Content

Introduction

• How to use this manual
• Identification information
• Repair instructions
• For all of vehicles
• How to troubleshoot
• Controlled systems
• Terms

Maintenance

• Outside vehicle
• Inside vehicle
• Under hood
• Engine
• Brake
• Chassis

Preparation

• Maintenance
• Engine mechanical (3RZ-FE)
• Engine mechanical (5VZ-FE)
• Emission control (3RZ-FE)
• Emission control (5VZ-FE)
• MFI (3RZ-FE)
• SFI (5VZ-FE)
• Cooling (3RZ-FE)
• Cooling (5VZ-FE)
• Lubrication (3RZ-FE)
• Lubrication (5VZ-FE)
• Ignition (3RZ-FE)
• Ignition (5VZ-FE)
• Starting (3RZ-FE)
• Starting (5VZ-FE)
• Charging (3RZ-FE)
• Charging (5VZ-FE)
• Clutch
• Manual transmission (R150, R150F)
• Manual transmission (W59)
• Automatic transmission
• Transfer
• Propeller shaft
• Suspension and axle
• Brake
• Steering
• Supplemental restraint system
• Body electrical
• Body
• Air conditioning

Service specifications

• Standard bolt
• Maintenance
• Engine mechanical (3RZ-FE)
• Engine mechanical (5VZ-FE)
• Emission control (3RZ-FE)
• Emission control (5VZ-FE)
• MFI (3RZ-FE)
• SFI (5VZ-FE)
• Cooling (3RZ-FE)
• Cooling (5VZ-FE)
• Lubrication (3RZ-FE)
• Lubrication (5VZ-FE)
• Ignition (3RZ-FE)
• Ignition (5VZ-FE)
• Starting (3RZ-FE)
• Starting (5VZ-FE)
• Charging (3RZ-FE)
• Charging (5VZ-FE)
• Clutch
• Manual transmission (R150, R150f)
• Manual transmission (W59)
• Automatic transmission
• Transfer
• Propeller shaft
• Suspension and axle
• Brake
• Steering
• Supplemental restraint system
• Body electrical
• Body
• Air conditioning

Diagnostics

• Engine (3RZ-FE)
• Engine (5VZ-FE)
• Automatic transmission
• Anti-lock brake system
• Supplemental restraint system
• Cruise control system

Engine mechanical (3RZ-FE)

• CO/HC
• Compression
• Valve clearance
• Ignition timing
• Idle speed
• Timing chain
• Cylinder head
• Engine unit
• Cylinder block
• Exhaust system

Engine mechanical

• CO/HC
• Compression
• Valve clearance
• Ignition timing
• Idle speed
• Timing belt
• Cylinder head
• Engine unit (2WD)
• Engine unit (4WD)
• Cylinder block
• Exhaust system

Emissions control (3RZ-FE)

• Emission control system
• Parts layout and schematic drawing
• Positive crankcase ventilation (PCV) system
• Evaporative emission (EVAP) control system
• Exhaust gas recirculation (EGR) system
• Three-way catalytic converter (TWC) system

Emissions control (5VZ-FE)

• Emission control system
• Parts layout and schematic drawing
• Positive crankcase ventilation (PCV) system
• Evaporative emission (EVAP) control system
• Exhaust gas recirculation (EGR) system
• Three-way catalytic convert (TWC) system

MFI system (3RZ-FE)

• MFI system
• Fuel pump
• Fuel pressure regulator
• Injector
• Fuel tank and line
• Throttle body
• Idle air control (IAC) valve
• Mass air flow (MAF) meter
• Efi main relay
• Circuit opening relay
• VSV for evaporative emission (EVAP)
• VSV for exhaust gas recirculation (EGR)
• Engine coolant temperature (ECT) sensor
• Intake air temperature (IAT) sensor
• Knock sensor
• Exhaust gas recirculation (EGR) gas temperature sensor
• Heated oxygen sensor
• Engine control module (ECM)
• Fuel cut RPM

SFI system (5VZ-FE)

• SFI system
• Fuel pump
• Fuel pressure regulator
• Injector
• Fuel tank and line
• Mass air flow (MAF) meter
• Throttle body
• Idle air control (IAC) valve
• Efi main relay
• Circuit opening relay
• VSV for fuel pressure control
• VSV for exhaust gas control valve
• VSV for evaporative emission (EVAP)
• Engine coolant temperature(ECT) sensor
• Knock sensor
• Exhaust gas recirculation (EGR) gas temperature sensor
• Heated oxygen sensor
• Engine control module (ECM)
• Fuel cut RPM

Cooling (3RZ-FE)

• Coolant
• Water pump
• Thermostat
• Radiator

Cooling (5VZ-FE)

• Coolant
• Water pump
• Thermostat
• Radiator

Lubrication (3RZ-FE)

• Oil and filter
• Oil pump

Lubrication (5VZ-FE)

• Oil and filter
• Oil pump
• Oil cooler

Ignition (3RZ-FE)

• Ignition system
• Distributor
• Crankshaft position sensor

Ignition (5VZ-FE)

• Ignition system
• Ignition coil
• Camshaft position sensor
• Crankshaft position sensor

Starting (3RZ-FE)

• Starter
• Starter relay

Starting (5VZ-FE)

• Starter
• Starter relay

Charging (3RZ-FE)

• Charging system
• Generator

Charging (5VZ-FE)

• Charging system
• Generator

Clutch

• Troubleshooting
• Clutch pedal
• Clutch master cylinder
• Clutch release cylinder
• Clutch unit

Manual transmission (R150, R150F)

• Manual transmission system
• Troubleshooting
• Manual transmission unit (2WD)
• Manual transmission unit (4WD)
• Manual transmission assembly
• Input shaft
• Output shaft
• Counter gear and reverse idler gear
• Front bearing retainer oil seal
• Extension housing and transfer adaptor

Manual transmission (W59)

• Manual transmission system
• Troubleshooting
• Manual transmission unit
• Manual transmission assembly
• Input shaft
• Output shaft
• Counter gear and reverse idler gear
• Front bearing retainer oil seal
• Extension housing

Automatic transmission

• Automatic transmission system
• Extension housing oil seal (A340E)
• Sensor rotor (A340E)
• Speedometer driven gear
• Vehicle speed sensor
• Park/neutral position (PNP) switch
• Valve body assembly
• Parking lock pawl
• Throttle cable
• Shift lock system
• Automatic transmission unit (A340E)
• Automatic transmission unit (A340F)
• Torque converter clutch and drive plate

Transfer

• Transfer system
• Troubleshooting
• Transfer unit
• Transfer assembly
• Oil pump body
• Driven sprocket
• Rear output shaft
• Input shaft
• Planetary gear
• Oil seal

Propeller shaft

• Troubleshooting
• Propeller shaft assembly (2WD)
• Propeller shaft assembly (4WD)
• Spider bearing

Suspension and axle

• Troubleshooting
• Tire and wheel (2WD)
• Tire and wheel (4WD)
• Front wheel alignment (2WD)
• Front wheel alignment (4WD)
• Front axle hub (2WD)
• Front axle hub (4WD)
• Front wheel hub bolt (2WD)
• Steering knuckle (4WD)
• Front drive shaft (4WD)
• Front differential rear oil seal (4WD)
• Front differential carrier (4WD)
• A.D.D. Control system
• Front shock absorber (2WD)
• Front shock absorber (4WD)
• Front torsion bar spring (2WD)
• Front torsion bar spring (2WD)
• Front strut bar (2WD)
• Front upper suspension arm (2WD)
• Front upper suspension arm (4WD)
• Front lower suspension arm (2WD)
• Front lower suspension arm (4WD)

Brake

• Brake system
• Troubleshooting
• Brake fluid
• Brake pedal
• Parking brake lever
• Brake master cylinder
• Brake booster assembly
• Front brake pad (2WD)
• Front brake pad (4WD)
• Front brake caliper (2WD)
• Front brake caliper (4WD)
• Rear drum brake (2WD)
• Rear drum brake (4WD)
• Lead sensing proportioning and by-pass valve (LSP & BV)
• Abs actuator
• Front speed sensor
• Rear speed sensor

Steering

• Steering system
• Troubleshooting
• Drive belt
• Power steering fluid
• Air control valve
• Steering wheel
• Non-tilt steering column
• Tilt steering column
• Power steering vane pump (3RZ-FE)
• Power steering vane pump (5VZ-FE)
• Power steering gear (2WD)
• Power steering gear (2WD)
• Steering linkage
• Idler arm

Supplemental restraint system

• SRS airbag
• Steering wheel pad and spiral cable
• Airbag sensor assembly
• Front airbag sensor
• Wire harness and connector

Body electrical

• Body electrical system
• Power source
• Ignition switch and key unlock warning switch
• Headlight and taillight system
• Turn signal and hazard warning system
• Interior light system
• Back-up light system
• Stop light system
• Wiper and washer system
• Combination meter
• Power window control system
• Power door lock control system
• Power mirror control system
• Audio system
• Antenna
• Clock

Body

• Clip
• Srs airbag
• Front bumper
• Hood
• Front door
• Front wiper and washer
• Wheel arch moulding
• Windshield
• Quarter window glass
• Back window glass
• Instrument panel
• Tail gate
• Front seat (bench type)
• Front seat (split bench type)
• Rear seat
• Seat belt

Air Conditioning

• Air conditioning system
• Drive belt
• Manifold gauge set
• Refrigerant line
• Cooling unit
• Heater unit
• Blower unit
• Compressor and magnetic clutch
• Receiver
• Condenser
• Evaporator
• Heater radiator
• Expansion valve
• Water valve
• Blower motor
• Blower resistor
• Thermistor
• Pressure switch
• Heater main relay
• Air conditioning amplifier
• Air conditioning switch
• Heater control assembly