. SS10V-
-01
SS-
-4
-
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation pressure (2WD)
E
Tire size: 185R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Europe
Tire size: 195R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Unladen with 2 occupants and 100 kg of luggage or less
A t li
Tire size: 195R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 220 kPa (2.2 kgf/cm2, 32 psi)
Australia
Fully laden
Tire size: 195R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Loaded
Tire size: Fr 6.00-
-14-
-6PRLT, Rr 6.50-
-14-
-8PRLT
Front 200 kPa (2.0 kgf/cm2, 29 psi)
Rear 425 kPa (4.25 kgf/cm2, 62 psi)
Tire size: 185R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
200 kPa (2.0 kgf/cm2, 29 psi)*1
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Tire size: 195R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Oth
Tire size: 195R15-
-6PRLT
Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 375 kPa (3.75 kgf/cm2, 54 psi)
Others
Unloaded
Tire size: Fr 6.00-
-14-
-6PRLT, Rr 6.50-
-14-
-8PRLT
Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
Tire size: 185R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
200 kPa (2.0 kgf/cm2, 29 psi)*1
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Tire size: 195R14C-
-8PR
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
Tire size: 195R15-
-6PRLT
Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 375 kPa (3.75 kgf/cm2, 54 psi)
1
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CONTINUED
* : RZN142 series only
CHAS. & BODY:
33. -
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS-
-5
Cold tire inflation pressure (4WD and pre runner)
Europe Tire size: 205R16 Reinforced radial tire
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 260 kPa (2.6 kgf/cm2, 38 psi)
Unladen with 2 occupants and 100 kg of luggage or less
Tire size: 205R16 Reinforced radial tire
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 170 kPa (1.7 kgf/cm2, 25 psi)
Tire size: 205R16C-
-6PR
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 220 kPa (2.2 kgf/cm2, 32 psi)
A li
Tire size: 255/70R15 112L LT
Front 190 kPa (1.9 kgf/cm2, 28 psi)
Rear 190 kPa (1.9 kgf/cm2, 28 psi)
Australia
Fully laden
Tire size: 205R16 Reinforced radial tire
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 240 kPa (2.4 kgf/cm2, 34 psi)
Tire size: 205R16C-
-6PR
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 300 kPa (3.0 kgf/cm2, 44 psi)
Tire size: 255/70R15 112L LT
Front 190 kPa (1.9 kgf/cm2, 28 psi)
Rear 240 kPa (2.4 kgf/cm2, 34 psi)
Tire size: 205R16 Reinforced radial tire
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
O h
Tire size: 205R16C-
-6PR
Front 170 kPa (1.7 kgf/cm2, 25 psi)
Rear 300 kPa (3.0 kgf/cm2, 44 psi)
Others
Tire size: 7.00-
-16-
-8PRLT
Front 240 kPa (2.4 kgf/cm2, 35 psi)
Rear 425 kPa (4.25 kgf/cm2, 62 psi)
Tire size: 255/70R15 112L LT
Front 190 kPa (1.9 kgf/cm2, 28 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
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CONTINUED
CHAS. & BODY:
34. SS-
-6
-
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
Wheel alignment (2WD)
Vehicle height
Front: A -
-B
Rear: C -
- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
LN145L-
-TRMDSW
Front 34 mm (1.34 in.)
Rear 33 mm (1.30 in.)
LN145R-
-TRMDSW
Front 43 mm (1.69 in.)
Rear 34 mm (1.34 in.)
Europe LN145L-
-PRMDSW
Front 41 mm (1.61 in.)
Rear 32 mm (1.26 in.)
LN145L-
-PRMSSW
Front 40 mm (1.57 in.)
Rear 33 mm (1.30 in.)
LN150L-
-CRMDSW
Front 38 mm (1.50 in.)
Rear 45 mm (1.77 in.)
RZN147R-
-TRMDEQ
RZN149R-
-TRMDKQ
Front 25 mm (0.98 in.)
Rear 39 mm (1.54 in.)
RZN149R-
-TRPDKQ
Front 25 mm (0.98 in.)
Rear 40 mm (1.57 in.)
RZN149R-
-PRMDKQ
Front 36 mm (1.42 in.)
Rear 42 mm (1.65 in.)
RZN149R-
-PRPDKQ
Front 36 mm (1.42 in.)
Rear 43 mm (1.69 in.)
Australia RZN149R-
-CRMDKQ
Front 34 mm (1.34 in.)
Rear 44 mm (1.73 in.)
RZN154R-
-CRPDKQ
Front 37 mm (1.46 in.)
Rear 44 mm (1.73 in.)
LN147R-
-TRMDSQ
Front 33 mm (1.30 in.)
Rear 41 mm (1.61 in.)
LN147R-
-PRMDSQ
Front 40 mm (1.57 in.)
Rear 44 mm (1.73 in.)
LN152R-
-CRMDSQ
Front 35 mm (1.38 in.)
Rear 44 mm (1.73 in.)
RZN142L-
-TRMDSV
Front 35 mm (1.38 in.)
Rear 42 mm (1.65 in.)
RZN147L-
-TRMDSV
RZN149L-
-TRMSUV
Front 24 mm (0.94 in.)
Rear 41 mm (1.61 in.)
G.C.C.
RZN147L-
-PRMDSV
Front 30 mm (1.18 in.)
Rear 33 mm (1.30 in.)
G.C.C.
Countries RZN144L-
-TRMDUV
RZN144L-
-TRMSUV
Front 34 mm (1.34 in.)
Rear 42 mm (1.65 in.)
RZN149L-
-PRMDUV
Front 31 mm (1.22 in.)
Rear 33 mm (1.30 in.)
LN141L-
-TRMDSV
Front 31 mm (1.22 in.)
Rear 42 mm (1.65 in.)
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CONTINUED
CHAS. & BODY:
35. -
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS-
-7
G.C.C.
LN146L-
-PRMDSV
Front 36 mm (1.42 in.)
Rear 34 mm (1.34 in.)
G.C.C.
Countries
RZN149L-
-PRMSUV
Front 30 mm (1.18 in.)
Rear 33 mm (1.30 in.)
RZN142L-
-TRMDS
Front 33 mm (1.30 in.)
Rear 39 mm (1.54 in.)
RZN147R-
-TRMDS
RZN147L-
-TRMDS
Front 23 mm (0.91 in.)
Rear 39 mm (1.54 in.)
RZN147R-
-PRMDS
RZN147L-
-PRMDS
Front 28 mm (1.10 in.)
Rear 41 mm (1.61 in.)
RZN148L-
-TRMDK
Front 23 mm (0.91 in.)
Rear 41 mm (1.61 in.)
RZN148L-
-PRMDK
Front 27 mm (1.06 in.)
Rear 43 mm (1.69 in.)
Others RZN149L-
-TRMDU
Front 22 mm (0.87 in.)
Rear 39 mm (1.54 in.)
RZN149L-
-PRMDU
Front 28 mm (1.10 in.)
Rear 42 mm (1.65 in.)
RZN149L-
-PRMSU
Front 38 mm (1.50 in.)
Rear 44 mm (1.73 in.)
RZN154L-
-CRMDU
Front 33 mm (1.30 in.)
Rear 44 mm (1.73 in.)
LN145R-
-TRMDS
LN145L-
-TRMDS
Front 30 mm (1.18 in.)
Rear 44 mm (1.73 in.)
LN145R-
-PRMDS
LN145L-
-PRMDS
Front 35 mm (1.38 in.)
Rear 46 mm (1.81 in.)
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CONTINUED
CHAS. & BODY:
40. SS-
-12
-
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
Wheel angle
Manual steering
Inside wheel
Outside wheel: Reference
36˚ (34˚ -
- 37˚)
32˚
Power steering
Inside wheel
Outside wheel: Reference
38˚ (36˚ -
- 39˚)
34˚
Wheel alignment (4WD and pre runner)
Vehicle height
Front: A -
-B
Rear: C -
- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm front bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
RZN168L-
-TRMDKW(3)
Front 64 mm (2.52 in.)
Rear -
-107 mm (-
-4.21 in.)
RZN168L-
-PRMDKW
Front 65 mm (2.56 in.)
Rear -
-99 mm (-
-3.90 in.)
RZN173L-
-CRMDKW
Front 66 mm (2.60 in.)
Rear -
-96 mm (-
-3.78 in.)
Europe
LN165L-
-TRMDXW
LN165R-
-TRMDXW(3)
Front 65 mm (2.56 in.)
Rear -
-106mm (-
-4.17 in.)
LN165L-
-PRMDXW
LN165R-
-PRMDXW
Front 66 mm (2.60 in.)
Rear -
-99 mm (-
-3.90 in.)
LN165L-
-PRMSXW
Front 66 mm (2.60 in.)
Rear -
-98 mm (-
-3.86 in.)
LN170L-
-CRMDXW
Front 67 mm (2.64 in.)
Rear -
-95 mm (-
-3.74 in.)
RZN169R-
-TRMDKQ(3)
Front 43 mm (1.69 in.)
Rear -
-121 mm (-
-4.76 in.)
RZN169R-
-PRMDKQ
Front 50 mm (1.97 in.)
Rear -
-111 mm (-
-4.37 in.)
A t li
RZN174R-
-CRMDKQ
Front 66 mm (2.60 in.)
Rear -
-106 mm (-
-4.17 in.)
Australia
LN167R-
-TRMDSQ(3)
Front 43 mm (1.69 in.)
Rear -
-119 mm (-
-4.69 in.)
LN167R-
-PRMDSQ
Front 50 mm (1.97 in.)
Rear -
-111 mm (-
-4.37 in.)
LN172R-
-CRMDSQ(3)
Front 67 mm (2.64 in.)
Rear -
-105 mm (-
-4.13 in.)
G.C.C.
RZN169L-
-TRMDUV
Front 58 mm (2.28 in.)
Rear -
-110 mm (-
-4.33 in.)
G.C.C.
Countries RZN169L-
-PRMDUV
LN166L-
-PRMDSV
Front 60 mm (2.36 in.)
Rear -
-101 mm (-
-3.98 in.)
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CONTINUED
CHAS. & BODY:
41. -
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS-
-13
RZN168L-
-TRMDK
Front 57 mm (2.24 in.)
Rear -
-111 mm (-
-4.37 in.)
RZN168L-
-PRMDK
Front 58 mm (2.28 in.)
Rear -
-104 mm (-
-4.09 in.)
RZN169R-
-TRMDU
Front 43 mm (1.69 in.)
Rear -
-119 mm (-
-4.69 in.)
RZN169L-
-TRMDU
Front 57 mm (2.24 in.)
Rear -
-110 mm (-
-4.33 in.)
RZN169R-
-PRMDU Tire size: 205R16C
Front 44 mm (1.73 in.)
Rear -
-112 mm (-
-4.41 in.)
Tire size: 255/70R15
Front 58 mm (2.28 in.)
Rear -
-104 mm (-
-4.09 in.)
Others RZN169L-
-PRMDU
Front 58 mm (2.28 in.)
Rear -
-103 mm (-
-4.06 in.)
RZN193L-
-PRMDK
Front 58 mm (2.28 in.)
Rear -
-106 mm (-
-4.17 in.)
LN166R-
-TRMDS
LN166L-
-TRMDS
Front 44 mm (1.73 in.)
Rear -
-119 mm (-
-4.69 in.)
LN166R-
-PRMDS Tire size: 7.00-
-16
LN166L-
-PRMDS Tire size: 205R16C
Front 45 mm (1.77 in.)
Rear -
-112 mm (-
-4.41 in.)
Tire size: 255/70R15
Front 59 mm (2.32 in.)
Rear -
-103 mm (-
-4.06 in.)
LN171L-
-CRMDS
Front 67 mm (2.64 in.)
Rear -
-105 mm (-
-4.13 in.)
LN191L-
-PRMDS
Front 45 mm (1.77 in.)
Rear -
-114 mm (-
-4.49 in.)
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CONTINUED
CHAS. & BODY:
46. SS10W-
-01
SS-
-18
-
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
2WD front
Upper suspension arm x Frame 96 980 71
Tie rod clamp lock nut 25 260 19
Knuckle stopper bolt lock nut 34 350 25
4WD and pre runner front
Lower suspension arm x Frame 195 2,000 145
Tie rod clamp lock nut 22 225 16
Knuckle stopper bolt lock nut 72 730 53
Pitman arm stopper bolt lock nut 72 730 53
Idler arm stopper bolt lock nut 72 730 53
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47. SS0AV-
-03
-
-
SERVICE SPECIFICATIONS STEERING
SS-
-19
STEERING
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
STEERING COLUMN
Non-
-tilt steering column:
Column tube support x Column tube 20 204 15
Sliding yoke x Main shaft assembly 35 360 26
Tilt steering column:
Tilt lever assembly lock nut 12 125 9
Tilt support No.1 reinforce set bolt 5.4 55 48 in.∙lbf
Steering support x Column tube 9.5 97 84 in.∙lbf
Sliding yoke x Main shaft assembly 35 360 26
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48. SS10U-
-01
SS-
-20
-
-
SERVICE SPECIFICATIONS BODY
BODY
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
FRONT SEAT (Sports type) -
- -
- -
-
Inner adjuster x Body 37 375 27
Outer adjuster x Body 37 375 27
Front seat cushion shield x Adjuster 18 185 13
REAR SEAT (Sports type ) -
- -
- -
-
Rear seat cushion frame x Body 18 185 13
Rear seatback frame x Rear seat cushion frame 18 185 13
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49. SUSPENSION AND AXLE
TIRE AND WHEEL
(2WD) SA--1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE AND WHEEL
(4WD and PRE RUNNER) SA--3
. . . . . . . . . . . . . . .
FRONT WHEEL ALIGNMENT
(2WD) SA--5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL ALIGNMENT
(4WD and PRE RUNNER) SA--10
. . . . . . . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
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BACK TO MAIN INDEX CHAS. & BODY:
50. SA091-
-05
R03031
-
-
SUSPENSION AND AXLE TIRE AND WHEEL (2WD)
SA-
-1
TIRE AND WHEEL (2WD)
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
Europe:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
185R14C-
-8PR
220 (2 2 32) 450 (4 5 65)
195R14C-
-8PR
220 (2.2, 32) 450 (4.5, 65)
Australia:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
Unladen or 2 passengers 100 kg of luggage or less
195R14C-
-8PR 220 (2.2, 32) 220 (2.2, 32)
Fully laden
195R14C-
-8PR 220 (2.2, 32) 450 (4.5, 65)
Others:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
Loaded
6.00-
-14-
-6PRLT
6.50-
-14-
-8PRLT
200 (2.0, 29)
-
-
-
-
425 (4.25, 62)
185R14C-
-8PR
220 (2.2, 32)
200 (2.0, 29)*
450 (4.5, 65)
195R14C-
-8PR 220 (2.2, 32) 450 (4.5, 65)
195R15-
-6PRLT 180 (1.8, 26) 375 (3.75, 54)
Unloaded
6.00-
-14-
-6PRLT
6.50-
-14-
-8PRLT
180 (1.8, 26)
-
-
-
-
240 (2.4, 35)
185R14C-
-8PR
220 (2.2, 32)
200 (2.0, 29)*
450 (4.5, 65)
195R14C-
-8PR 220 (2.2, 32) 450 (4.5, 65)
195R15-
-6PRLT 180 (1.8, 26) 375 (3.75, 54)
*: RZN142 series only
(b) Check the tire runout.
Tire runout: 3.0 mm (0.118 in.) or less
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CHAS. & BODY:
51. F03265
(a) (b)
Front
R07928
F01415
SA-
-2
-
-
SUSPENSION AND AXLE TIRE AND WHEEL (2WD)
2. ROTATING TIRES
(a) Vehicle with front and rear tires of the different size:
Replace the right tire with the left one, vice versa.
(b) Vehicle with front and rear tires of the same size:
See the illustration for where to rotate each tire when you
include the spare tire in rotation.
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off--the--car balance.
(b) If necessary, check and adjust the On--the--car balance.
Imbalance after adjustment:
195R15-
-6PRLT: 13.0 g (0.029 lb) or less
Others: 15.0 g (0.033 lb) or less
4. CHECK WHEEL BEARING LOOSENESS
Check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check that oil leaks
S Check the mounting bushings for wear
S Bounce front and rear of the vehicle
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52. SA0LA-
-03
R03031
-
-
SUSPENSION AND AXLE TIRE AND WHEEL (4WD and PRE RUNNER)
SA-
-3
TIRE AND WHEEL (4WD and PRE
RUNNER)
INSPECTION
HINT:
Pre runner is the model described below.
RZN193L-
-PRMDK, LN191L-
-PRMDS
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
Europe:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
205R16
Reinforced radial tire
170 (1.7, 25) 260 (2.6, 38)
Australia:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
Unladen or 2 passengers 100 kg of luggage or less
205R16
Reinforced radial tire
170 (1.7, 25) 170 (1.7, 25)
205R16C-
-6PR 170 (1.7, 25) 220 (2.2, 32)
255/70R15 112L LT 190 (1.9, 28) 190 (1.9, 28)
Fully laden
205R16
Reinforced radial tire
170 (1.7, 25) 240 (2.4, 35)
205R16C-
-6PR 170 (1.7, 25) 300 (3.0, 44)
255/70R15 112L LT 190 (1.9, 28) 240 (2.4, 34)
Others:
Tire size
Front
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
205R16
Reinforced radial tire
170 (1.7, 25) 240 (2.4, 35)
205R16C-
-6PR 170 (1.7, 25) 300 (3.0, 44)
7.00-
-16-
-8PRLT 240 (2.4, 35) 425 (4.25, 62)
255/70R15 112L LT 190 (1.9, 28) 240 (2.4, 35)
(b) Check the tire runout.
Tire runout: 3.0 mm (0.118 in.) or less
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CONTINUED
CHAS. & BODY:
53. R13503
Front
R07928
SA-
-4
-
-
SUSPENSION AND AXLE TIRE AND WHEEL (4WD and PRE RUNNER)
2. ROTATING TIRES
HINT:
See the illustration for where to rotate each tire when you in-
clude the spare tire in rotation.
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off--the--car balance.
(b) If necessary, check and adjust the On--the--car balance.
Imbalance after adjustment:
14.0 g (0.031 lb) or less
4. CHECK FRONT SUSPENSION FOR LOOSENESS
5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
7. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check that oil leaks
S Check the mounting bushings for wear
S Bounce front and rear of the vehicle
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54. F03230
Front:
Rear:
B A
D C
SA0LB-
-02
Z03382
F03227
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (2WD)
SA-
-5
FRONT WHEEL ALIGNMENT (2WD)
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SS-
-4)
Front: A -- B
Rear: C -- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specified value.
If the vehicle height is not the specified value, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-
-CASTER-
-KINGPIN GAUGE OR
POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION (See page SS-
-4)
If the steering axis inclination is not within the specified value,
after the camber and caster have been correctly adjusted, re-
check the steering knuckle and front wheel for bearing or loose-
ness.
4. ADJUST CAMBER AND CASTER
(a) Loosen the 2 bolts.
(b) Adjust the camber and caster by adding or removing
shims on the upper suspension arm.
HINT:
Try to adjust the camber and caster to the centerof the specified
values.
Shim thickness:
4.0 mm (0.157 in.) 1.6 mm (0.063 in.) 1.2 mm (0.047 in.)
If the steering axis inclination is not as specified value, after the
camber and caster have been correctly adjusted, recheck the
steering knuckle and front wheel for distortion or looseness.
NOTICE:
Adjust the shim thickness to 6.8 mm (3.8 -
- 10.8 mm), and
adjust the difference between the front and rear of the up-
per suspension arm shaft to within 4 mm.
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CHAS. & BODY:
55. F05464
Example:
F = Standard value point
f = Measurement point
Camber
Caster
SA-
-6
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (2WD)
(c) How to read adjustment chart.
(1) Find the wheel alignment standard value applicable
for the particular model.
(2) Mark the selected standard value on the adjustment
chart.
Example:
Camber: -
-0˚06’ (-
-0.1˚)
Caster: 1˚00’ (1˚)
(3) Mark the alignment value measured when the ve-
hicle was non--loaded on the adjustment chart.
Example:
Camber: 0˚18’ (0.3˚)
Caster: 1˚30’ (1.5˚)
(4) As shown in the chart, read the distance from the
standard value to the measured value, and adjust
the front and/or rear adjusting shims accordingly.
Example:
Front shim: +(Increase) 2.2 mm
Rear shim: +(Increase) 1.2 mm
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CONTINUED
CHAS. & BODY:
56. F03255
Camber
Front Shim Thickness Graduation
Caster
+ (Increase)
Rear Shim Thickness
Graduation
+ (Increase)
-- (Decrease)
-- (Decrease)
mm
mm
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (2WD)
SA-
-7
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CHAS. & BODY:
57. SA3213
A B
C
D
Front
F03228
F03235
Front
A B
A = B
FA0018
A
Front
B A
B
A: Inside
B: Outside
SA-
-8
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (2WD)
(d) Tighten the 2 bolts.
Torque: 96 N∙m (980 kgf∙cm, 71 ft∙lbf)
5. INSPECT TOE-
-IN (See page SS-
-4)
If the toe--in is not within the specified value, adjust the tie rod
ends.
6. ADJUST TOE-
-IN
(a) Remove the 2 clamp nuts.
(b) Adjust toe--in by turning the right and left tie rod tubes an
equal amount.
HINT:
Try to adjust the toe--in to the center of the specified value.
(c) Make sure that the lengths of the right and left tie rod ends
are equal.
Tie rod end length difference:
3.0 mm (0.118 in.) or less
(d) Torque the clamp nuts.
Torque: 25 N∙m (260 kgf∙cm, 19 ft∙lbf)
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the wheel turning
angle.
Wheel turning angle:
Item Inside wheel
Outside wheel:
Reference
Manual steering 36˚ (34˚ --- 37˚) 32˚
Power steering 38˚ (36˚ --- 39˚) 34˚
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CHAS. & BODY:
58. F03231
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (2WD)
SA-
-9
If the right and left inside wheel turning angles differ from the
specified value, adjust the wheel turning angle with the knuckle
stopper bolts.
Torque: 34 N∙m (350 kgf∙cm, 25 ft∙lbf)
If the wheel turning angle still cannot be adjusted within limits,
inspect and replace damaged or worn steering parts.
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59. SA1FL-
-01
F03224
Front:
Rear:
B A
D
C
Z03382
F03232
+ --
+
--
--
SA-
-10
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
FRONT WHEEL ALIGNMENT (4WD
and PRE RUNNER)
INSPECTION
HINT:
Pre runner is the model described below.
RZN193L-
-PRMDK, LN191L-
-PRMDS
1. MEASURE VEHICLE HEIGHT (See page SS-
-4)
Front: A -- B
Rear: C -- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm front bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specified value.
If the vehicle height is not the specified value, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-
-CASTER-
-KINGPIN GAUGE OR
POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION (See page SS-
-4)
If the steering axis inclination is not within the specified value,
after the camber and caster have been correctly adjusted, re-
check the steering knuckle and front wheel for bearing or loose-
ness.
4. ADJUST CAMBER AND CASTER
(a) Loosen the front and/or rear adjusting cam nuts.
(b) Adjust the camber and caster by front and/or rear adjust-
ing cams.
HINT:
Try to adjust the camber and caster to the centerof the specified
values.
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CHAS. & BODY:
60. F05465
Example:
F = Standard value point
f = Measurement point
Camber
Caster
R08019
Front
Front Cam Front Cam
Rear Cam Rear Cam
(Longer) (Longer)
(Longer)
(Shorter)
(Shorter) (Shorter)
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
SA-
-11
(c) How to read adjustment chart.
(1) Find the wheel alignment standard value applicable
for the particular model.
(2) Mark the selected standard value on the adjustment
chart.
Example:
Camber: 0˚00’ (0˚)
Caster: 1˚30’ (1.5˚)
(3) Mark the alignment value measured when the ve-
hicle was non--loaded on the adjustment chart.
Example:
Camber: 0˚30’ (0.5˚)
Caster: 1˚30’ (1.5˚)
(4) As shown in the chart, read the distance from the
standard value to the measured value, and adjust
the front and/or rear adjusting cams accordingly.
Example:
Front cam: +(Longer) 2.8
Rear cam: +(Longer) 2.6
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CHAS. & BODY:
61. F03237
Camber
Caster
Front Cam
Graduation
+ (Longer)
Rear Cam
Graduation
-- (Shorter)
-- (Shorter)
+ (Longer)
SA-
-12
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
(d) Torque the front and/or rear adjusting cam nuts.
Torque: 195 N∙m (2,000 kgf∙cm, 145 ft∙lbf)
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CHAS. & BODY:
62. SA3213
A B
C
D
Front
F03234
F03235
Front
A B
A = B
FA0927
Front
90˚
FA0018
A
Front
B A
B
A: Inside
B: Outside
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
SA-
-13
5. INSPECT TOE-
-IN (See page SS-
-4)
If the toe--in is not within the specified value, adjust the tie rod
ends.
6. ADJUST TOE-
-IN
(a) Remove the 2 clamp nuts.
(b) Adjust toe--in by turning the right and left tie rod tubes an
equal amount.
HINT:
Try to adjust the toe--in to the center of the specified value.
(c) Make sure that the lengths of the right and left tie rod ends
are equal.
Tie rod end length difference:
3.0 mm (0.118 in.) or less
(d) Torque the clamp nuts.
Torque: 22 N∙m (225 kgf∙cm, 16 ft∙lbf)
HINT:
Face the clamp bolts toward the front of the vehicle.
7. INSPECT WHEEL ANGLE
(a) With the vehicle unladen, turn the ignition switch ON and
turn the steering wheel (steering effort: 20 N∙m (2 kgf∙m,
14 ft∙lbf)) then measure the wheel turning angle.
Wheel turning angle:
Inside wheel
Outside wheel:
Reference
33˚ (31˚ -
- 34˚) 32˚
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CHAS. & BODY:
63. F03238
Pitman Arm
Idler Arm
Stopper Bolt
Steering Knuckle
Arm Stopper Bolt
Front
Clearance:
3.0 ± 1.0 mm
(0.018± 0.039in.)
Clearance:
3.0 ± 1.0 mm
(0.018± 0.039in.)
Stopper Bolt
SA-
-14
-
-
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
If the right and left inside wheel turning angles differ from the
specified value, adjust the wheel turning angle with the pitman
arm and idler arm stopper bolts.
Torque: 72 N∙m (730 kgf∙cm, 53 ft∙lbf)
(b) Measure the clearance between the stopper bolt on the
steering knuckle side and bracket on the lower suspen-
sion arm side at the maximum wheel turning angles.
Clearance: 3.0 ± 1.0 mm (0.118 ± 0.039 in.)
Torque: 72 N∙m (730 kgf∙cm, 53 ft∙lbf)
If the wheel turning angle is not within the specified value, ad-
just the stopper bolt on the steering knuckle side.
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64. STEERING
STEERING COLUMN SR--1
. . . . . . . . . . . . . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
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BACK TO MAIN INDEX CHAS. & BODY:
65. STEERING:
1. Components SR-1 / 2
2. Removal SR-3
3. Disassembly SR-4 / 5
4. Inspection SR-6
5. Reassembly SR-7 / 9
6. Installation SR-10
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66. SR0QS-
-02
F04882
Column Upper Bracket
Key Cylinder
Ignition Switch
with Key Unlock
Warning Switch
z Wave Snap Ring
Column Upper Clamp
Column Tube
z Lower Bushing
z Tapered--head Bolt
Thrust Stopper
Sliding Yoke
35 (360, 26)
Main Shaft Assembly
z Energy Absorbing
Clip
z Energy Absorbing
Plate
z Energy Absorbing Guide
z Non--reusable part
Molybdenum disulfide lithium base grease
N∙m (kgf∙cm, ft∙lbf) : Specified torque
20 (204, 15)
Lower Tube Attachment
Column Tube Support
z Energy Absorbing
Plate
z Brake Away Capsule
z Energy Absorbing
Clip
z Energy Absorbing Guide
z Brake Away Capsule
Non-
-tilt steering column:
Transponder Key Coil
Transponder Key
Amplifier
z Snap Ring
-
-
STEERING STEERING COLUMN
SR-
-1
STEERING COLUMN
COMPONENTS
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CONTINUED
CHAS. & BODY:
67. F04883
z Snap Ring
Thrust Stopper
Sliding Yoke
35 (360, 26)
Main Shaft Assembly
Column Upper Clamp
z Tapered--head Bolt
Tilt Support No. 1
Reinforce
12 (125, 9)
Lock Nut
5.4 (55, 48 in.∙lbf)
Tilt Lever Assembly
Tilt Sub Lever
Torsion Spring
Column Upper
Bracket
Ignition Switch with Key
Unlock Warning Switch
z Energy Absorbing Clip
z Brake Away Capsule
z Energy Absorbing Plate
z Energy Absorbing
Guide
z Energy Absorbing Clip
z Energy Absorbing Plate
z Brake Away Capsule
z Energy Absorbing Guide
No. 1 Tilt Lever
Lock Bolt
Brake Away Bracket
z Non--reusable part
Molybdenum disulfide lithium base grease
N∙m (kgf∙cm, ft∙lbf) : Specified torque
z Lower Bushing
Pawl Set Bolt
Tilt Steering
Support
z Wave Snap Ring
Column Tube
z Lock Nut
No. 1 Support
Collar
9.5 (97, 84 in.∙lbf)
Tilt steering column:
Key Cylinder
Transponder Key Coil
Transponder Key
Amplifier
Plate Washer
SR-
-2
-
-
STEERING STEERING COLUMN
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69. SR0QU-
-02
F02540
Matchmarks
F01493
Screw
Extractor
R14934
SR-
-4
-
-
STEERING STEERING COLUMN
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE TRANSPONDER KEY COIL
Remove the screw and transponder key coil.
2. REMOVE SLIDING YOKE
(a) Remove the bolt.
(b) Place matchmarks on the sliding yoke and main shaft as-
sembly.
(c) Remove the sliding yoke and thrust stopper.
3. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered--head bolts.
(b) Using a 3--4 mm (0.12--0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts, column up-
per bracket and column upper clamp.
4. Non-
-tilt steering column:
REMOVE COLUMN TUBE SUPPORT
(a) Remove the bolt.
(b) Remove the column tube support with lower tube attach-
ment.
(c) Remove the lower tube attachment from the column tube
support.
5. Tilt steering column:
REMOVE TILT STEERING SUPPORT
(a) Remove the pawl set bolt, lock nut and plate washer.
(b) Remove the 2 No. 1 support collars and tilt steering sup-
port.
6. REMOVE 2 ENERGY ABSORBING PLATES
(a) Using pliers, remove the 2 energy absorbing clips.
(b) Remove the 2 energy absorbing plates, 2 energy absorb-
ing guides and 2 brake away capsules.
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CHAS. & BODY:
70. F01494
F01495
R15090
Extension Bar
F01496
-
-
STEERING STEERING COLUMN
SR-
-5
7. Tilt steering column:
REMOVE TILT LEVER ASSEMBLY AND BREAK AWAY
BRACKET
(a) Using a screwdriver, remove the torsion spring.
(b) Remove the tilt support No. 1 reinforce with the bolt.
HINT:
This bolt is left--handed one.
(c) To remove the lock nut, turn it clockwise.
HINT:
This nut is left--handed one.
(d) Remove the No. 1 tilt lever lock bolt, tilt lever assembly
and tilt sub lever.
(e) Remove the break away bracket.
8. REMOVE MAIN SHAFT ASSEMBLY AND LOWER
BUSHING
(a) Using a snap ring expander, remove the wave snap ring
from the shaft assembly.
(b) Using an extension bar and a hammer, tap out the shaft
assembly.
(c) Using a screwdriver, tap out the bushing.
(d) Using a snap ring expander, remove the snap ring from
the shaft assembly.
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71. SR0QV-
-02
R14935
R14998
F01497
SR-
-6
-
-
STEERING STEERING COLUMN
INSPECTION
1. INSPECT STEERING LOCK OPERATION
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 screwdriver, and pull out
the cylinder.
(c) Install a new cylinder.
HINT:
Make sure the key is at the ACC position.
3. INSPECT IGNITION SWITCH
(See Pub. No. RM585E on page BE-
-13)
4. INSPECT KEY UNLOCK WARNING SWITCH
(See Pub. No. RM585E on page BE-
-13)
5. IF NECESSARY, REPLACE IGNITION SWITCH WITH
KEY UNLOCK WARNING SWITCH
(a) Remove the 2 screws from the column upper bracket.
(b) Remove the key cylinder.
(c) Slide out the switch.
(d) Install a new ignition switch with key unlock warning
switch with the 2 screws.
6. INSPECT TRANSPONDER KEY COIL
(See page BE-
-30)
7. IF NECESSARY, REPLACE TRANSPONDER KEY
COIL
8. IF NECESSARY, REPLACE TRANSPONDER KEY AM-
PLIFIER
(a) Remove the screw and transponder key amplifier.
(b) Install a new transponder key amplifier with the screw.
9. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube.
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72. SR0QW-
-02
R14999
SST
Lower Bushing
F01498
Lower
Side
F01499
-
-
STEERING STEERING COLUMN
SR-
-7
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH MOLYB-
DENUM DISULFIDE LITHIUM BASE GREASE
(See page SR-
-1)
2. INSTALL MAIN SHAFT ASSEMBLY AND LOWER
BUSHING
(a) Using a snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly into the column tube.
(c) Coat a new bushing with molybdenum disulfide lithium
base grease.
(d) Using SST and a hammer, tap in the bushing.
SST 09612--22011
(e) Using a snap ring expander, install a new wave snap ring
to the shaft assembly.
3. Tilt steering column:
INSTALL TILT LEVER ASSEMBLY AND BREAK AWAY
BRACKET
(a) Install the break away bracket.
HINT:
Install the bracket so that its bridge comes to the back of the
tube surface stopper.
(b) Install the No. 1 tilt lever lock bolt, tilt sub leverand tilt lever
assembly.
HINT:
Align the holes of the break away bracket and projections of the
tilt sub lever and No. 1 tilt lever lock bolt.
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CHAS. & BODY:
73. F01500
W03347
F01501
SR-
-8
-
-
STEERING STEERING COLUMN
(c) Torque the lock nut by turning it counterclockwise.
Torque: 12 N∙m (125 kgf∙cm, 9 ft∙lbf)
HINT:
S This nut is left--handed one.
S While tilting up the steering column, fix the tilt lever to the
highest position and tighten the nut.
(d) Install the tilt support No. 1 reinforce with the bolt.
Torque: 5.4 N∙m (55 kgf∙cm, 48 in.∙lbf)
HINT:
S This bolt is left--handed one.
S Align the reinforce and nut to eliminate looseness by turn-
ing the reinforce counterclockwise a little, then torque the
bolt.
(e) Install the torsion spring.
4. INSTALL 2 ENERGY ABSORBING PLATES
(a) Install the 2 new break away capsules.
(b) Install the 2 new energy absorbing guides and 2 new ab-
sorbing plates.
(c) Install the 2 new energy absorbing clips.
5. Non-
-tilt steering column:
INSTALL COLUMN TUBE SUPPORT
(a) Install the column tube attachment to the column tube
support.
(b) Install the column tube support with the bolt .
Torque: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
6. Tilt steering column:
INSTALL TILT STEERING SUPPORT
(a) Install the 2 No. 1 support collars to the tilt steering sup-
port.
(b) Install the tilt steering support to the column tube.
(c) Install the pawl set bolt and plate washer.
(d) Install a new lock nut.
Torque: 9.5 N∙m (97 kgf∙cm, 84 in.∙lbf)
7. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Install the column upper bracket and column upper clamp
with 2 new tapered--head bolts.
(b) Tighten the 2 new tapered--head bolts until the bolt heads
break off.
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CHAS. & BODY:
74. -
-
STEERING STEERING COLUMN
SR-
-9
8. INSTALL SLIDING YOKE
(a) Install the thrust stopper and sliding yoke.
(b) Align the matchmarks on the sliding yoke and main shaft
assembly.
(c) Install the bolt.
Torque: 35 N∙m (360 kgf∙cm, 25 ft∙lbf)
9. INSTALL TRANSPONDER KEY COIL
Install the transponder key coil with the screw.
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76. BODY ELECTRICAL
AUDIO SYSTEM BE--1
. . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE IMMOBILISER SYSTEM BE--23
. . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
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77. AUDIO SYSTEM:
Page 1 of 2
DESCRIPTION:
1. Radio Wave Band BE-1
2. Service area BE-1
3. Reception problems BE-1 / 2
4. Noise problems BE-2 / 3
5. Outline of AVC-LAN BE-3
TROUBLESHOOTING:
1. Always inspect the trouble with taking the following into consideration
BE-4
2. Diagnosis function BE-5 / 6
3. Diagnosis code list BE-6 / 7
4. Troubleshooting for ANTI-THEFT SYSTEM BE-8
1. Radio No power coming in BE-9
2. Radio Power coming on, but radio not operating BE-9
3. Radio Noise present, but AM-FM not operating BE-10
4. Radio Either speaker does not work BE-10
5. Radio Either AM-FM does not work, reception poor BE-11
6. Radio Sound quality poor BE12
7. Radio Cannot set station select button, present memory
disappears BE-12
8. Tape Player cassette tape cannot be inserted BE-13
9. Tape player cassette tape inserted, but no power BE13
10.Tape Player power coming in, but tape player not operating BE-14
11.Tape Player either speaker does not work BE-14
12.Tape Player sound quality poor (volume faint) BE-15
13.Tape Player tape jammed, malfunction with tape speed or
auto reverse BE15
14.Tape Player APS, SKIP, RPT, buttons not working BE-16
15.Tape Player cassette tape will not be ejected BE-16
16.CD Player CD cannot be inserted BE-17
17.CD Player CD inserted, but no power BE-17
18.CD Player power coming in, but CD player not operating BE-18
19.CD Player sound jumps BE18
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CHAS. & BODY:
78. AUDIO SYSTEM:
Page 2 of 2
20.CD Player sound quality poor (volume faint) BE-19
21,CD Player either speaker not working BE-19
22.CD Player CD will not be ejected BE-20
23.Antenna Antenna-related BE-21
24.Noise, noise produced by vibration or shock while driving BE-21
25.Noise, noise produced when engine starts BE-22
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79. The radio wave bands used in radio broadcasting are as follows:
Frequency
Designation
Radio wave
Modulation method
LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency
Amplitude modulation Frequency modulation
30 kHz 300 kHz 3 MHz 30 MHz 300 MHz
LF MF HF VHF
AM FM
BE109-
-01
BE2818
FM (Stereo)
FM (Monaural)
AM
BE2819
Fading Ionosphere
-
-
BODY ELECTRICAL AUDIO SYSTEM
BE-
-1
AUDIO SYSTEM
DESCRIPTION
1. RADIO WAVE BAND
2. SERVICE AREA
There are great differences in the size of the service area forAM
and FM monaural. Sometimes FM stereo broadcasts cannot be
received even though AM comes in very clearly.
Not only does FM stereo have the smallest service area, but it
also picks up static and other types of interference (”noise”)
easily.
3. RECEPTION PROBLEMS
Besides the problem of static, there are also the problems
called ”fading”, ”multipath” and ”fade out”. These problems are
caused not by electrical noise but by the nature of the radio
waves themselves.
S Fading
Besides electrical interference, AM broadcasts are
also susceptible to other types of interference, es-
pecially at night. This is because AM radio waves
bounce off the ionosphere at night. These radio
waves then interfere with the signals from the same
transmitter that reach the vehicle’s antenna directly.
This type of interference is called ”fading”.
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80. BE2820
Multipath
BE2821
Fade Out
AM
FM
Noise occurs at a specific place. Strong possibility of foreign noise.
Noise occurs when listening to
faint broadcasting.
Noise occurs only at night.
Noise occurs while driving and
at a specific place.
There is a case that the same program is broadcasted
from each local station. This may be the case you are
listening to the weaker station.
Strong possibility of the beat from a distant broadcasting.
Strong possibility of multipath noise and fade out.
BE-
-2
-
-
BODY ELECTRICAL AUDIO SYSTEM
S Multipath
One type of interference caused by bouncing of ra-
dio waves off obstructions is called ”multipath”. Mul-
tipath occurs when a signal from the broadcast
transmitter antenna bounces off buildings and
mountains and interferes with the signal that is re-
ceived directly.
S Fade Out
Because FM radio waves are of higher frequencies
than AM radio waves, they bounce off buildings,
mountains, and other obstructions. For this reason,
FM signals often seem to gradually disappear or
fade away as the vehicle goes behind a building or
other obstructions. This is called ”fade out”.
4. NOISE PROBLEMS
(a) Questionnaire for noise:
It is very important for noise troubleshooting to have good un-
derstanding of the claims from the customers, so make the best
use of the following questionnaire and diagnose the problem
accurately.
HINT:
In the case that the noise occurrence condition does not meet
any of the above questionnaire, check based on the ”Trouble
Phenomenon”.
Refer to previous page for multipath and fading.
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CHAS. & BODY:
81. -
-
BODY ELECTRICAL AUDIO SYSTEM
BE-
-3
(b) Matters that require attention when checking:
S Noise coming into the radio usually has no harm for
practical use as the noise protection is taken and it
is hardly thinkable for an extremely loud noise to
come in. When extremely loud noise comes into the
radio, check if the grounding is normal where the
antenna is installed.
S Check if all the regular noise prevention parts are
properly installed and if there is any installation of
non--authorized parts and non--authorized wiring.
S If you leave the radio out of tune (not tuning), it is
easy to diagnose the phenomenon as noise occurs
frequently.
5. OUTLINE OF AVC-
-LAN
(a) What is AVC--LAN?
AVC--LAN is the abbreviation, which stands for Audio Visual Communication--Local Area Network.
This is a unified standard co--developed by 6 audio manufactures associated with Toyota MotorCorpo-
ration.
The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication
and communication signal.
(b) Objectives
Recently the car audio system has been rapidly developed and functions have been changed drasti-
cally. The conventional system has been switched to the multi--media type such as a navigation sys-
tem. At the same time the level of customers needs to audio system has been heightened. This lies
behind this standardization.
The concrete objectives are explained below.
S When products by different manufactures were combined together, there used to be a case
that malfunction occurred such as sound did not come out. This problemhas been resolved
by standardization of signals.
S Various types of after market products have been able to add or replace freely.
S Thanks to the above (2), each manufacture has become able to concentrate on developing
products in their strongest field. This has enabled many types of products provided inex-
pensively.
S Conventionally, a new product developed by a manufacture could not be used due to a lack
of compatibility with other manufactures products. Thanks to this new standard, users can
enjoy compatible products provided for them timely.
The above descriptions are the objectives to introduce AVC--LAN. By this standardization, development of
new products will no longer cause systematic errors. Thus, this is very effective standard for a product in the
future.
HINT:
S When +B short or GND short is detected in AVC--LAN circuit, communication stops. Accordingly the
audio system does not function normally.
S When audio system is not equipped with a navigation system, audio head unit is the master unit.
S The car audio system using AVC--LAN circuit has a diagnosis function.
S Each product has its own specified numbers called physical address. Numbers are also allotted to
each function in one product, which are called logical address.
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82. BE10A-
-01
BE-
-4
-
-
BODY ELECTRICAL AUDIO SYSTEM
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (ECU part)of the audio system, be careful that no part ofyour
body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement
part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during sys-
tem operation and was prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
1. Always inspect the trouble with taking the following items into consideration.
(a) Open or short circuit of the wire harness
(b) Connector or terminal connection fault
(c) For audio systems with anti--theft system, troubleshooting items marked (*) indicate that ”Trouble-
shooting for ANTI--THEFT SYSTEM” should be carried out first.
Problem No.
Radio No power coming in. *1
Power coming in, but radio not operating. *2
Noise present, but AM -
- FM not operating. 3
Either speaker does not work. 4
Either AM or FM does not work. 5
Reception poor (Volume faint). 5
Few preset tuning bands. 5
Sound quality poor. 6
Cannot set station select button. 6
Preset memory disappears. 7
Tape Player Cassette tape cannot be inserted. 8
Cassette tape inserted, but no power. *9
Power coming in, but tape player not operating. 10
Either speaker does not work. 11
Sound quality poor (Volume faint). 12
Tape jammed, malfunction with tape speed or auto -
- reverse. 13
APS, SKIP, RPT buttons not operating. 14
Cassette tape will not be ejected. *15
CD Player CD cannot be inserted. 16
CD inserts, but no power. 17
Power coming in, but CD player not operating. 18
Sound jumps. 19
Sound quality poor (Volume faint). 20
Either speaker does not work. 21
CD will not be ejected. 22
Antenna Antenna does not fully extend or fully retract. 23
Antenna -
- related. 24
Noise Noise produced by vibration or shock while driving. 25
Noise produced when engine starts. 26
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