ENGINE IDENTIFICATION - trollholescruisers.comtrollholescruisers.com/Tech/Manuals/Chassis and...

4.5L 6-CYL

1997 ENGINES Lexus/Toyota 4.5L 6-Cylinder

ENGINE IDENTIFICATION

Engine serial number is stamped on cylinder block. See Fig. 1 .

ENGINE IDENTIFICATION CODE

Fig. 1: Locating Engine Serial Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

Engine Code4.5L 6-Cylinder 1FZ-FE

NOTE: Adjust valve clearance with engine cold.

1997 Lexus LX 450

4.5L 6-CYL 1997 ENGINES Lexus/Toyota 4.5L 6-Cylinder

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Thursday, August 27, 2009 2:17:50 PM © 2005 Mitchell Repair Information Company, LLC.

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1. Drain cooling system. Disconnect PCV hoses. Remove air intake hose located between throttle body and airflow meter. Disconnect control cables, coolant hoses, electrical connectors and vacuum hoses at throttle body. Remove throttle body and gasket.

2. Remove heater coolant valve and engine wiring from firewall for access to valve cover. Remove front andrear spark plug wire covers from valve cover. Disconnect spark plug wires from spark plugs. Remove valve cover and gasket.

3. Rotate crankshaft clockwise so timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Ensure timing marks with one dot on camshaft sprockets are aligned. See Fig. 2 . Timing marks with the 2 dots should be even with cylinder head surface. See Fig. 2 . If timing marks with one dot are not aligned, rotate crankshaft clockwise one full revolution (360 degrees).

4. With cylinder No. 1 at TDC, check valve clearance on specified valves. See VALVE CLEARANCE ADJUSTMENT SEQUENCE . Using feeler gauge, measure and record valve clearance between valve lifter and camshaft.

VALVE CLEARANCE ADJUSTMENT SEQUENCE

Fig. 2: Checking Camshaft Sprocket Timing Mark Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees), until cylinder No. 6 is at TDC on compression stroke. Measure valve clearance on specified valves. See VALVE CLEARANCE ADJUSTMENT SEQUENCE . Valve clearance should be within specification. See VALVE CLEARANCE SPECIFICATIONS .

Cylinder No. At TDC

Adjust Intake Valves

Adjust Exhaust Valves

1 1, 2 & 4 1, 3 & 56 3, 5 & 6 2, 4 & 6

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VALVE CLEARANCE SPECIFICATIONS (1)

6. If valve clearance requires adjustment on any valve except rear valves on cylinder No. 6, rotate crankshaft so camshaft lobe on valve to be adjusted faces upward, away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.

7. Valve Clearance Adjuster (SST 09248-55050) is used to remove adjusting shim. Using SST "A" of valve clearance adjuster, push downward on valve lifter. Place SST "B" between camshaft and valve lifter with "11" facing proper direction. See Fig. 3 . Remove SST "A".

Fig. 3: Adjusting Valve Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Application In. (mm)Intake Valve .006-.010 (.15-.25)Exhaust Valve .010-.014 (.25-.35)(1) Adjust valve clearance with engine cold.

NOTE: Manufacturer recommends camshaft removal for access to adjusting shim for adjusting valve clearance on rear valves on cylinder No. 6. See CAMSHAFTS under REMOVAL & INSTALLATION. On all other cylinders, valve clearance may be adjusted with camshaft installed.

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8. On all cylinders, use small screwdriver and magnet to remove adjusting shim. Measure thickness of adjusting shim removed. Using measured clearance and adjusting shim thickness, determine correct thickness of replacement adjusting shim. See Fig. 4 and Fig. 5 .

9. Install adjusting shim and camshaft (if removed). Recheck valve clearance. If spark plug tube gasket in valve cover requires replacement, pry spark plug tube gasket from cylinder head side of valve cover. DO NOT scratch valve cover sealing surface.

10. Using Handle (SST 09951-07150) and Gasket/Seal Installer(SST 09951-00480), install spark plug tube gasket in valve cover. Coat spark plug tube gasket sealing area with grease.

11. To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system. Adjust control cables. Check ignition timing if distributor was removed.

Fig. 4: Intake Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 5: Exhaust Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

1. Disconnect electrical connector for electric fuel pump. See Fig. 6 . Start engine and allow engine to idle until engine stalls. Turn ignition off. Disconnect negative battery cable.

WARNING: Ensure negative battery cable is disconnected at least 90 seconds before working on vehicle, to prevent air bag deployment.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

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2. Reconnect electrical connector for electric fuel pump. Place an approved gasoline container under fuel line. Cover fuel line connection with shop towel and slowly loosen fuel line to release pressure. Once fuel pressure is released, fuel system components may be serviced.

Fig. 6: Locating Electrical Connector For Electric Fuel Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE

Removal

1. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Drain engine oil and cooling system.

2. Remove battery, battery tray, hood and grille. Remove accessory drive belts. Remove cooling fan, water pump pulley, fan shroud and radiator. Remove air intake hose with airflow meter and air cleaner cover. Remove air cleaner case.

3. Disconnect control cables at throttle body. Disconnect necessary electrical connectors, fuel lines, coolant hoses and vacuum hoses for engine removal. Remove A/C compressor with hoses attached and secure aside. Remove A/C compressor mounting bracket from cylinder block.

NOTE: Remove engine and transmission as an assembly.

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4. Remove radiator coolant pipe for radiator hose from cylinder block. Disconnect hoses from power steering pump. Remove heater coolant valve and engine wiring from firewall.

5. Remove glove compartment door. Remove speaker panel from passenger's side of instrument panel, next to glove compartment door. Remove retaining screw and A/C amplifier. See Fig. 7 .

6. Disconnect electrical connectors from Engine Control Module (ECM). Disconnect remaining 2 electrical connectors for engine wiring harness. See Fig. 7 . Pull engine wiring harness out through firewall.

Fig. 7: Locating A/C Amplifier, ECM & Engine Wiring Harness Electrical Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

7. Raise and support vehicle. Remove stabilizer bar. Place reference marks on drive shaft flanges for installation reference. Remove all drive shafts. Disconnect transmission shift linkage at control rod on transmission.

8. Remove knob from transfer case shift lever. Remove center console panel located above transmission and transfer case shift levers. Remove boot from transfer case shift lever. Remove center console storage box

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located between seats.

9. Disconnect electrical connectors at transmission shift lever assembly. Remove transmission shift lever assembly. Disconnect control rod at transfer case shift lever. Remove transfer case shift lever.

10. Disconnect necessary electrical connectors at transmission and transfer case. Disconnect oil cooler lines at transmission. Disconnect front exhaust pipe with front catalytic converter from exhaust manifold and rear catalytic converter on center exhaust pipe.

11. Remove transfer case skid plates. Support transmission with floor jack. Remove transmission crossmember located below transmission. Support engine with hoist. Remove engine mount-to-frame nuts. Lift engine and transmission from vehicle.

Installation

1. To install, reverse removal procedure using NEW gaskets. If installing torque converter bolts, ensure the Green-colored bolt is installed first. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Ensure reference marks on drive shaft flanges are aligned.

2. To adjust shift linkage for transmission, place transmission shift lever in Neutral. Rotate control rod on transmission fully backward, toward rear of vehicle. Move control rod forward 2 notches to Neutral position. Install transmission shift linkage on control rod. Install and tighten transmission shift linkage-to-control rod nut to specification. See TORQUE SPECIFICATIONS .

3. When installing stabilizer bar, loosely install stabilizer-to-axle housing bolts. Install and tighten stabilizer bar mount-to-frame bolts to specification. See TORQUE SPECIFICATIONS . Lower vehicle. Bounce vehicle up and down several times. Tighten stabilizer bar-to-axle housing bolts to specification. See TORQUE SPECIFICATIONS . Install remaining components.

CYLINDER HEAD & MANIFOLDS

Removal

1. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Drain cooling system. Remove battery and battery tray. Remove PCV hoses. Remove air intake hose with airflow meter and air cleaner cover. Disconnect control cables and electrical connectors at throttle body.

2. Disconnect necessary electrical connectors, coolant hoses and vacuum hoses for removal of cylinder head and manifolds. Remove heater coolant valve and engine wiring from firewall. Remove spark plug wire covers from valve cover. See Fig. 8 . Disconnect spark plug wires from spark plugs. Remove distributor and plug wires. Remove power steering reservoir with hoses attached and secure aside.

3. Remove accessory drive belts and generator. Remove throttle body and gasket. Remove dipstick, dipstick tube and "O" ring for engine oil and transmission fluid. Remove air intake chamber support brace located between cylinder block and air intake chamber.

4. Disconnect fuel inlet hose at fuel filter. Remove coolant by-pass pipe from front of cylinder head. See Fig. 8 . Disconnect front exhaust pipe with front catalytic converter from exhaust manifold and rear catalytic converter on center exhaust pipe.

5. Remove heat insulators, No. 1 and 2 exhaust manifolds and gaskets from cylinder head. Remove heater coolant pipe from exhaust manifold side of cylinder head. See Fig. 8 .

6. Remove coolant by-pass outlet, coolant by-pass outlet pipe and "O" rings from passenger's side front corner of cylinder head. See Fig. 8 . Remove valve cover and gasket. See Fig. 10 . Remove spark plugs.

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Remove camshafts. See CAMSHAFTS under REMOVAL & INSTALLATION.

Fig. 8: Exploded View Of Intake Manifold & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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7. Remove 2 cylinder head-to-timing chain cover bolts. Remove cylinder head bolts in sequence using several steps. See Fig. 9 . Remove cylinder head and cylinder head gasket. If removing valve lifters and adjusting shims from cylinder head, ensure component location is marked for installation reference.

8. Remove generator mounting bracket, coolant outlet and gasket from cylinder head. Remove EGR pipe from EGR valve. Remove coolant by-pass hose from cylinder head, at rear of intake manifold.

9. Remove intake manifold bolts/nuts. Remove intake manifold with air intake chamber from cylinder head. Disconnect vacuum hose from fuel pressure regulator. Remove air intake chamber.

10. If removing delivery pipe with fuel injectors from intake manifold, remove fuel return pipe from fuel pressure regulator and intake manifold. See Fig. 8 . Remove union bolts, gaskets and No. 1 fuel pipe from delivery pipe and fuel filter.

11. Remove delivery pipe-to-intake manifold bolts and delivery pipe with fuel injectors. Remove 3 spacers and 6 insulators for delivery pipe from intake manifold. See Fig. 11 . Remove fuel injectors from delivery pipe.

CAUTION: Cylinder head bolts must be removed in proper sequence to prevent cylinder head warpage.

CAUTION: DO NOT allow fuel injectors to fall from delivery pipe when removing delivery pipe.

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Fig. 9: Cylinder Head-To-Cylinder Block Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Exploded View Of Cylinder Head & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 11: Locating Insulators & Spacers For Delivery Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspection

1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS.

2. Using caliper, measure outside diameter of cylinder head bolts on threaded area at 1.18" (30.0 mm) for bottom end of bolt. Replace cylinder head bolt if outside diameter is less than .417" (10.60 mm).

3. Inspect intake manifold-to-air intake chamber surface and intake manifold-to-cylinder head surface for warpage. Inspect air intake chamber-to-intake manifold surface for warpage. Inspect exhaust manifold-to-cylinder head surface for warpage. Replace any manifold if warpage exceeds .0118" (.300 mm).

4. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS.

5. Ensure valve lifter diameter, bore diameter and oil clearance is within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS. Replace components if not within specification.

6. Inspect camshaft and components. See CAMSHAFTS under REMOVAL & INSTALLATION. Ensure cylinder block orifice is installed in cylinder block is not damaged or restricted. See Fig. 37 .

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Installation

1. If installing fuel injector in delivery pipe, remove "O" ring and grommet from fuel injector. Apply light coat of gasoline to NEW "O" ring for fuel injector. Install NEW grommet and "O" ring on fuel injector. Using twisting motion, install fuel injector into delivery pipe.

2. Install NEW insulators and spacers on intake manifold. See Fig. 11 . Install fuel injectors with delivery pipe on intake manifold. Loosely install delivery pipe-to-intake manifold bolts. Ensure fuel injectors rotate smoothly. If fuel injectors fail to rotate smoothly, check for improperly installed "O" rings. Position each fuel injector so electrical connector is facing upward. Tighten delivery pipe-to-intake manifold bolts to specification. See TORQUE SPECIFICATIONS .

3. Install fuel return pipe on fuel pressure regulator and intake manifold. Using NEW gaskets, install No. 1 fuel pipe between delivery pipe and fuel filter. Install and tighten union bolts to specification. See TORQUE SPECIFICATIONS .

4. Using NEW gaskets, install air intake chamber on intake manifold. Install and tighten air intake chamber bolts/nuts to specification. See TORQUE SPECIFICATIONS .

5. Install NEW intake manifold gasket on cylinder head with rear identification mark toward rear of cylinder head. See Fig. 12 . Install intake manifold. Install and tighten intake manifold-to-cylinder head bolts/nuts to specification. See TORQUE SPECIFICATIONS .

Fig. 12: Installing Intake Manifold Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. Install heater coolant pipe. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Using NEW gasket, install EGR pipe on cylinder head and EGR valve. Install and tighten bolts and EGR pipe union nut to specification. See TORQUE SPECIFICATIONS .

7. Using NEW gasket, install coolant outlet on cylinder head. Install and tighten nuts to specification. See TORQUE SPECIFICATIONS . Install generator mounting bracket on cylinder head. Install and tighten

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bolts to specification. See TORQUE SPECIFICATIONS .

8. Ensure cylinder block orifice is installed in cylinder block. See Fig. 37 . Apply Sealant (08826-00080) on front corners of cylinder block. See Fig. 13 . Install NEW cylinder head gasket on cylinder block. Ensure all holes in cylinder head gasket align with holes in cylinder block.

9. Install cylinder head. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Ensure washers are installed on cylinder head bolts.

10. Install and tighten cylinder head-to-cylinder block bolts to specification in sequence. See Fig. 9 . See TORQUE SPECIFICATIONS . Install and tighten cylinder head-to-timing chain cover bolts to specification.

11. Install camshafts using proper procedure. See CAMSHAFTS under REMOVAL & INSTALLATION. Check and adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

12. Install and tighten spark plugs to specification. Apply sealant on half-circular plug where it contacts cylinder head. Install half-circular plugs at front of cylinder head. See Fig. 10 .

13. Rotate crankshaft clockwise so cylinder No. 1 is at TDC of compression stroke. Ensure timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover.

14. Ensure timing marks with one dot on camshaft sprockets are aligned. See Fig. 2 . Timing marks with the 2 dots should be even with cylinder head surface. See Fig. 2 . If timing marks with one dot are not aligned, rotate crankshaft clockwise one full revolution (360 degrees).

15. If spark plug tube gasket in valve cover requires replacement, pry spark plug tube gasket from valve cover. DO NOT scratch valve cover sealing surface.

16. Using Handle (SST 09951-07150) and Gasket/Seal Installer (SST 09951-00480), install spark plug tube gasket in valve cover. Coat spark plug tube gasket sealing area with grease. Using NEW gasket, install valve cover.

17. To install remaining components, reverse removal procedure. Use NEW gaskets or "O" rings. Apply soapy water solution to coolant by-pass outlet pipe "O" rings before installing coolant by-pass outlet pipe. Apply engine oil to dipstick tube "O" rings before installing. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS .

18. When installing distributor, ensure cylinder No. 1 is at TDC on compression stroke. Ensure timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover.

19. Install NEW "O" ring on distributor. Apply engine oil on "O" ring. Align protrusion on drive gear with groove on distributor housing. See Fig. 14 . Install distributor in cylinder head so center of flange on distributor aligns with bolt hole in cylinder head. Install distributor hold-down bolt.

20. To install remaining components, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS . Adjust control cables and ignition timing. Fill cooling system. Check all fluid levels.

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Fig. 13: Applying Sealant On Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 14: Installing Distributor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CRANKSHAFT FRONT SEAL

Removal & Installation (Timing Chain Cover Installed)

Remove accessory drive belts. Using Pulley Holder (SST 09213-58012) and Handle (SST 09330-00021), hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Pry seal from timing chain cover. DO NOT damage sealing surfaces.

Installation

To install, apply grease to seal lip of NEW seal. Using hammer, Handle (SST 09316-00011) and Seal Installer (SST 09316-00051), install seal until seal surface is even with timing chain cover. To install remaining components, reverse removal procedure. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (Timing Chain Cover Removed)

Using hammer and punch, tap seal from timing chain cover. DO NOT damage sealing surfaces. To install, apply grease to seal lip of NEW seal. Using hammer, Handle (SST 09316-00011) and Seal Installer (SST

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09316-00051), install seal until seal surface is even with timing chain cover.

TIMING CHAIN

Removal

1. Drain cooling system and engine oil. Remove lower engine cover. Remove accessory drive belts. Remove cooling fan, water pump pulley, shroud and radiator.

2. Remove A/C compressor with hoses attached and secure aside. Remove A/C compressor bracket from cylinder block. Remove radiator coolant pipe and hose from cylinder block. See Fig. 15 . Remove bolts/nuts, water pump and gasket. Remove cylinder head. See CYLINDER HEAD & MANIFOLDS under REMOVAL & INSTALLATION. Remove No. 1 and 2 oil pans. See OIL PAN under REMOVAL & INSTALLATION.

3. Using Pulley Holder (SST 09213-58012) and Handle (SST 09330-00021), hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.

4. Using dial indicator, check oil pump drive shaft gear thrust clearance when moving gear back and forth. See Fig. 16 . Standard oil pump drive shaft gear thrust clearance is .0016-.0063" (.040-.160 mm) with maximum thrust clearance of .0118" (.300 mm). Replace oil pump drive shaft gear and or/timing chain cover if thrust clearance exceeds maximum specification.

5. Remove drive belt idler pulley and drive belt adjusting bar. See Fig. 15 . Remove bolts from timing chain cover. Note bolt length and location for installation reference. Remove timing chain cover by gently prying between cylinder block and timing chain cover.

6. Remove "O" rings from rear of timing chain cover. Remove timing chain and camshaft sprocket. Remove crankshaft sprocket, damper and slipper. See Fig. 15 .

7. Remove bolt and oil jet from front of cylinder block. Remove crankshaft rotor and oil pump drive shaft gear. See Fig. 15 . If removing pump drive shaft gear, place shop towels against block. Using 2 screwdrivers, pry pump drive shaft gear from crankshaft.

NOTE: Manufacturer recommends cylinder head removal when servicing timing chain, as cylinder head gasket fits on top of timing chain cover.

NOTE: Oil pump drive shaft gear thrust clearance must be checked before removing timing chain cover.

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Fig. 15: Exploded View Of Oil Pans, Timing Chain & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 16: Checking Oil Pump Drive Shaft Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspection

1. Inspect components for damage. Apply air pressure to oil jet to ensure passage is not restricted. Using micrometer, check amount of wear on slipper and damper. Replace slipper or damper if wear exceeds .039" (1.00 mm) from original surface.

2. Using caliper, measure length of timing chain between 16 links at several different areas on timing chain. Perform STEP 1. See Fig. 17 . Replace timing chain if length exceeds specification. See TIMING CHAIN & SPROCKET SPECIFICATIONS .

3. Wrap timing chain around crankshaft sprocket. Using caliper, measure outside diameter of timing chain with caliper contacting rollers on timing chain. Perform STEP 2. See Fig. 17 .

4. Repeat procedure on camshaft sprocket. Replace timing chain and sprocket if outside diameter measurement is less than specified. See TIMING CHAIN & SPROCKET SPECIFICATIONS .

TIMING CHAIN & SPROCKET SPECIFICATIONS Application In. (mm)Sprocket & Timing Chain Outside Diameter

Timing Chain With Camshaft Sprocket 4.961 (126.00)Timing Chain With Crankshaft Sprocket 2.575 (65.40)

Timing Chain Length Between 16 Links 5.772 (146.60)

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Fig. 17: Measuring Timing Chain & Sprockets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Installation

1. If installing crankshaft front seal in timing chain cover, use hammer, Handle (SST 09316-00011) and Seal Installer (SST 09316-00051). Install seal until seal surface is even with timing chain cover. Apply grease to seal lip of seal.

2. If installing pump drive shaft gear on crankshaft, rotate crankshaft until key in crankshaft is facing downward. Install pump drive shaft gear on crankshaft. If installing oil pump drive shaft gear, apply engine oil to splines at center of gear where shaft of oil pump drive rotor engages. Install oil pump drive shaft gear.

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3. Install crankshaft rotor with flat side of crankshaft rotor toward cylinder block. See Fig. 15 . Install oil jet on cylinder block. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS . Install damper and slipper. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure slipper moves smoothly.

4. Install crankshaft sprocket with flat side toward cylinder block and crankshaft rotor. See Fig. 15 . If necessary, use hammer and Sprocket Installer (SST 09636-20010) to install crankshaft sprocket.

5. Install timing chain. Align bright link on timing chain with timing mark on camshaft sprocket. Perform STEP 1. See Fig. 18 . Align bright link on timing chain with timing mark on crankshaft sprocket. Perform STEP 2. See Fig. 18 .

6. Place tie around timing chain to ensure timing chain does not come loose. Perform STEP 3. See Fig. 18 . Ensure sealing surfaces on front of cylinder block and rear of timing chain cover are clean. Apply sealant on rear of timing chain cover. Ensure sealant does not enter "O" ring areas on timing chain cover. See Fig. 19 .

7. Install NEW "O" rings on rear of timing chain cover. Install timing chain cover on cylinder block. Engage splines on oil pump drive rotor with oil pump drive shaft gear. Install drive belt adjusting bar and bolts/nuts of timing chain cover. Ensure proper length bolt is installed in designated area. See Fig. 20 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove tie from timing chain.

8. Install drive belt idler pulley and crankshaft pulley. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install No. 1 and 2 oil pans using proper procedure. See OIL PAN under REMOVAL & INSTALLATION.

9. Install cylinder head using proper procedure. See CYLINDER HEAD under REMOVAL & INSTALLATION . To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill crankcase and cooling system.

CAUTION: Ensure crankshaft rotor is installed with flat side toward cylinder block. See Fig. 15 .

CAUTION: Ensure crankshaft sprocket is installed with flat side toward cylinder block. See Fig. 15 .

CAUTION: When installing timing chain cover, ensure splines on oil pump drive rotor of oil pump in timing chain cover fully engage with oil pump drive shaft gear or components may be damaged.

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Fig. 18: Installing Timing Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 19: Identifying Timing Chain Cover Sealant Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 20: Identifying Timing Chain Cover Bolt Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VALVE LIFTER

Removal

Camshaft must be removed for valve lifter removal. See CAMSHAFTS under REMOVAL & INSTALLATION. Note location of adjusting shims and valve lifters for installation reference. Remove valve lifters and adjusting shims from cylinder head.

Inspection

Inspect components for damage. Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS.

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Installation

To install, reverse removal procedure. Coat components with engine oil before installing. Ensure components are installed in original location and valve lifter rotates smoothly in cylinder head. If camshaft, adjusting shims or valve lifters are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

CAMSHAFTS

Removal

1. Drain cooling system. Disconnect PCV hoses. Remove air intake hose located between throttle body and airflow meter. Disconnect control cables, coolant hoses, electrical connectors and vacuum hoses at throttle body. Remove throttle body and gasket.

2. Remove heater coolant valve and engine wiring from firewall for access to valve cover. Remove front andrear spark plug wire covers from valve cover. Disconnect spark plug wires from spark plugs. Remove valve cover and gasket.

3. Rotate crankshaft clockwise so timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Ensure timing marks with one dot on camshaft sprockets are aligned. See Fig. 2 . Timing marks with the 2 dots should be even with cylinder head surface. See Fig. 2 . If timing marks with one dot are not aligned, rotate crankshaft clockwise one full revolution (360 degrees).

4. Remove nuts, timing chain tensioner and gasket from cylinder head. See Fig. 10 . Remove half-circular plug from front of cylinder head. Place reference mark on timing chain and camshaft sprocket for installation reference.

5. Hold intake camshaft by placing wrench on hexagonal portion of camshaft. Remove camshaft sprocket bolt and distributor gear. See Fig. 10 . Remove camshaft sprocket with timing chain, allowing camshaft sprocket and timing chain to rest on slipper and damper. See Fig. 15 .

6. For exhaust camshaft removal, use wrench on hexagonal portion of camshaft to rotate exhaust camshaft for access to service bolt hole on sub-gear. Secure sub-gear on exhaust camshaft to main gear using a 6 x

CAUTION: DO NOT allow timing chain to disengage from crankshaft sprocket.

NOTE: Camshaft bearing caps are numbered for location. No. 1 bearing cap is at timing chain end of cylinder head and No. 7 at rear of cylinder head. Camshaft bearing caps are stamped with an "I" for intake camshaft or "E" for exhaust camshaft. Arrow on camshaft bearing cap points toward timing chain end of cylinder head.

CAUTION: Camshafts must be properly positioned to lift camshaft straight from cylinder head to prevent damage to cylinder head and camshaft. DO NOT pry or force camshafts from cylinder head as component damage may result.

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1 x 18-mm service bolt "B". See Fig. 21 . Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is held by service bolt "B".

Fig. 21: Securing Sub-Gear On Exhaust Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

7. Rotate intake camshaft to position timing mark with 2 dots at a 35-degree angle. Perform STEP 1. See Fig. 22 . Lightly push exhaust camshaft toward rear of cylinder head.

8. Alternately loosen bolts on No. 1 exhaust camshaft bearing cap. Remove No. 1 exhaust camshaft bearing cap. Alternately loosen and remove No. 2, 3, 5 and 7 exhaust camshaft bearing cap bolts. DO NOT loosen No. 4 and 6 exhaust camshaft bearing cap bolts. Remove No. 2, 3, 5 and 7 exhaust camshaft bearing caps.

9. Alternately loosen No. 4 and 6 exhaust camshaft bearing cap bolts. Ensure camshaft is lifted upward evenly as No. 4 and 6 exhaust camshaft bearing cap bolts are removed. Remove No. 4 and 6 exhaust camshaft bearing caps and exhaust camshaft.

10. For intake camshaft removal, rotate intake camshaft so timing mark with 2 dots is at 25-degree angle. Perform STEP 2. See Fig. 22 . This aids in camshaft removal by using lobes on cylinder No. 1 and 4 to push on valve lifters.

11. Lightly push intake camshaft toward front of cylinder head. Alternately loosen bolts on No. 1 intake camshaft bearing cap. Remove No. 1 intake camshaft bearing cap.

12. Alternately loosen and remove No. 3, 4, 6 and 7 intake camshaft bearing cap bolts. DO NOT loosen No. 2

NOTE: If exhaust camshaft is not lifted upward evenly, retighten No. 4 and 6 exhaust camshaft bearing cap bolts. Reinstall all exhaust camshaft bearing caps and reposition timing mark. Repeat procedure and remove exhaust camshaft.

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and 5 intake camshaft bearing cap bolts. Remove No. 3, 4, 6 and 7 intake camshaft bearing caps.

13. Alternately loosen No. 2 and 5 intake camshaft bearing cap bolts. Ensure intake camshaft is lifted upward evenly as No. 2 and 5 camshaft bearing caps bolts are removed. Remove No. 2 and 5 intake camshaft bearing caps and intake camshaft.

14. If removing sub-gear from exhaust camshaft, install service bolt "A" in camshaft. See Fig. 23 . Using screwdriver, rotate sub-gear clockwise and remove service bolt "B". Remove snap ring, wave washer, sub-gear and camshaft gear spring from exhaust camshaft. See Fig. 10 .

15. Remove valve lifters and adjusting shims from cylinder head (if necessary). Mark component location for installation reference as components must be installed in original location.

NOTE: If intake camshaft is not lifted upward evenly, retighten No. 2 and 5 intake camshaft bearing cap bolts. Reinstall all intake camshaft bearing caps and reposition timing mark. Repeat procedure and remove intake camshaft.

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Fig. 22: Positioning Camshaft Timing Marks For Servicing Of Camshafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 23: Disassembling Exhaust Camshaft Gears Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspection

1. Check camshaft journal diameter, lobe height and journal runout. Replace camshaft if not within specification. See CAMSHAFT under ENGINE SPECIFICATIONS.

2. Install camshaft in cylinder head. Using Plastigage, check camshaft oil clearance with camshaft bearing cap bolts tightened to specification. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft and/or cylinder head if oil clearance or camshaft end play clearance is not within specification. See CAMSHAFT under ENGINE SPECIFICATIONS.

3. Install camshafts in cylinder head without sub-gear installed on exhaust camshaft. Tighten camshaft bearing cap bolts to specification. Using dial indicator, measure gear backlash between camshaft gears. Replace camshaft if gear backlash exceeds specification. See CAMSHAFT under ENGINE SPECIFICATIONS.

4. Measure distance between ends of camshaft gear spring. Replace camshaft gear spring if distance is not .717-.740" (18.20-18.80 mm). Hold timing chain tensioner and push plunger inward. Ensure plunger moves smoothly inward and outward. Replace timing chain tensioner if plunger does not move smoothly.

Installation

CAUTION: When installing camshaft to check oil clearance, camshaft end play and gear backlash, proper installation procedure of camshaft must be followed. See INSTALLATION under CAMSHAFTS .

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1. For reassembly of exhaust camshaft, install camshaft gear spring, sub-gear, wave washer and snap ring on exhaust camshaft. Ensure pins on sub-gear and main gear engage with ends of camshaft gear spring.

2. Install service bolt "A" in camshaft sub-gear. See Fig. 23 . Using screwdriver, rotate sub-gear clockwise. Align holes of main gear and sub-gear. Install service bolt "B". Remove service bolt "A".

3. Coat thrust surfaces of camshafts with engine oil. To install intake camshaft, position intake camshaft so cylinder No. 1 and 4 camshaft lobes are facing downward, toward valve lifter. This will place timing mark with 2 dots on intake camshaft at a 25-degree angle. Perform STEP 2. See Fig. 22 . Install intake camshaft on cylinder head.

4. Lightly push intake camshaft toward timing chain end of cylinder head. Install No. 2 and 5 camshaft bearing caps on intake camshaft. Install bolts in No. 2 and 5 camshaft bearing caps. Alternately tighten bolts until No. 2 and 5 camshaft bearing caps are snug against cylinder head.

5. Install No. 3, 4, 6 and 7 camshaft bearing caps and bolts on intake camshaft. Alternately tighten bolts until No. 3, 4, 6 and 7 camshaft bearing caps are snug against cylinder head.

6. Install No. 1 camshaft bearing cap and bolts on intake camshaft. Ensure no gap exists between No. 1 camshaft bearing cap and surface of cylinder head. Alternately tighten bolts until No. 1 camshaft bearing cap is snug against cylinder head surface. Tighten all intake camshaft bearing cap bolts to specification starting at the center of camshaft and moving outward. See TORQUE SPECIFICATIONS .

7. To install exhaust camshaft, rotate intake camshaft until timing mark with 2 dots is at 35-degree angle. Perform STEP 1. See Fig. 22 . Engage gear on exhaust camshaft with gear on intake camshaft so timing marks with the 2 dots are aligned. See Fig. 24 . Roll exhaust camshaft onto cylinder head. Ensure timing marks with the 2 dots are still aligned.

CAUTION: Ensure intake camshaft bearing caps are stamped with letter "I" and installed in numerical sequence with arrow pointing toward timing chain end of cylinder head. No. 1 camshaft bearing cap should be at front of cylinder head and No. 7 at rear of cylinder head.

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Fig. 24: Aligning Timing Marks On Camshaft Gears Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

8. Lightly push exhaust camshaft toward timing chain end of cylinder head. Install No. 4 and 6 camshaft bearing caps on exhaust camshaft. Install bolts in No. 4 and 6 camshaft bearing caps on exhaust camshaft. Alternately tighten bolts until No. 4 and 6 camshaft bearing caps are snug against cylinder head surface.

9. Install No. 2, 3, 5 and 7 camshaft bearing caps and bolts on exhaust camshaft. Alternately tighten bolts until No. 2, 3, 5 and 7 camshaft bearing caps are snug against cylinder head surface.

10. Install No. 1 camshaft bearing cap and bolts on exhaust camshaft. Ensure no gap exists between No. 1 camshaft bearing cap and surface of cylinder head. Alternately tighten bolts until No. 1 camshaft bearing cap is snug against cylinder head surface.

11. Tighten all exhaust camshaft bearing cap bolts to specification starting at the center of camshaft and moving outward. See TORQUE SPECIFICATIONS . Remove service bolt "B" from exhaust camshaft.

CAUTION: Ensure exhaust camshaft bearing caps are stamped with letter "E" and installed in numerical sequence with arrow pointing toward timing chain end of cylinder head. No. 1 camshaft bearing cap should be at front of cylinder head and No. 7 at rear of cylinder head.

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12. Ensure cylinder No. 1 is at TDC of compression stroke and timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover. Rotate camshafts so timing marks with one dot on camshaft sprockets are aligned. See Fig. 2 . Timing marks with the 2 dots should be even with cylinder head surface.

13. Ensure reference mark on camshaft sprocket and timing chain are aligned. Install camshaft sprocket on intake camshaft. Ensure groove in camshaft sprocket engages pin in camshaft.

14. Install distributor gear on camshaft sprocket. Ensure pin on distributor gear engages groove on camshaft sprocket. Install and tighten camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS .

15. Install NEW gasket for timing chain tensioner on cylinder head. Ensure gasket is properly positioned on cylinder head with front mark toward front of cylinder head. See Fig. 25 . Install timing chain tensioner on cylinder head. Push timing chain, against cylinder head. Install and tighten nuts to specification. See TORQUE SPECIFICATIONS .

Fig. 25: Installing Gasket For Timing Chain Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

16. To check for proper valve timing, rotate crankshaft clockwise so cylinder No. 1 is at TDC of compression

CAUTION: Ensure service bolt "B" is removed from exhaust camshaft.

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stroke. Ensure timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover.

17. Ensure timing marks with one dot on camshaft sprockets are aligned. See Fig. 2 . Timing marks with the 2 dots should be even with cylinder head surface. See Fig. 2 . If timing marks with one dot are not aligned, rotate crankshaft clockwise one full revolution (360 degrees), and recheck alignment.

18. Adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. If spark plug tube gasket in valve cover requires replacement, pry spark plug tube gasket from valve cover. DO NOT scratch valve cover sealing surface.

19. Using Handle (SST 09951-07150) and Gasket/Seal Installer(SST 09951-00480), install spark plug tube gasket in valve cover. Coat spark plug tube gasket sealing area with grease.

20. Apply sealant on half-circular plug where it contacts cylinder head and install in cylinder head. See Fig. 10 . To install remaining components, reverse removal procedure. Use NEW gaskets. See TORQUE SPECIFICATIONS . Fill cooling system. Adjust control cables.

CRANKSHAFT REAR OIL SEAL

Removal & Installation

1. Remove transmission and drive plate. See TRANSMISSION REMOVAL & INSTALLATION - A/T article in AUTOMATIC TRANSMISSION SERVICING.

TRANSMISSION REMOVAL & INSTALLATION - A/T - Lexus

TRANSMISSION REMOVAL & INSTALLATION - A/T - Toyota

Using knife, cut seal lip from crankshaft rear oil seal. Pry crankshaft rear oil seal from rear oil seal housing. DO NOT damage rear oil seal housing and crankshaft surfaces.

2. To install, use Handle (SST 09951-07150) and Oil Seal Installer(SST 09223-15030) to install NEW crankshaft rear oil seal in rear oil seal housing until oil seal is even with surface of rear oil seal housing. Coat lip of crankshaft rear oil seal with grease.

3. To install remaining components, reverse removal procedure. Tighten drive plate bolts to specification in a crisscross pattern. See TORQUE SPECIFICATIONS .

WATER PUMP


1. Drain cooling system. Disconnect necessary coolant hoses for access to water pump. Remove accessory drive belts. Remove cooling fan, water pump pulley and fan shroud. Remove bolts/nuts, water pump and gasket.

2. To install, reverse removal procedure using NEW gasket. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

OIL PAN

NOTE: A one-piece crankshaft rear oil seal is mounted in rear oil seal housing on rear of cylinder block.

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Removal

1. Raise and support vehicle. Drain engine oil. Remove lower engine cover for access to oil pans (if necessary). Disconnect oil cooler pipe bracket. Remove bolts, oil level sensor and gasket from No. 1 oil pan. See Fig. 15 .

2. To remove No. 2 oil pan, remove No. 2 oil pan bolts/nuts. Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Using hammer, tap seal cutter along sides of No. 2 oil pan surface to loosen seal between No. 1 and 2 oil pans. DO NOT damage sealing surfaces. Remove No. 2 oil pan.

3. To remove No. 1 oil pan, remove No. 1 oil pan-to-transmission housing bolts located at rear of oil pan. Remove remaining No. 1 oil pan bolt/nuts. Remove No. 1 oil pan by prying between oil pan and cylinder block at designated areas. See Fig. 26 .

4. Remove oil pump passage gasket located between No. 1 oil pan and timing chain cover. See Fig. 27 . Remove oil pan baffle plate and oil pump pick-up tube from No. 1 oil pan (if necessary).

NOTE: Oil pan consists of a No. 1 and No. 2 oil pan. See Fig. 15 .

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Fig. 26: Removing No. 1 Oil Pan Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 27: Locating Oil Pump Passage & Oil Pump Passage Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Installation

1. Using NEW gasket, install oil pump pick-up tube on No. 1 oil pan (if removed). Tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS . Install oil pan baffle plate on No. 1 oil pan (if removed). Tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS . Ensure all sealing surfaces are clean.

2. Install NEW oil pump passage gasket on timing chain cover. Pour .5 oz. engine oil in oil pump passage of timing chain cover. See Fig. 27 . Apply a .12-.16" (3.0-4.0 mm) diameter bead of sealant at specified areas on No. 1 oil pan. See Fig. 28 .

3. Install No. 1 oil pan. Install and tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS . Apply a .12-.16" (3.0-4.0 mm) diameter bead of sealant at specified areas on No. 2 oil pan. See Fig. 28 .

4. Install No. 2 oil pan. Install and tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification.

5. Use NEW gasket when installing oil level sensor. Ensure gasket is installed on oil level sensor with flat side against oil level sensor and cupped side toward No. 1 oil pan. Fill crankcase with oil.

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Fig. 28: Locating No. 1 & 2 Oil Pan Sealant Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OVERHAUL

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CYLINDER HEAD

Cylinder Head

1. Inspect cylinder head warpage at cylinder block and manifold surfaces. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS.

2. Using Plastigage, check camshaft oil clearance with camshaft installed using proper procedure. See CAMSHAFTS under REMOVAL & INSTALLATION. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft and/or cylinder head if camshaft oil clearance or end play is not within specification. See CAMSHAFT under ENGINE SPECIFICATIONS.

3. Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS.

4. If installing spark plug tube into cylinder head, apply Sealant (08833-00070) on spark plug tube bore in cylinder head. Using press, press spark plug tube into cylinder head until distance from top surface of spark plug tube to camshaft bearing cap surface of cylinder head is 1.791" (45.50 mm).

Valve Springs

Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Different style valve stem oil seals are used for intake and exhaust valves. See Fig. 29 . Lubricate valve stem oil seal with engine oil. Using Oil Seal Installer (SST 09236-15010), install valve stem oil seal.

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Fig. 29: Identifying Valve Stem Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Valve Guides

1. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.

2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and Valve Guide Remover/Installer (SST 09201-01070), drive valve guide out from cylinder block side of cylinder head.

3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4524-.4533" (11.492-11.513 mm), use standard valve guide. If bore inside diameter is .4544-.4552" (11.542-11.563 mm), use oversize valve guide.

4. If bore inside diameter exceeds .4533" (11.513 mm), machine valve guide bore to .4544-.4552" (11.542-11.563 mm) for oversize valve guide. If bore I.D. exceeds .4552" (11.563 mm), replace cylinder head.

5. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Use hammer and valve guide remover/installer to install valve guide. Install valve guide until valve guide installed height is within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Valve guide installed height is measured from top of valve guide to cylinder head surface. See Fig. 30 .

6. Using .275" (7.00 mm) reamer, ream valve guide to obtain specified valve stem-to-guide oil clearance. See CYLINDER HEAD under ENGINE SPECIFICATIONS.

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Fig. 30: Measuring Valve Guide Installed Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Valve Seat

Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Valve seat replacement information is not available.

Valves

Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

Use 30-degree and 45-degree stones to lower valve seat contact area. Use 75-degree and 45-degree stones to raise valve seat contact area.

VALVE TRAIN

Valve Lifters

Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS.

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CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

1. Ensure connecting rod and connecting rod cap are marked with corresponding cylinder number for installation reference. Piston, connecting rod and connecting rod cap must be installed with front mark toward front of engine. See Fig. 31 .

2. Check for movement of piston back and forth on piston pin. Replace piston and piston pin as an assembly if movement exists. When removing piston from connecting rod, remove snap rings from piston. Heat piston to 176-194°F (80-90°C) in water. Remove piston pin. Separate piston from connecting rod.

3. Ensure nut rotates easily on connecting rod bolt. If nut does not rotate easily, use caliper to measure outside diameter of connecting rod bolt. Measure connecting rod bolt outside diameter at .98" (25.0 mm) from end of bolt, just above threads. Replace connecting rod bolt and nut if bolt outside diameter is less than .315" (8.00 mm).

4. Measure piston diameter at 1.65" (42.0 mm) from top of piston at 90-degree angle to piston pin. Different piston sizes are used. Piston diameter is determined by size mark ("1", "2" or "3") stamped on top of piston. See Fig. 32 . Ensure piston and piston pin diameter are within specification. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.

5. Ensure connecting rod pin bushing bore diameter, crankpin bore diameter, bend and twist are within specification. See CONNECTING RODS under ENGINE SPECIFICATIONS.

6. Bushing in connecting rod may be replaced if bore diameter is not within specification. Ensure bushing oil hole aligns with connecting rod oil hole. Bushing must be honed to obtain correct piston pin-to-rod clearance. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.

7. To reassemble, install NEW snap ring in one side of piston. Install piston on connecting rod with front marks on top of piston and connecting rod aligned. See Fig. 31 . Heat piston to 176-194°F (80°C) in water. Coat piston pin with engine oil and install. Install NEW snap ring on other end of piston.

NOTE: Crankpin bore diameter is identified by size mark ("1", "2" or "3") stamped on connecting rod. See Fig. 34 .

NOTE: Piston pin should slide in piston using thumb pressure with piston heated to 176-194°F (80-90°C).

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Fig. 31: Locating Front Marks & Aligning Piston With Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fitting Pistons

1. To determine piston-to-cylinder clearance, measure piston skirt diameter at 1.65" (42.0 mm) from top of piston at 90-degree angle to piston pin.

2. Different piston sizes are used. Piston diameter is determined by size mark ("1", "2" or "3") stamped on top of piston. See Fig. 32 . Ensure piston diameter is within specification. See PISTONS, PINS &

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RINGS under ENGINE SPECIFICATIONS.

3. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and bottom of cylinder bore and at center of cylinder bore. Different cylinder bore sizes are used. Cylinder bore diameter may be identified by size mark ("1", "2" or "3") stamped on cylinder block deck surface. See Fig. 32 . Front size mark is for cylinder No. 1 and rear size mark is for cylinder No. 6.

4. Ensure cylinder bore diameter is within specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS. Determine piston clearance. Replace pistons or bore cylinder block if piston clearance is not within specification. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS. Cylinder block may be bored for .020" (.50 mm) or .040" (1.00 mm) oversize pistons.

Fig. 32: Locating Piston & Cylinder Bore Size Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Piston Rings

1. Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.

2. Position piston rings with ring end gaps in proper areas with identification mark on piston ring toward top of piston. See Fig. 33 . No. 1 compression ring contains a 1R identification mark and N o. 2 compression ring contains a 2R identification mark. Ensure piston rings are installed in correct location.

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Fig. 33: Positioning Piston Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Rod Bearings

1. Ensure connecting rod and connecting rod cap are marked with corresponding cylinder number for installation reference. Connecting rod and connecting rod cap must be installed with front mark (protrusion) toward front of engine. See Fig. 31 .

2. Ensure nut rotates easily on connecting rod bolt. If nut does not rotate easily, use caliper to measure outside diameter of connecting rod bolt. Measure connecting rod bolt outside diameter at .98" (25.0 mm) from end of bolt, just above threads. Replace connecting rod bolt and nut if bolt outside diameter is less than .315" (8.00 mm).

3. Connecting rod, rod bearing and crankshaft are stamped with a size mark. See Fig. 34 . If replacing rod bearing, ensure size mark on replacement rod bearing is same as size mark on original rod bearing.

4. If size mark on original rod bearing cannot be obtained, add size marks on crankshaft and connecting rod together to determine size mark of rod bearing. For example, if size mark on crankshaft is "2" and size mark on connecting rod is "1", use rod bearing with size mark "3".

5. Rod bearing thickness is determined by size mark. See ROD BEARING SPECIFICATIONS . Ensure connecting rod and connecting rod cap are installed with front mark (protrusion) toward front of engine. See Fig. 31 .

6. Coat bolt threads and nut-to-connecting rod cap surface with engine oil. Tighten connecting rod nuts to specification. See TORQUE SPECIFICATIONS . Ensure bearing oil clearance and connecting rod side play are within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS under ENGINE SPECIFICATIONS.

ROD BEARING SPECIFICATIONS Size Mark In. (mm)

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Fig. 34: Locating Crankshaft Rod Journal, Connecting Rod & Rod Bearing Size Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

"2" .0687-.0688 (1.744-1.747)"3" .0688-.0689 (1.747-1.750)"4" .0689-.0690 (1.750-1.753)"5" .0690-.0691 (1.753-1.756)"6" .0691-.0693 (1.756-1.759)

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Crankshaft & Main Bearings

1. Main bearing caps are numbered on top of cap for location and arrow on cap points toward front of engine. Main bearing cap No. 1 is at front of engine and No. 7 is at rear of engine. Evenly loosen main bearing cap bolts in sequence using several steps. See Fig. 35 . Remove main bearing caps, crankshaft, thrust bearings and main bearings.

2. Using caliper, measure main bearing cap bolt outside diameter on threaded area 1.18" (30.0 mm) from bottom of bolt. Replace main bearing cap bolt if bolt outside diameter is less than .417" (10.60 mm). Cylinder block main bearing bore inside diameter is determined by size mark ("1", "2" or "3") stamped on cylinder block. See Fig. 36 . Front size mark indicates No. 1 bore and rear size mark indicates No. 7 bore.

3. Crankshaft main bearing journal diameter is determined by size mark ("1", "2" or "3") stamped on crankshaft counterweight. See Fig. 36 . Ensure journal diameter, taper and out-of-round are within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS. Replace crankshaft if not within specification.

4. Main bearing size mark ("2", "3", "4", "5" or "6") is stamped on side of main bearing. See Fig. 36 . If replacing main bearing, ensure size mark on replacement main bearing is same as size mark on original main bearing.

5. If size mark on original main bearing cannot be obtained, add size marks on cylinder block and crankshaft to determine size mark of main bearing. For example, if size mark on cylinder block is "2" and size mark on crankshaft is "1", use main bearing with size mark "3".

6. Main bearing thickness is determined by size mark. See MAIN BEARING SPECIFICATIONS . Install main bearings, thrust bearings, crankshaft and main bearing caps.

7. Coat threads and bolt head-to-main bearing cap contact surfaces with engine oil. Install and tighten main bearing cap bolts to specification in sequence using several steps. See Fig. 35 . See TORQUE SPECIFICATIONS .

8. Ensure crankshaft end play and main bearing oil clearance are within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS . Replace thrust bearing if crankshaft end play is not within specification.

MAIN BEARING SPECIFICATIONS

CAUTION: Main bearing caps must be installed with arrow pointing toward front of engine. Ensure main bearing caps are installed in numerical order with No. 1 at front of engine and No. 7 at rear of engine.

Size Mark In. (mm)"2" .0981-.0982 (2.492-2.495)"3" .0982-.0983 (2.495-2.498)"4" .0983-.0985 (2.498-2.501)"5" .0985-.0986 (2.501-2.504)"6" .0986-.0987 (2.504-2.507)

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Fig. 35: Main Bearing Cap Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 36: Locating Crankshaft Main Journal, Cylinder Block & Main Bearing Size Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Thrust Bearing

Install thrust bearing on No. 4 main bearing with grooves toward crankshaft (away from cylinder block and main bearing cap). Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.

Cylinder Block

1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck surface warpage exceeds specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS.

2. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and bottom of cylinder bore and at center of cylinder bore. Different cylinder bore sizes are used. Cylinder bore diameter may be identified by size mark ("1", "2" or "3") stamped on cylinder block deck surface. See Fig. 32 . Front size mark is for cylinder No. 1 and rear size mark is for cylinder No. 6.

3. Ensure cylinder bore diameter is within specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS. Determine piston clearance. Bore all cylinders on cylinder block if cylinder bore diameter exceeds specification. Cylinder block may be bored for .020" (.50 mm) or .040" (1.00 mm) oversize pistons.

4. Install main bearing caps in numerical sequence with arrow on cap pointing toward front of engine. Install tighten bolts to specification in sequence. See Fig. 35 . Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS.

5. Check cylinder block orifice for damage or restriction. Cylinder block orifice is screwed into cylinder block at front corner of cylinder block deck surface. See Fig. 37 . Replace cylinder block orifice if damaged or restricted.

NOTE: Main bearing bore inside diameter is determined by size mark ("1", "2" or "3") stamped on cylinder block. See Fig. 36 .

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Fig. 37: Locating Cylinder Block Orifice Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE OILING

ENGINE LUBRICATING SYSTEM

Oil pump provides pressurized engine lubrication. Oil cooler is mounted on side of cylinder block. Oil spray nozzles, mounted in cylinder block are used to cool pistons. Oil jet is mounted on front of cylinder block and provides lubrication to timing chain and sprockets. See Fig. 38 .

Crankcase Capacity

Crankcase capacity with oil filter is 7.5 qts. (7.2L).

Oil Pressure

With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm2 ) at idle and approximately 36-71 psi (2.5-5.0 kg/cm2 ) at 3000 RPM.

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Fig. 38: Cross-Sectional View Of Engine Oiling System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OIL PUMP

Removal & Disassembly

Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove timing chain cover. See TIMING CHAIN under REMOVAL & INSTALLATION. Remove oil pump relief valve plug, gasket, spring and relief valve. See Fig. 39 . Remove bolts, oil pump cover, gasket and rotors. Remove crankshaft front seal (if necessary).

Inspection

NOTE: Manufacturer recommends cylinder head and timing chain cover removal when servicing oil pump. Cylinder head gasket is on top of timing chain cover and oil pump is mounted in timing chain cover.

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1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in bore of timing chain cover. Replace relief valve and/or timing chain cover if relief valve fails to slide freely.

2. Install drive and driven rotors in timing chain cover. Using feeler gauge, measure driven rotor-to-timing chain cover clearance. Replace rotor assembly or timing chain cover if clearance exceeds specification. See OIL PUMP SPECIFICATIONS .

3. Using feeler gauge, measure rotor tip clearance between tip of drive rotor and tip of driven rotor. Tip of drive rotor is on outside of rotor and tip of driven rotor is on inside of rotor. Replace rotor assembly if clearance exceeds specification. See OIL PUMP SPECIFICATIONS .

4. Place straightedge across timing chain cover, above both rotors. Using feeler gauge, measure rotor end clearance between straightedge and surface of each rotor. Replace rotor assembly or timing chain cover if end clearance exceeds specification. See OIL PUMP SPECIFICATIONS .

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. To reassemble, reverse disassembly procedure using NEW gaskets. Tighten oil pump relief valve plug to specification. See TORQUE SPECIFICATIONS .

2. If installing crankshaft front seal, apply grease to seal lip of NEW seal. Using hammer, Handle (SST 09316-00011) and Seal Installer (SST 09316-00051), install seal until seal surface is even with timing chain cover.

3. To install, reverse removal procedure. Ensure proper procedures are used when installing timing chain cover and cylinder head. See CYLINDER HEAD and TIMING CHAIN under REMOVAL & INSTALLATION.

Application In. (mm)Driven Rotor-To-Timing Chain Cover Clearance

Standard .0039-.0067 (.100-.170)Wear Limit .0118 (.300)

Rotor End ClearanceStandard .0012-.0035 (.030-.090)Wear Limit .0059 (.150)

Rotor Tip ClearanceStandard .0012-.0063 (.030-.160)Wear Limit .0098 (.250)

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Fig. 39: Exploded View Of Oil Pump & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OIL COOLER

Removal

1. Oil cooler is mounted on side of cylinder block. See Fig. 40 . Drain cooling system. Remove air intake hose with airflow meter and air cleaner cover. Remove front exhaust pipe with front catalytic converter and gasket from exhaust manifold and rear catalytic converter on center exhaust pipe.

2. Remove heat insulator, No. 1 (front) exhaust manifold and gasket from cylinder head. See Fig. 8 . Remove oil pressure switch for access to oil cooler. Remove oil cooler cover-to-cylinder block bolts/nuts, oil cooler cover, oil cooler and gasket from cylinder block. See Fig. 40 .

3. Remove oil cooler-to-oil cooler cover nuts. Separate oil cooler and gaskets from oil cooler cover. Remove oil cooler relief valve plug, gasket, spring and relief valve.

Inspection

Coat relief valve with engine oil and ensure relief valve slides freely in bore of oil cooler cover. Replace relief

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valve and/or oil cooler cover if relief valve fails to slide freely. Inspect oil cooler for damage or restriction. Replace oil cooler if damaged or restricted.

Installation

To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. Fill cooling system.

Fig. 40: Exploded View Of Oil Cooler & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OIL SPRAY NOZZLE

NOTE: Cylinder block has oil spray nozzles for each piston. See Fig. 38 . A check valve ball is located in oil spray nozzle-to-cylinder block bolt. Ensure proper bolts are used for oil spray nozzle installation.

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Removal

Remove timing chain cover and timing chain. See TIMING CHAIN under REMOVAL & INSTALLATION. Remove crankshaft. See CRANKSHAFT & MAIN BEARINGS under CYLINDER BLOCK ASSEMBLY under OVERHAUL. Remove oil spray nozzle-to-cylinder block bolt. Remove oil spray nozzle.

Inspection

Inspect oil spray nozzle for damage or restriction. Insert small wooden object into threaded end of oil spray nozzle-to-cylinder block bolt. Apply pressure against check ball inside oil spray nozzle-to-cylinder block bolt. Ensure check ball moves. Replace oil spray nozzle-to-cylinder block bolt if check ball fails to move.

Installation

1. Install oil spray nozzle in cylinder block. Ensure pin on oil spray nozzle engages with pin hole in cylinder block. Install and tighten oil spray nozzle-to-cylinder block bolt to specification. See TORQUE SPECIFICATIONS .

2. Install crankshaft using proper procedure. See CRANKSHAFT & MAIN BEARINGS under CYLINDER BLOCK ASSEMBLY under OVERHAUL. Install timing chain and timing chain cover using proper procedure. See TIMING CHAIN under REMOVAL & INSTALLATION.

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application SpecificationDisplacement 274 Cu. In. (4.5L)Bore 3.94" (100.0 mm)Stroke 3.74" (95.0 mm)Compression Ratio 9.0:1Fuel System SFIHorsepower @ RPM 212 @ 4600Torque Ft. Lbs. @ RPM 275 @ 3200

Application In. (mm)Crankshaft

End PlayStandard .0008-.0087 (.020-.220)Wear Limit .0118 (.300)

Maximum Runout .0024 (.060)

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CONNECTING RODS

CONNECTING RODS

Main Bearings

Journal Diameter (1) Size Mark "1" 2.7163-2.7165 (68.994-69.000)Size Mark "2" 2.7161-2.7163 (68.988-68.994)Size Mark "3" 2.7158-2.7161 (68.982-68.988)

Journal Out-Of-Round & Taper .0008 (.020)Oil Clearance

Standard Crankshaft JournalStandard .0014-.0021 (.036-.054)Wear Limit .0039 (.100)

.010" (.25 mm) Undersize Crankshaft JournalStandard .0014-.0030 (.036-.075)Wear Limit .0039 (.100)

Connecting Rod Bearings

Journal Diameter (2) Size Mark "1" 2.2439-2.2441 (56.994-57.000)Size Mark "2" 2.2436-2.2439 (56.988-56.994)Size Mark "3" 2.2434-2.2436 (56.982-56.988)

Journal Out-Of-Round & Taper .0008 (.020)Oil Clearance

Standard Crankshaft JournalStandard .0013-.0020 (.032-.050)Wear Limit .0039 (.100)

.010" (.25 mm) Undersize Crankshaft JournalStandard .0013-.0029 (.032-.073)Wear Limit .0039 (.100)

(1) Main bearing journal diameter is determined by size mark on crankshaft. See Fig. 36 .

(2) Connecting rod journal diameter is determined by size mark on crankshaft. See Fig. 34 .

Application In. (mm)Bore Diameter

Bushing Pin Bore 1.0239-1.0244 (26.008-26.020)

Crankpin Bore (1) Size Mark "1" 2.3829-2.3831 (60.526-

60.532)Size Mark "2" 2.3831-2.3834 (60.532-

60.538)

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PISTONS, PINS & RINGS

PISTONS, PINS & RINGS

Size Mark "3" 2.3834-2.3836 (60.538-60.544)

Maximum Bend .0020 Per 3.94 (.050 Per 100.0)Maximum Twist .0059 Per 3.94 (.150 Per 100.0)Side Play


(1) Crankpin bore diameter is determined by size mark on connecting rod. See Fig. 34 .

Application In. (mm)Pistons

Clearance .0016-.0024 (.040-.060)

Diameter (1) Size Mark "1" 3.9350-3.9354 (99.950-99.960)Size Mark "2" 3.9354-3.9358 (99.960-99.970)Size Mark "3" 3.9358-3.9362 (99.970-99.980)

PinsDiameter 1.0236-1.0241 (26.000-26.012)Piston Fit (2)

Rod FitStandard .0002-.0005 (.005-.012)Wear Limit .0020 (.050)

RingsNo. 1

End GapStandard .0118-.0205 (.300-.520)Wear Limit .0441 (1.120)

Side Clearance .0016-.0031 (.040-.080)No. 2


Side Clearance .0012-.0028 (.030-.070)No. 3 (Oil)


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CYLINDER BLOCK

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

(1) Piston diameter is determined by size mark stamped on top of piston. See Fig. 32 .

(2) Piston pin should slide into piston using thumb pressure after piston is heated to 176-194°F (80-90°C).

Application In. (mm)Cylinder Bore

Standard Diameter (1) Size Mark "1" 3.9370-3.9374 (100.000-

100.010)Size Mark "2" 3.9374-3.9378 (100.010-

100.020)Size Mark "3" 3.9378-3.9382 (100.020-

100.030)Maximum Deck Warpage .0020 (.050)

Main Bearing Bore I.D. (2) Size Mark "1" 2.9144-2.9146 (74.026-74.032)Size Mark "2" 2.9146-2.9149 (74.032-74.038)Size Mark "3" 2.9149-2.9151 (74.038-74.044)

(1) Cylinder bore diameter is determined by size mark on cylinder block deck surface. See Fig. 32 . Maximum cylinder bore diameter is 3.9461" (100.230 mm).

(2) Main bearing bore diameter is determined by size mark stamped on cylinder block. See Fig. 36 .

Application SpecificationIntake Valves

Face Angle 44.5°Minimum Margin .039" (1.00 mm)Minimum Refinish Length 3.854" (97.90 mm)Stem Diameter .2744-.2750" (6.970-6.985

mm)Exhaust Valves

Face Angle 44.5°Minimum Margin .039" (1.00 mm)Minimum Refinish Length 3.835" (97.40 mm)Stem Diameter .2742-.2748" (6.965-6.980

mm)

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CYLINDER HEAD

CYLINDER HEAD

Valve SpringsFree Length 1.7299-1.7740" (43.940-

45.060 mm)Out-Of-Square .079" (2.00 mm)Pressure 48-53 Lbs. @ 1.437 In. (21.8-

24.0 kg @ 36.50 mm)

Application SpecificationMaximum Warpage

Cylinder Block Surface .0059" (.150 mm)Manifold Surface .0039" (.100 mm)

Valve SeatsIntake Valve

Seat Angle 45°Seat Width .047-.063" (1.20-1.60 mm)

Exhaust ValveSeat Angle 45°Seat Width .039-.055" (1.00-1.40 mm)

Valve GuidesIntake Valve

Valve Guide Cylinder Head Bore I.D.Standard Valve Guide .4524-.4533" (11.492-11.513

mm)Oversize Valve Guide .4544-.4552" (11.542-11.563

mm)Valve Guide I.D. .2760-.2768" (7.010-7.030 mm)Valve Guide Installed Height .323-.339" (8.20-8.60 mm)Valve Stem-To-Guide Oil Clearance

Standard .0010-.0024" (.025-.060 mm)Wear Limit .0031" (.080 mm)

Exhaust ValveValve Guide Cylinder Head Bore I.D.

Standard Valve Guide .4524-.4533" (11.492-11.513 mm)

Oversize Valve Guide .4544-.4552" (11.542-11.563 mm)

Valve Guide I.D. .2760-.2768" (7.010-7.030 mm)Valve Guide Installed Height .323-.339" (8.20-8.60 mm)Valve Stem-To-Guide Oil Clearance

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CAMSHAFT

CAMSHAFT

VALVE LIFTERS

VALVE LIFTERS

TORQUE SPECIFICATIONS


Standard .0012-.0026" (.030-.065 mm)Wear Limit .0039" (.100 mm)

Application In. (mm)End Play


Gear BacklashStandard .0008-.0079 (.020-.200)Wear Limit .0118 (.300)

Journal Diameter 1.0614-1.0620 (26.959-26.975)Journal Runout .0024 (.060)Lobe Height

Standard 1.9925-1.9965 (50.610-50.710)

Wear Limit 1.9886 (50.510)Oil Clearance


Application In. (mm)Bore Diameter 1.3386-1.3394 (34.000-34.021)Lifter Diameter 1.3372-1.3376 (33.966-33.976)Oil Clearance


Application Ft. Lbs. (N.m)A/C Compressor Bolt 18 (24)A/C Compressor Mounting Bracket Bolt 27 (37)Air Intake Chamber Bolt/Nut 15 (20)Air Intake Chamber Support Brace Bolt 26 (35)Camshaft Bearing Cap Bolt 12 (16)

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Camshaft Sprocket Bolt 54 (73)Connecting Rod Nut

Step 1 35 (47)Step 2 Additional 90 Degrees

Coolant By-Pass Outlet Bolt 15 (20)Coolant By-Pass Outlet Pipe Bolt 15 (20)Coolant Outlet Nut 15 (20)Crankshaft Pulley Bolt 304 (412)

Cylinder Head-To-Cylinder Block Bolt (1) Step 1 29 (39)Step 2 Additional 90 DegreesStep 3 Additional 90 Degrees

Cylinder Head-To-Timing Chain Cover Bolt 15 (20)Damper Bolt 15 (20)Delivery Pipe Bolt-To-Intake Manifold Bolt 15 (20)Distributor Hold-Down Bolt 13 (18)Drive Belt Idler Pulley Bolt 32 (43)Drive Plate Bolt 74 (100)Drive Shaft Flange Bolt/Nut

Front Drive Shaft 54 (73)Rear Drive Shaft 65 (88)

EGR Pipe Union Nut 58 (79)EGR Pipe-To-Cylinder Head Bolt 15 (20)Engine Hanger-To-Cylinder Head Bolt 30 (41)Engine Mount-To-Frame Nut 55 (75)Front Exhaust Pipe-To-Exhaust Manifold Nut 46 (62)Front Exhaust Pipe-To-Rear Catalytic Converter Bolt/Nut 34 (46)Fuel Inlet Hose-To-Fuel Filter Union Bolt 21 (29)Fuel Return Pipe Bolt 15 (20)Generator Mounting Bracket-To-Cylinder Head Bolt 32 (43)Heater Coolant Pipe Bolt/Nut 15 (20)Heat Insulator Bolt 14 (19)Intake Manifold-To-Cylinder Head Bolt/Nut 15 (20)Knock Sensor 33 (45)

Main Bearing Cap Bolt (2) Step 1 54 (73)Step 2 Additional 90 Degrees

No. 1 Fuel Pipe BoltUnion Bolt 21 (29)Retaining Bolt 15 (20)

No. 1 Oil Pan Bolt/Nut

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12-mm Head 15 (20)14-mm Head 32 (43)

No. 1 Oil Pan-To-Transmission Housing Bolt 53 (72)No. 1 & 2 Exhaust Manifold Nut 29 (39)Oil Cooler Cover-To-Cylinder Block Bolt/Nut 15 (20)Oil Cooler Line-To-Transmission Union Nut 25 (34)Oil Cooler Relief Valve Plug 27 (37)Oil Cooler-To-Oil Cooler Cover Nut 12 (16)Oil Filter Union 33 (45)Oil Jet Bolt 15 (20)Oil Pump Pick-Up Tube-To-No. 1 Oil Pan Bolt/Nut 15 (20)Oil Pump Relief Valve Plug 36 (49)Oil Spray Nozzle-To-Cylinder Block Bolt 18 (24)Power Steering Pump-To-Cylinder Block Bolt 27 (37)Power Steering Reservoir Bolt 15 (20)Pressure Hose-To-Power Steering Pump Union Bolt 42 (57)Rear Oil Seal Housing Bolt 15 (20)Slipper Bolt 51 (69)Spark Plug 15 (20)Stabilizer Bar Mount-To-Frame Bolt 13 (18)Stabilizer Bar-To-Axle Housing Bolt 18 (24)Starter Bolt 29 (39)Throttle Body Bolt 15 (20)Timing Chain Cover Bolt 15 (20)Timing Chain Tensioner Nut 15 (20)Torque Converter Bolt 41 (56)Transfer Case Shift Lever Bolt 13 (18)Transmission Crossmember-To-Frame Bolt 45 (61)Transmission Mount-To-Transmission Crossmember Nut 55 (75)Transmission-To-Cylinder Block Bolt 53 (72)Water Pump Bolt/Nut 15 (20)

INCH Lbs. (N.m)Cylinder Block Orifice 69 (7.8)No. 2 Oil Pan Bolt/Nut 78 (8.8)Oil Level Sensor Bolt 48 (5.4)Oil Pan Baffle Plate-To-No. 1 Oil Pan Bolt/Nut 80 (9.0)Transmission Shift Lever Assembly Bolt 48 (5.4)Transmission Shift Linkage-To-Control Rod Nut 115 (13.0)(1) Tighten bolts to specification in sequence. See Fig. 9 .

(2) Tighten bolts to specification in sequence. See Fig. 35 .

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AIR BAG RESTRAINT SYSTEM

1997-98 ACCESSORIES/SAFETY EQUIPMENT Lexus - Air Bag Restraint System

DESCRIPTION & OPERATION

Supplemental Restraint System (SRS) deploys a steering wheel pad (driver-side air bag) and passenger-side air bag during a frontal impact of sufficient force. See Fig. 1 .

Air bag sensor assembly is mounted on the floor inside the console box, and consists of an air bag sensor, safing sensor, diagnosis sensor circuit and ignition control, drive circuit, etc. It receives signals from the air bag sensors and determines whether SRS must be activated or not.

Inflator and bag of SRS are stored in steering wheel pad (driver-side air bag) and passenger-side air bag assemblies and cannot be disassembled. The inflator contains a squib, igniter charge, gas generant, and inflates when activated by air bag sensor assembly. The spiral cable is used as an electrical joint from vehicle body side to the steering wheel.

Air bag warning light, located in instrument cluster, goes on to alert driver of trouble in system when a malfunction is detected in air bag sensor assembly.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and SERVICE PRECAUTIONS .

1997 Lexus LX 450

AIR BAG RESTRAINT SYSTEM 1997-98 ACCESSORIES/SAFETY EQUIPMENT Lexus - Air Bag Restraint System

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Fig. 1: Locating SRS Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SYSTEM OPERATION CHECK

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Turn ignition switch to ACC or ON position. Air bag warning light in instrument cluster should come on for about 6 seconds and then go out. If light does not respond as specified, SRS is malfunctioning and needs repair. See DIAGNOSIS .

SERVICE PRECAUTIONS

Observe the following precautions when working on SRS:

Before servicing any SRS or steering column component, disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Failure to disable system could result in accidental air bag deployment and personal injury.

When troubleshooting SRS, always check for diagnostic codes before disconnecting battery.

After ignition switch is turned to LOCK position and negative battery cable is disconnected, wait at least 90 seconds before working on SRS. SRS is equipped with a back-up power source that may allow air bag to deploy within 90 seconds of disconnecting negative battery cable.

In a minor collision in which air bags do not deploy, steering wheel pad must be inspected.

NEVER use air bag parts from another vehicle. Replace air bag parts with new parts.

Air bag sensor assembly contains mercury. After replacement, DO NOT destroy the old part. When scrapping vehicle or replacing air bag sensor assembly, remove air bag sensor assembly and dispose of as toxic waste.

Never disassemble or repair system components. Replace cracked, dented or otherwise damaged system components.

When troubleshooting electrical circuits, use a Digital Volt/Ohmmeter (DVOM) with high impedance (10-k/ohm minimum).

Information labels are attached to air bag components. Follow all notices on labels.

After servicing SRS, check air bag warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

Always wear safety glasses when servicing or handling an air bag.

When placing a live air bag on a bench or other surface, always face air bag and trim cover up, away from surface. This will reduce motion of module if accidentally deployed.

After deployment, air bag surface may contain deposits of sodium hydroxide which irritates skin. During clean-up, always wear safety glasses, rubber gloves and long-sleeved shirt. After clean-up, wash hands using mild soap and water.

When carrying a live air bag module, trim cover must be pointed away from your body to minimize injury in case of accidental deployment.

If SRS is not fully functional for any reason, vehicle should not be driven until system is repaired and again becomes operational. DO NOT remove bulbs, modules, sensors or other components or in any way disable system from operating normally. If SRS is not functional, park vehicle until it is repaired and functions properly.

ADJUSTMENTS

SPIRAL CABLE

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Ensure front wheels are in straight-ahead position. Turn spiral cable counterclockwise until it is hard to turn. Turn spiral cable clockwise about 3 turns until Red mating mark is aligned. See Fig. 2 .

Fig. 2: Aligning Marks On Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISABLING & ACTIVATING AIR BAG SYSTEM

NOTE: If diagnosing SRS, check for diagnostic codes before disconnecting negative battery cable.

WARNING: Back-up power supply maintains SRS voltage for about 90 seconds after battery is disconnected. After disabling SRS, wait at least 90 seconds

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DISABLING SYSTEM

Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds before working on system. Remove steering wheel pad. See STEERING WHEEL PAD & SPIRAL CABLE under REMOVAL & INSTALLATION. Disconnect passenger-side air bag connector. Disconnect air bag sensor assembly connector. See Fig. 3 and Fig. 7 .

Fig. 3: Disconnecting Passenger-Side Air Bag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ACTIVATING SYSTEM

Turn ignition switch to LOCK position. Connect steering wheel pad, passenger-side air bag assembly, and air bag sensor assembly connectors. Install steering wheel pad. Reconnect negative battery cable. Check air bag warning light for proper system function, perform SYSTEM OPERATION CHECK .

DISPOSAL PROCEDURES

before servicing SRS. Servicing SRS before 90 seconds may cause accidental air bag deployment and possible personal injury.

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DEPLOYING DRIVER-SIDE AIR BAG

On-Vehicle Deployment (Scrapped Vehicles Only)

1. Before proceeding, follow service precautions. See SERVICE PRECAUTIONS . Ensure SRS Air Bag Deployment Tool (09082-00700) is functioning properly, see DEPLOYMENT TOOL CHECK .

2. If steering wheel or steering wheel pad is loose and cannot be tightened, DO NOT deploy air bag using this procedure. Instead, go to Off-Vehicle Deployment. If steering wheel and steering wheel pad are not loose, remove under cover No. 1 and disconnect spiral cable air bag connector. See Fig. 9 . Connect deployment tool to spiral cable connector.

3. Position deployment tool and power source (battery) 33 ft. from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Ensure no one is within 33 ft. of vehicle. Press deployment tool activation switch to deploy air bag. DO NOT touch air bag for 30 minutes after deployment.

Off-Vehicle Deployment

1. Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove steering wheel pad from vehicle. See STEERING WHEEL PAD & SPIRAL CABLE under REMOVAL & INSTALLATION.

2. Obtain a road wheel rim and tire assembly from a scrap vehicle. Install two 1.4 in. (35 mm) bolts in steering wheel pad mounting holes. Tighten bolts by hand until they become difficult to turn. DO NOT overtighten bolts.

3. Wrap heavy-gauge wire around bolts at least twice. See Fig. 4 . Ensure no slack is present in wire. If slack is present, or if wire is not strong enough, steering wheel pad may become loose due to shock when air bag is deployed.

4. Position steering wheel pad on rim and tire assembly with pad side facing upward. Ensuring wire is tight, separately tie left and right sides of steering wheel pad to wheel rim through lug nut holes. See Fig. 5 . Position steering wheel pad connector so that it hangs downward through hub hole in disc wheel.

5. Ensure SRS Air Bag Deployment Tool (09082-00700) is functioning properly, see DEPLOYMENT TOOL CHECK . Connect deployment tool to steering wheel pad connector. To prevent damage to deployment connector and harness, do not lock secondary lock of twin lock and provide slack for deployment harness.

6. Position deployment tool and power source (battery) 33 ft. from steering wheel pad. Obtain cardboard box larger than wheel assembly and place it over wheel assembly, or stack 3 scrap tires on top of rim and tire assembly (but NOT directly on steering wheel pad).

7. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.

WARNING: Undeployed air bags contain substances that can cause illness or injury if improperly handled. Disposing of undeployed components may violate federal, state and/or local laws. If scrapping vehicle, components must be deployed while still mounted in vehicle. DO NOT deploy components inside vehicle unless vehicle is to be scrapped. Wear gloves and safety glasses when handling components. Wrap deployed components in a sturdy plastic bag. Dispose of components like any other part.

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Ensure no one is within 33 ft. of steering wheel pad. Press activation switch to deploy air bag. Wait 30 minutes before handling air bag.

Fig. 4: Installing Wire On Steering Wheel Pad Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 5: Installing Steering Wheel Pad On Wheel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DEPLOYING PASSENGER-SIDE AIR BAG

On-Vehicle Deployment (Scrapped Vehicles Only)

1. Before proceeding, see SERVICE PRECAUTIONS . Ensure SRS Air Bag Deployment Tool (09082-00700) is functioning properly, see DEPLOYMENT TOOL CHECK .

2. If passenger-side air bag is loose and cannot be tightened, DO NOT deploy air bag using this procedure. Instead, go to Off-Vehicle Deployment. If passenger-side air bag is not loose, remove glove box and air bag connector from bracket. Disconnect passenger-side air bag connector. See Fig. 11 . Connect deployment tool connector to passenger-side air bag connector.

3. Position deployment tool and power source (battery) 33 ft. from vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Ensure no one is within 33 ft. of vehicle. Press deployment tool activation switch to deploy air bag. DO NOT touch air bag for 30 minutes after deployment.

Off-Vehicle Deployment

1. Before proceeding, see SERVICE PRECAUTIONS . Remove passenger-side air bag. See PASSENGER-SIDE AIR BAG under REMOVAL & INSTALLATION.

2. Obtain a scrap tire without a rim, that exceeds the following dimensions: 7.3 in. (185 mm) width and 14.2 in. (360 mm) inner diameter. Install the 4 nuts in passenger-side air bag assembly. Remove 2 passenger-side air bag bracket retainer nuts and bracket.

3. Wrap heavy gauge wire harness around the tire and ensure wire is tight to prevent air bag assembly from

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coming free. Position air bag assembly inside the tire with air bag deployment direction facing inside.

4. Place 2 tires under and over the tire to which air bag assembly is tied, the top tire should have wheel installed. Tie tires together using 2 heavy gauge wiring harnesses and ensure wires are tight. See Fig. 6 .

5. Ensure SRS Air Bag Deployment Tool (09082-00700) is functioning properly, see DEPLOYMENT TOOL CHECK . Connect deployment tool connector to air bag assembly connector, and place inside tires. To prevent damage, do not lock secondary lock of twin lock and provide slack for deployment harness.

6. Position deployment tool and power source (battery) 33 ft. from air bag assembly. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Ensure no one is within 33 ft. of air bag assembly. Press activation switch to deploy air bag. Wait 30 minutes before handling air bag.

Fig. 6: Deploying Passenger-Side Air Bag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DEPLOYMENT TOOL CHECK

Connect Red clip of SRS Air Bag Deployment Tool (09082-00700) to positive battery terminal and Black clip to negative battery terminal. Press deployment tool activation switch and confirm deployment tool light comes on. If light does not function as indicated, replace tool and repeat procedure.

POST-COLLISION INSPECTION

POST-COLLISION AIR BAG SAFETY INSPECTION Action Components

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AIR BAG SENSOR ASSEMBLY


1. Before proceeding, see SERVICE PRECAUTIONS . Disable SRS. See Disabling System under DISABLING & ACTIVATING AIR BAG SYSTEM .

2. Air bag sensor located forward of center console (Fig. Fig. 1 ). Remove transfer shift knob, and front console box. See Fig. 7 . Disconnect the connector with air bag sensor installed. Remove 4 Torx screws and air bag sensor.

Replace After Deployment Air Bag Module(s), Air Bag Sensor AssemblyInspect & If Damaged, Replace Component (Even If Air Bag Did Not Deploy)

Glove Compartment Door, Instrument Panel, Instrument Panel Reinforcement, Spiral Cable, Steering Wheel, Wiring Harness & Connectors

Comments If any components are damaged or bent, they must be replaced.

WARNING: Failure to follow air bag service precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS . After component replacement, perform a system operational check to ensure proper system operation. See SYSTEM OPERATION CHECK .

NOTE: Disconnect air bag sensor electrical connector before removing sensor mounting screws.

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Fig. 7: Removing Air Bag Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Installation

To install, reverse removal procedure. Tighten air bag sensor screws to specification. See TORQUE SPECIFICATIONS . Connect air bag sensor connector after the sensor is installed. Activate SRS. See Activating System under DISABLING & ACTIVATING AIR BAG SYSTEM . Check air bag warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

STEERING WHEEL PAD & SPIRAL CABLE

Removal

1. Before proceeding, see SERVICE PRECAUTIONS . Ensure front wheels are in a straight-ahead position. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .

2. Remove steering wheel lower covers No. 2 and 3. Loosen 2 Torx screws until groove along screw circumference catches on screw case. See Fig. 8 . Pull steering wheel pad out from steering wheel and

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disconnect air bag connector. See Fig. 9 .

3. Remove steering wheel nut. Match mark steering wheel and main shaft. Remove steering wheel using puller. Remove instrument lower finish panel, No. 2 heater register duct, upper and lower column covers. See Fig. 10 .

4. Disconnect the 2 combination switch/spiral cable connectors. Disconnect air bag connector. Remove the 4 screws. Remove combination switch and spiral cable. Remove spiral cable from combination switch. DO NOT disassemble cable or apply oil to it.

Fig. 8: Removing Steering Wheel Pad Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 9: Disconnecting Steering Wheel Pad Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Steering Wheel Pad & Spiral Cable Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WARNING: During installation, if spiral cable mating mark is not properly aligned, steering wheel may not turn completely, or flat cable inside spiral cable may be severed, disabling SRS system.

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Installation

To install, reverse removal procedure. Ensure spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS. Connect air bag connector. Using new Torx screws, tighten 2 screws to specification. See TORQUE SPECIFICATIONS . Install steering wheel side covers. Perform SYSTEM OPERATION CHECK .

PASSENGER-SIDE AIR BAG


1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds before working on system.

2. Remove glove box door. See Fig. 13 . Remove air bag connector from air bag bracket. Disconnect passenger-side air bag connector. See Fig. 3 . Remove instrument panel. Remove the 4 bolts and 2 nuts securing passenger-side air bag. See Fig. 11 . Remove air bag assembly. Pry up the 6 air bag door clips and remove the air bag door. See Fig. 12 .

3. To install, reverse removal procedure. Tighten passenger-side air bag bolts to specification. See TORQUE SPECIFICATIONS . Activate SRS. See Activating System under DISABLING & ACTIVATING AIR BAG SYSTEM . Check air bag warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

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Fig. 11: Removing Passenger-Side Air Bag Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 12: Removing Passenger-Side Air Bag Door Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 13: Passenger-Side Air Bag Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SELF-DIAGNOSTIC

AIR BAG WARNING LIGHT CHECK

Turn ignition switch to ACC or ON position. If air bag warning light comes on then goes out after about 6 seconds, the system is OK at this time. If air bag warning light comes on and stays on (or flashes), diagnostic code is stored in the air bag sensor. Go to RETRIEVING CODES . If air bag warning light responds in any other way, go to DIAGNOSIS .

RETRIEVING CODES

Diagnosis Check Wire

CAUTION: If jumper wire is incorrectly connected across terminals of Data Link Connector (DLC), system may be damaged.

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1. Turn ignition switch to ACC or ON position. Wait about 20 seconds. Using Diagnosis Check Wire (09843-18020), jump terminals Tc and E1 of Data Link Connector (DLC), located in right, rear corner of engine compartment. See Fig. 14 .

2. If air bag warning light does not flash codes, go to CODE(S) NOT DISPLAYED under DIAGNOSIS. If air bag warning light flashes continuously at a rate of 2 times per second, source voltage is low. Go to NO CODES - SOURCE VOLTAGE DROP under appropriate TROUBLE SHOOTING.

3. If air bag warning light flashes codes, count number of flashes to determine code(s) that are set. For example, Code 12 is: FLASH, pause, FLASH, FLASH. If more than one code is present, a 2.5-second pause will occur between each code. Lowest numbered codes will be displayed followed by higher numbered codes. See SRS DIAGNOSTIC TROUBLE CODES (DTC) table.

4. After all codes are displayed, a 4-second pause will occur and codes will be repeated. After code(s) have been identified, see appropriate diagnostic code under TROUBLE SHOOTING and perform tests as specified. After repairing system, clear codes. See CLEARING CODES .

Electrical Tester

Connect the Lexus Electrical Tester (09082-00040) to DLC3. Read codes by following prompts on tester screen. Refer to electrical tester manual for instructions.

Fig. 14: Identifying Data Link Connector (DLC) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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SRS DIAGNOSTIC TROUBLE CODES (DTC)

CLEARING CODES

Diagnosis Check Wire

1. At DLC, connect a jumper wire to terminal Tc, and another jumper wire to terminal AB. See Fig. 14 . Turn ignition switch to ACC or ON position. Wait about 6 seconds.

2. Starting with terminal Tc, apply body ground alternately to terminal Tc and terminal AB twice each, in cycles of 1 second. Finally, keep applying body ground to terminal Tc. Several seconds after performing clearing procedure, air bag warning light flashes 0.5 second cycle, indicating codes are cleared.

Electrical Tester

Connect the Lexus Electrical Tester (09082-00040) to DLC1. Clear codes by following prompts on tester screen. Refer to electrical tester manual for instructions.

DIAGNOSIS

NOTE: If a code that is not listed in SRS CODES table is displayed, replace air bag sensor. If air bag warning light does not function as described, go to CODE(S) NOT DISPLAYED or see CODE(S) CONTINUOUSLY DISPLAYED .

DTC Possible CauseNormal System Normal/Source Voltage Drop11 Short To Ground In Squib Circuit12 Short To B+ In Squib Circuit14 Open In D Squib Circuit31 Air Bag Sensor Assembly Malfunction54 Open In P Squib Circuit

NOTE: When alternately connecting jumper probes to terminals, simultaneously release one probe from one terminal while connecting other probe to other terminal. If time interval between probings is too long, codes will not clear.

WARNING: Failure to follow air bag service precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS . After component replacement, perform system operational check to ensure proper system operation. See SYSTEM OPERATION CHECK .

CAUTION: Ensure ignition switch is in LOCK position before disconnecting or connecting negative battery cable. If ignition switch is in ACC or ON position when negative battery cable is disconnected or connected, center air bag sensor may be damaged.

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AIR BAG WARNING LIGHT DOES NOT COME ON AT ALL

1. Remove and check continuity of ECU-B fuse. Fuse is in fuse panel, behind lower left side of instrument panel. If fuse is faulty, replace fuse and go to step 5). If fuse is OK, go to next step.

2. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect negative battery cable and turn ignition to ACC or ON position. Measure voltage at terminal LA of harness side connector of air bag sensor assembly. If voltage is 10-14 volts, go to step 3). If voltage is not as specified, check air bag warning light bulb and repair air bag warning light circuit. See Fig. 15 .

3. Disconnect negative battery cable. Connect air bag sensor assembly connector. Connect negative battery cable and wait at least 2 seconds. Turn ignition to ACC or ON position. If air bag warning light operates correctly, the malfunction is normal, go to step 4). If air bag warning light does not operate correctly, check terminal LA of air bag sensor assembly If normal, replace air bag sensor assembly.

4. Check ECU-B fuse. If fuse is not OK, check harness between ECU-B fuse and air bag warning light, repair or replace as necessary. If fuse is OK, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

5. Check air bag warning light for proper system function, see SYSTEM OPERATION CHECK . If warning light functions properly and does not indicate fault in SRS, system is OK, no further action necessary. If warning light does not function properly or fault is indicated in SRS, go to appropriate procedure for system diagnosis.

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Fig. 15: Air Bag Sensor Connector Terminal ID Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AIR BAG WARNING LIGHT STAYS ON WITH IGNITION IN LOCK POSITION

Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Turn ignition switch to LOCK position. Disconnect air bag sensor assembly connector. Reconnect negative battery cable. If air bag warning light is off, replace air bag sensor assembly. If air bag warning light is still on, repair warning light circuit or AB circuit leading to DLC. See Fig. 14 .

CODE(S) NOT DISPLAYED

NOTE: Use the following procedure if code(s) are not displayed or air bag warning light

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1. Turn ignition switch from LOCK to ACC or ON position. If air bag warning light does not come on, repair air bag warning light circuit. If air bag warning light comes on, go to next step.

2. Measure voltage between terminals Tc and E1 of DLC. See Fig. 14 . If voltage is 10-14 volts, go to step 4). If voltage is not as specified, go to next step.

3. Measure voltage between body ground and terminal Tc of DLC1. If voltage is 10-14 volts, check harness between body ground and terminal E1 of DLC, repair or replace as necessary. If voltage is not as specified, go to next step.

4. Turn ignition to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Disconnect air bag sensor assembly connector. Insert jumper wire into terminal Tc from back side. Connect air bag sensor assembly connector with jumper wire. Connect negative battery cable. Turn ignition to ACC or ON and wait 20 seconds. Connect jumper wire of terminal Tc to ground. If air bag warning light comes on, check harness between air bag sensor assembly and DLC1. If warning light does not come on, replace air bag sensor assembly.

CODE(S) CONTINUOUSLY DISPLAYED

Turn ignition switch to LOCK position. Disconnect negative battery cable and wait 90 seconds. Disconnect air bag sensor assembly connector. Check resistance between terminal Tc of air bag sensor assembly connector and body ground. See Fig. 15 . If resistance is 1 Mohm or greater, replace air bag sensor assembly. If resistance is not as specified, repair or replace harness or connector. Check air bag warning light for proper system function, see SYSTEM OPERATION CHECK .

RELEASE METHOD OF ACTIVATION PREVENTION

An air bag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the air bag activation prevention mechanism is directed in diagnostic procedures, insert paper which is same thickness as male terminal, between terminal and short spring. See Fig. 16 .

stays on when jumper wire is connected between terminals Tc and E1 of DLC connector.

NOTE: Use the following procedure if code(s) are displayed without connecting jumper wire between terminals Tc and E1 of DLC connector.

CAUTION: NEVER release activation prevention mechanism on steering wheel pad connector.

CAUTION: DO NOT release activation prevention mechanism unless specifically directed by procedures. If paper is too thick, it can damage the terminal and short spring. Always use paper the same thickness as male terminal.

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Fig. 16: Release Method Of Activation Prevention Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SIMULATION METHOD CHECK

When a system fault or DTC has been diagnosed and repaired, ensure malfunction is normal. Reproduce malfunction symptoms by performing tests to simulate driving conditions:

Wiggle-test wiring harness.

Using a hair dryer, apply heat to components.

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Spray water onto entire vehicle (not directly onto electrical components) to simulate humidity.

TROUBLE SHOOTING

NO CODES - SOURCE VOLTAGE DROP

1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect negative battery cable. Turn ignition on. Measure voltage at IG2 or ACC on sensor with electrical accessories on (defogger, wiper, headlights, heater blower, etc.) If voltage is 10-14 volts, go to next step. If voltage is not as specified, check harness between battery and air bag sensor assembly and check battery and charging system.

2. Turn ignition to LOCK. Connect steering wheel pad connector. Connect steering wheel pad, passenger-side air bag, and air bag sensor assembly connector. Turn ignition on and operate electrical system as specified. If air bag warning light turns off, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

3. If air bag warning light does not turn off, check for codes. Repair conditions that caused code to set. If normal code is output, replace air bag sensor assembly. Check air bag warning light for proper system function, see SYSTEM OPERATION CHECK .

DTC 11

1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . For connector between spiral cable and steering wheel pad (spiral cable side), measure resistance between D+, D- and body ground. See Fig. 15 . If resistance is 1 Mohm or greater, go to next step. If resistance is not as specified, go to step 9).

2. For connector between air bag sensor assembly and passenger-side air bag assembly (air bag sensor assembly side), measure resistance between P+, P- and body ground. If resistance is 1 Mohm or greater, go to next step. If resistance is not as specified, repair or replace harness or connector between air bag sensor assembly and passenger-side air bag assembly.

3. Connect connector to air bag sensor assembly. Connect jumper wire between D+ and D- on spiral cable side of connector between spiral cable and steering wheel pad. Connect jumper wire between P+ and P- on air bag sensor assembly side of connector between air bag sensor assembly and passenger-side airbag assembly. Reconnect negative battery cable and wait at least 2 seconds. Go to next step.

4. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear malfunction codes stored in memory. Turn ignition to LOCK and wait at least 20 seconds. Turn ignition to ACC or ON and wait at least 20 seconds. Using Diagnosis Check Wire (09843-18020) check code. If DTC 11 is not displayed, go to next step. If DTC 11 is displayed, replace air bag sensor assembly.

NOTE: Use Diagnosis Check Wiring (09843-18020) when connecting jumper wire between terminals of DLC. Spiral cable upper connector is same as steering wheel pad (squib) connector. Spiral cable lower connector (located under steering column) connects the harness between spiral cable and air bag sensor assembly.

NOTE: During testing, if codes other than DTC 11 are displayed, disregard them.

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5. Turn ignition to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Connect steering wheel pad connector. Connect negative battery cable and wait at least 2 seconds. Turn ignition to ACC or ON and wait at least 20 seconds. Clear codes. See CLEARING CODES . Go to next step.

6. Turn ignition to LOCK and wait at least 20 seconds. Using diagnosis check wire (09843-18020) connect terminals Tc and E1 of DLC1. See Fig. 14 . Check code. If DTC 11 is not displayed, go to next step. If DTC 11 is displayed, replace steering wheel pad.

7. Turn ignition switch to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Reconnect passenger-side air bag assembly connector. Connect negative battery cable and wait at least 2 seconds. Clear malfunction code. Turn ignition to LOCK and wait for at least 20 seconds. Go to next step.

8. Turn ignition to ACC or ON and wait for at least 20 seconds. Using diagnosis check wire (09843-18020) connect terminals Tc and E1 of DLC1. Check code. If DTC 11 is displayed, replace passenger-side air bag assembly. If DTC 11 is not displayed, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

9. Disconnect connector between air bag sensor assembly and spiral cable. Measure resistance between D+ and body ground on spiral cable side of connector between spiral cable and steering wheel pad. If resistance is 1 Mohm or greater, repair or replace harness or connector between air bag sensor assembly and spiral cable. If resistance is not as specified, repair or replace spiral cable.

DTC 12

1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . For connector between spiral cable and steering wheel pad (spiral cable side), measure voltage between D+, D- and body ground. See Fig. 15 . If voltage is 0 volts, go to next step. If voltage is not as specified, go to step 9).

2. For connector between air bag sensor assembly and passenger-side air bag assembly (air bag sensor assembly side), measure voltage between P+ and body ground. If voltage is 0 volts, go to next step. If voltage is not as specified, repair or replace harness or connector between air bag sensor assembly and passenger-side air bag assembly.

3. Connect connector to air bag sensor assembly. Connect jumper wire between D+ and D- of connector between spiral cable and steering wheel pad (spiral cable side). Connect jumper wire between P+ and P- on air bag sensor assembly side of connector between air bag sensor assembly and passenger-side airbag assembly. Reconnect negative battery cable and wait at least 2 seconds. Go to next step.

4. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear malfunction codes stored in memory. Turn ignition to LOCK and wait at least 20 seconds. Turn ignition to ACC or ON and wait at least 20 seconds. Using Diagnosis Check Wire (09843-18020) check code. If DTC 12 is not displayed, go to next step. If DTC 12 is displayed, replace air bag sensor assembly.

5. Turn ignition to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Connect steering wheel pad connector. Connect negative battery cable and wait at least 2 seconds. Turn ignition to ACC or ON and wait at least 20 seconds. Clear codes. See CLEARING CODES . Go to next step.

6. Turn ignition to LOCK and wait at least 20 seconds. Using diagnosis check wire (09843-18020) connect terminals Tc and E1 of DLC1. See Fig. 14 . Check code. If DTC 12 is not displayed, go to next step. If DTC 12 is displayed, replace steering wheel pad.

7. Turn ignition switch to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Reconnect


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passenger-side air bag assembly connector. Connect negative battery cable and wait at least 2 seconds. Clear malfunction code. Turn ignition to LOCK and wait for at least 20 seconds. Go to next step.

8. Turn ignition to ACC or ON and wait for at least 20 seconds. Using diagnosis check wire (09843-18020) connect terminals Tc and E1 of DLC1. Check code. If DTC 12 is displayed, replace passenger-side air bag sensor. If DTC 12 is not displayed, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

9. Turn ignition switch to LOCK position. Disconnect connector between air bag sensor assembly and spiral cable.Turn ignition switch to ON position. Measure voltage between D+ and body ground on spiral cable side of connector between spiral cable and steering wheel pad. If voltage is 0 volts, repair or replace harness or connector between air bag sensor assembly and spiral cable. If resistance is not as specified, repair or replace spiral cable.

DTC 14

1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect jumper wire between D+ and D- on air bag sensor assembly connector. For connector between spiral cable and steering wheel pad (spiral cable side), measure resistance between terminals D+ and D-. If resistance is less than 1 ohm, go to next step. If resistance is not as specified, go to step 6).

2. Connect connector to air bag sensor assembly. Connect jumper wire between D+ and D- of connector between spiral cable and steering wheel pad (spiral cable side). Connect negative battery cable and wait at least 2 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear codes. See CLEARING CODES . Go to next step.

3. Turn ignition switch to LOCK position and wait at least 20 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Use Diagnosis Check Wire (09843-18020) to connect terminals Tc and E1 of DLC1. See Fig. 14 . If DTC 14 is displayed, replace air bag sensor assembly. If DTC 14 is not displayed, go to next step.

4. Turn ignition to LOCK. Disconnect negative battery cable and wait at least 90 seconds. Connect steering wheel pad connector. Connect negative battery cable and wait at least 2 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear codes. See CLEARING CODES . Turn ignition to LOCK and wait at least 20 seconds. Go to next step.

5. Turn ignition to ACC or ON and wait at least 20 seconds. Use Diagnosis Check Wire (09843-18020) to connect terminals Tc and E1 of DLC1. If DTC 14 is displayed, replace steering wheel pad. If DTC 14 is not displayed, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

6. Disconnect connector between air bag sensor assembly and spiral cable. For connector between spiral cable and steering wheel pad (spiral cable side), measure resistance between D+ and D-. If resistance is less than 1 ohm, go to next step. If resistance is not as specified, repair or replace spiral cable.

7. Connect jumper wire between D+ and D- on air bag sensor assembly. For connector between air bag sensor assembly and spiral cable (air bag sensor assembly side), measure resistance between D+ and D-. If resistance is less than 1 ohm, malfunction is normal, see SIMULATION METHOD CHECK . If resistance is not as specified, replace harness or connector between air bag sensor assembly and spiral cable.

DTC 31


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1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Turn ignition switch on. Measure voltage between terminals IG2 and ACC of air bag sensor assembly and body ground. If voltage is less than 16 volts, go to next step. If voltage is not as specified, check battery and charging system.

2. Clear codes. See CLEARING CODES . Turn ignition to LOCK and wait at least 20 seconds. Turn ignition to ACC or ON position and wait for at least 20 seconds. Repeat ignition switch LOCK and ON cycle at least 5 times. Connect Diagnosis Check Wire (09843-18020) between terminals Tc and E1 of DLC1. See Fig. 14 . If DTC 31 is displayed, replace air bag sensor assembly. If DTC 31 is not displayed, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

3. Check air bag warning light for proper system function, see SYSTEM OPERATION CHECK . If warning light does not indicate fault in SRS, system is OK, no further action necessary. If warning light indicates fault in SRS, go to appropriate procedure for system diagnosis.

DTC 54

1. Disable SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect jumper wire between P+ and P- on air bag sensor assembly connector. For connector between air bag sensor assembly and passenger-side air bag assembly (air bag sensor assembly side), measure resistance between P+ and P-. If resistance is less than 1 ohm, go to next step. If resistance is not as specified, repair or replace harness or connector between air bag sensor and passenger-side air bag assembly.

2. Connect connector to air bag sensor assembly. Connect jumper wire between P+ and P- of connector between air bag sensor and passenger-side air bag assembly (air bag sensor assembly side). Reconnect negative battery cable and wait at least 2 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear codes. See CLEARING CODES . Go to next step.

3. Turn ignition switch to LOCK position and wait at least 20 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Connect Diagnosis Check Wire (09843-18020) between terminals Tc and E1 of DLC1. See Fig. 14 . If DTC 54 is not displayed, go to next step. If DTC 54 is displayed, replace air bag sensor assembly.

4. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. Connect passenger-side air bag connector. Reconnect negative battery cable and wait at least 2 seconds. Turn ignition switch to LOCK position and wait at least 2 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Clear codes. See CLEARING CODES . Go to next step.

5. Turn ignition switch to LOCK position and wait at least 20 seconds. Turn ignition switch to ACC or ON position and wait at least 20 seconds. Connect diagnosis wire between terminals Tc and E1 of DLC1. See Fig. 14 . If DTC 54 is displayed, replace passenger-side air bag assembly. If DTC 54 is not displayed, malfunction is normal, see SIMULATION METHOD CHECK and go to next step.

6. Check air bag warning light for proper system function, see SYSTEM OPERATION CHECK . If warning light does not indicate fault in SRS, system is OK, no further action necessary. If warning light indicates fault in SRS, go to appropriate procedure for system diagnosis.

AIR BAG SENSOR CONNECTOR TERMINAL

NOTE: If a code other than DTC 31 is displayed at same time as DTC 31, repair the fault indicated by code other than DTC 31. Clear codes and retest.


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WIRING DIAGRAM

Terminal CircuitA Electrical Connection Check MechanismB Electrical Connection Check Mechanism1 (P-) Passenger-Side Squib (-)2 (P+) Passenger-Side Squib (+)3 (D-) Driver-Side Squib (-)4 (D+) Driver-Side Squib (+)5 (E1) Ground6 (E2) Ground7 (Tc) Diagnosis8 (LA) SRS Warning Light9 (IG2) Power Source (IGN Fuse)10 (ACC) Power Source (CIG Fuse)

Application Ft. Lbs. (N.m)Air Bag Sensor Screw 15 (21)Passenger-Side Air Bag Bolt 15 (21)Steering Wheel Nut 25 (34)

INCH Lbs. (N.m)Steering Wheel Pad Torx Screw 78 (9)

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Fig. 17: SRS Wiring Diagram

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1997-99 AUTOMATIC TRANSMISSIONS

Toyota A-340 & A-343 Series Overhaul (Trucks)

APPLICATION

TRANSMISSION APPLICATIONS

IDENTIFICATION

Vehicle Identification Number (VIN) is used for current application of component parts and assemblies. VIN is stamped on vehicle identification plate, located at top left corner of dash, and on certification label, located on driver's door jam.

GEAR RATIOS

GEAR RATIOS

Vehicle Model Transmission ModelLexus

LX 450 (1997) A-343FLX 470 (1998-99) A-343F

ToyotaLand Cruiser A-343FTacoma

2WD 4-Cyl. & V6 A-340E4WD 4-Cyl. & V6 A-340F

T1002WD 4-Cyl. & V6 A-340E4WD V6 A-340F

4Runner2WD 4-Cyl. & V6 A-340E4WD 4-Cyl. & V6 A-340F

CAUTION: Models are equipped with a Supplemental Restraint System (SRS). When servicing vehicle, use care to avoid accidental air bag deployment. All SRS electrical connections and wiring harness are covered by Yellow insulation. SRS-related components are located in steering column, center console, instrument panel and lower panel on instrument panel. DO NOT use electrical test equipment on these circuits. If necessary, deactivate SRS before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

Gear Ratio1st 2.804

1998 Lexus LX 470

1997-99 AUTOMATIC TRANSMISSIONS Toyota A-340 & A-343 Series Overhaul (Trucks)

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DESCRIPTION

INTRODUCTION

All A-340 series automatic transmissions are 4-speed Electronic Controlled Transmissions (ECT). Solenoids that control shifts are located in valve body. Transmission consists of lock-up type torque converter, OD direct clutch, direct clutch, forward clutch, 2nd brake, 2nd coast brake, OD brake, overdrive planetary gear unit, planetary gear unit, hydraulic control system and electronic control system. See Fig. 1 .

Solenoids are controlled by an Electronic Controlled Transmission (ECT) Electronic Control Unit (ECU). Control unit is referred to as the ECT ECU. For electronic diagnosis, see appropriate ELECTRONIC CONTROLS article. ECT ECU receives information from various input devices and uses this information to control solenoids for transmission shifting and lock-up solenoid for torque converter lock-up.

An Overdrive (OD) switch is mounted on shift lever. When OD switch is depressed to ON position, transmission will shift into 4th gear when shift lever is in "D" position, and OD OFF light on instrument panel will go off. When OD switch is released to OFF position, transmission will shift into 3rd gear, and OD OFF light on instrument panel will illuminate.

A pattern select switch is located near shift lever on center console. Pattern select switch contains a POWER (PWR) and a NORMAL operating position. When pattern select switch is depressed (PWR position), transmission upshifts and downshifts will occur at a higher vehicle speed than with switch released. An indicator light on instrument panel indicates pattern select switch is in PWR (on) position. On some models, pattern select switch may include a 2nd start switch. Transmission starts out in 2nd gear when 2nd start switch is activated.

A-340F and A-343F transmission has a mechanically controlled 2-speed 4WD transfer case. Transfer case consists of planetary gears, hydraulic clutches and hydraulic brake. Transfer case is mounted to rear of transmission case.

Transmission is equipped with a shift lock and key lock system. Shift lock system prevents shift lever from being moved from Park unless brake pedal is depressed. Key lock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless shift lever is in Park. For more information on shift lock and key lock system, see TOYOTA & LEXUS SHIFT LOCK SYSTEM article.

2nd 1.5313rd 1.000OD .705Reverse 2.393

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Fig. 1: Identifying Transmission Component Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LUBRICATION

For transmission refill capacities, see TRANSMISSION CAPACITIES table.

TRANSMISSION CAPACITIES Application Qts. (L)Lexus

LX 450 & LX 470Drain & Refill 2.1 (2.0)Dry Refill 12.0 (11.7)

ToyotaLand Cruiser

Drain & Refill 2.1 (2.0)Dry Refill 12.0 (11.7)

TacomaA-340E


A-340FDrain & Refill 2.1 (2.0)Dry Refill 10.7 (10.1)

T100A-340E


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ON-VEHICLE SERVICE

DRIVE AXLE SHAFTS

See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES.

TRANSMISSION VALVE BODY

Removal

1. Drain fluid. Remove oil pan, filler tube, gasket, oil filter and magnets from oil pan. Disconnect connectors from each solenoid. Remove solenoid wiring and stopper plate.

2. Note location of oil tubes. Using screwdrivers, pry at both ends of oil tubes and remove oil tubes. Remove transmission fluid temperature sensor (if applicable). Remove valve body bolts. Note location and bolt length. See Fig. 2 .

3. Lower valve body slightly and remove accumulator piston springs. Note location of springs. Disconnect throttle cable from valve body cam. Remove valve body. Use care not to lose check ball and spring located above valve body (if equipped).

Installation

1. To install, reverse removal procedure. Ensure check ball and spring are installed above valve body (if equipped). Ensure manual shift lever in transmission case aligns with manual valve of valve body.

2. Install accumulator piston springs and spacers in original location. See TRANSMISSION REASSEMBLY . Proper length bolts must be installed in designated areas. See Fig. 2 . Use NEW "O" ring on solenoid, oil filter and gasket if necessary. Ensure oil tubes do not contact oil pan. Install magnets in oil pan. Install pan with NEW gasket. Fill fluid to proper level.


4RunnerA-340E



NOTE: During valve body removal, note location of accumulator piston springs, oil tubes, bolt length and location, check ball and spring (if equipped). Component locations should be marked for reassembly reference.

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Fig. 2: Identifying Valve Body Mounting Bolts (A-340 Series Models) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PARKING LOCK PAWL


Remove valve body. Remove parking lock pawl bracket. Disconnect parking lock rod from manual valve lever on A-340E and A-340F models. On all models, note location of shaft spring. Remove shaft spring from shaft. Remove shaft and parking lock pawl. Remove "E" ring from shaft. To install, reverse removal procedure.

EXTENSION HOUSING & SENSOR ROTOR (A-340E)

Removal

1. Raise and support vehicle. Place reference marks on drive shaft and companion flange. Remove drive shaft and center bearing assembly.

2. Remove front exhaust pipe and converter. Disconnect speedometer cable. Remove speedometer driven gear and speed sensor from extension housing.

1998 Lexus LX 470


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3. Using jack, support transmission. Remove ground cable and rear support member from extension housing. Remove extension housing bolts. Note bolt length and location. Remove extension housing.

4. If sensor rotor is to be replaced, remove snap ring, speedometer drive gear and lock ball from output shaft. Use care not to lose lock ball when removing drive gear. Remove sensor rotor.

Cleaning & Inspection

Clean components with solvent. Dry with compressed air. Inspect components for damage. Measure inside diameter of extension housing bushing bore. Replace extension housing if inside diameter exceeds 1.578" (40.09 mm).

Installation

Install sensor rotor on output shaft, ensuring key is installed in groove. Install extension housing using a NEW housing gasket. Apply sealant to extension housing bolt threads prior to installation. Shorter mounting bolts go on bottom of extension housing. To complete installation, reverse removal procedure.

THROTTLE CABLE

Removal

Disconnect throttle cable from cam. Remove transmission valve body. See TRANSMISSION VALVE BODY . Pull out throttle cable.

Installation

1. Install throttle cable in transmission case. Ensure cable is fully seated. Install valve body. Connect throttle cable to cam. New cables do not have cable stopper installed. To make adjustment possible, stake stopper as described.

2. Pull inner cable lightly until a slight resistance is felt. Stake stopper 0-.04" (0-1.0 mm) on Tacoma, or .031-.059" (.80-1.50 mm) on all other models, from end of outer cable. See Fig. 3 . Connect throttle cable on throttle linkage. Adjust throttle cable. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING. Test drive vehicle.

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Fig. 3: Staking Throttle Cable Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING

PRELIMINARY CHECKS

Ensure fluid level is correct. Inspect and adjust throttle cable, shift linkage and park/neutral position switch (if necessary). Check idle speed RPM and adjust as necessary.

SYMPTOM DIAGNOSIS

Fluid Discolored Or Smells Burnt

Fluid contaminated. Torque converter or transmission faulty.

No Movement In Any Gear

Shift linkage out of adjustment. Faulty valve body or primary regulator. Parking lock pawl faulty. Faulty torque converter. Converter drive plate damaged or broken. Oil pump intake screen blocked. ECT computer faulty. Control shaft lever out of adjustment. Faulty OD one-way clutch, OD brake, OD direct clutch or OD planetary gear.

Selector Lever Position Incorrect

NOTE: See appropriate ELECTRONIC CONTROLS article for trouble shooting solenoids, sensors and computer control unit. Ensure transmission fluid level is correct before diagnosing transmission.

1998 Lexus LX 470


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Shift linkage out of adjustment. Faulty manual valve and lever.

Harsh Engagement Into Any Drive Range

Throttle cable out of adjustment. Faulty valve body, primary regulator or accumulator pistons. Faulty OD brake, OD direct clutch, OD planetary gear unit or torque converter. Faulty 1st and reverse brake, direct clutch or forward clutch.

Delayed 1-2, 2-3 Or 3-OD Upshifts, Or Downshifts From OD-3 Or 3-2, Then Changes Back To OD Or 3rd

Faulty valve body, ECT ECU or solenoid valve.

Slips On Any Upshift Or Slips Or Shudders On Acceleration

Shift linkage or throttle cable out of adjustment. Faulty valve body or solenoid valve.

Drag Or Binding On Upshifts

Shift linkage out of adjustment or faulty valve body.

No Lock-Up In 2nd, 3rd Or OD

Faulty valve body, solenoid valve or electronic control unit.

Harsh Downshift

Throttle cable out of adjustment or faulty. Accumulator pistons or valve body faulty.

No Downshift When Coasting

Faulty valve body, electronic control or solenoid valve.

Downshifts Too Soon Or Too Late When Coasting

Throttle cable out of adjustment or faulty. Faulty valve body, electronic control or solenoid valve.

No OD-4, OD-3, 3-2 Or 2-1 Kickdown

Faulty valve body, electronic control or solenoid valve faulty.

No Engine Braking In "2" Or "L" Range

Faulty valve body, electronic control or solenoid valve.

Vehicle Does Not Move In "R" Range

Faulty 2nd coast brake, front and rear planetary gear unit or direct clutch. Faulty 1st and reverse brake. Faulty OD direct clutch.

1998 Lexus LX 470


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Vehicle Does Not Move In "D", "2" Or "L" Range

Faulty forward clutch. Faulty No. 2 one-way clutch. Faulty 1st and reverse brake. Faulty 2nd coast brake, direct clutch or 2nd brake.

No Upshift 1-2, 2-3, 3-OD, 3-4, 4-OD

Faulty 2nd brake or No. 1 one-way clutch. Faulty direct clutch. Faulty OD brake.

No Downshift 2-1

Faulty 2nd coast brake. Faulty 2nd brake.

No Lock-Up Or No Lock-Up Off

Faulty torque converter or solenoid.

Slip Or Shudder In "D", "R", 1st, 2nd, 3rd, 4th Or OD

Faulty torque converter, OD one-way clutch or OD direct clutch. Faulty 1st and reverse brake or direct clutch. Faulty forward clutch or No. 2 one-way clutch. Faulty 2nd brake, 2nd coast brake or No. 1 one-way clutch. Faulty OD brake.

No Engine Braking 1st-3rd

Faulty OD direct clutch, 1st and reverse brake or 2nd coast brake.

Poor Acceleration

Faulty torque converter, OD direct clutch, OD planetary gear unit or OD brake. Faulty 2nd coast brake, direct clutch, 2nd brake or 1st and reverse brake. Faulty forward clutch.

Engine Stalls When Starting Off Or Stopping

Faulty torque converter.

Vehicle Does Not Hold In "P" Range

Shift linkage faulty or out of adjustment. Defective parking lock pawl assembly.

No Transfer Case Gear Changes On 4WD Models

Transfer linkage out of adjustment. Faulty transfer case.

CLUTCH & BAND APPLICATION Selector Lever Position Elements In Use"D" (Drive)

1998 Lexus LX 470


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TESTING

ELECTRICAL TESTING

Electrical tests should be performed prior to hydraulic testing to ensure problem is not in electrical circuit. See

1st Gear Forward Clutch, No. 2 One-Way Clutch, OD One-Way Clutch &

OD Direct Clutch2nd Gear Forward Clutch, No. 1 One-Way

Clutch, 2nd Brake, OD Direct Clutch & OD One-Way Clutch

3rd Gear Forward Clutch, 2nd Brake, Direct Clutch, OD Direct Clutch

& OD One-Way ClutchOD (4th Gear) Forward Clutch, 2nd Brake, OD

Brake & Direct Clutch"2" (Intermediate)

1st Gear Forward Clutch, No. 2 One-Way Clutch OD Direct Clutch & OD

One-Way Clutch2nd Gear Forward Clutch, 2nd Coast

Brake, 2nd Brake, No. 1 One-Way Clutch, OD Direct Clutch

& OD One-Way Clutch

3rd Gear (1) Forward Clutch, OD Direct Clutch, Direct Clutch 2nd Brake

& OD One-Way Clutch"L" (Low)

1st Gear Forward Clutch, OD One-Way Clutch, No. 2 One-Way Clutch,

OD Direct Clutch & 1st & Reverse Brake

2nd Gear (2) Forward Clutch, 2nd Coast Brake, 2nd Brake, No. 1 One-

Way Clutch, OD Direct Clutch & OD One-Way Clutch

"R" (Reverse) OD Direct Clutch, Direct Clutch, OD One-Way Clutch & 1st &

Reverse Brake"N" (Neutral) OD Direct Clutch"P" (Park) OD Direct Clutch(1) Downshift only in "2" range and 3rd gear. No upshift.

(2) Downshift only in "L" range and 2nd gear. No upshift.

1998 Lexus LX 470


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appropriate ELECTRONIC CONTROLS article.

PRELIMINARY CHECKS

Before testing transmission and transfer case, perform following procedures:

Ensure fluid level is correct.

Inspect and adjust throttle cable.

Ensure battery is fully charged for accurate testing.

Adjust shift linkage.

Adjust park/neutral position switch.

Inspect idle speed RPM.

TIME LAG TEST

Test Procedure

1. Engine and transmission must be at normal operating temperature. Start engine and ensure idle RPM is within specification. See IDLE SPEED SPECIFICATIONS table. On 4Runner and T100 models, place transfer gear shift selector in "H2".

2. On all models, apply service and parking brakes. Using stop watch, measure time until engagement shock is felt when lever is shifted from "N" to "D". Allow one minute interval between tests. Perform time measurements 2 more times and calculate average value. Time should be less than 1.2 seconds.

3. Use same procedure to test time lag when gear selector is moved from "N" to "R". Time lag should be less than 1.5 seconds.

Test Results

1. If "N" to "D" time lag exceeds specification, check for low main line pressure, worn forward clutch or overdrive one-way clutch not operating correctly.

2. If "N" to "R" time lag exceeds specification, check for low main line pressure, worn direct clutch, worn 1st and reverse brake or overdrive one-way clutch not operating correctly.

IDLE SPEED SPECIFICATIONS (1) (2)

Vehicle Transmission RPMLexus

LX 450 A-343F 650LX 470 A-343F 700

ToyotaLand Cruiser A-343F 650Tacoma & T100

4-Cyl. A-340E 700V6 A-340E & A-340F 700

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ROAD TEST

Test Procedure

Before road testing, note following information:

No overdrive upshift or lock-up will occur when engine coolant is below 140°F (60°C) on Lexus models.

No 3rd upshift or lock-up will occur when engine coolant temperature is below 95°F (35°C) and speed is below 25 MPH on Lexus models.

No overdrive upshift or lock-up will occur when engine coolant temperature is below 133°F (55°C) on Land Cruiser or below 140°F (60°C) on Tacoma, T100 and 4Runner models.

No overdrive upshift or lock-up will occur if a 6 MPH difference between set cruise control speed and actual speed exists on all models.

All shift points vary due to transfer case gear position on Tacoma, T100 and 4Runner models.

Overdrive gear and lock-up are cancelled when transfer case is engaged in L4 on Tacoma, T100 and 4Runner models.

"D" Range Test in NORM Or PWR Pattern Ranges

1. Shift into "D". Hold accelerator at constant full throttle position. Check 1-2, 2-3 and 3-OD upshift points. See appropriate SHIFT SPEED SPECIFICATIONS table.

If no 1st-2nd gear upshift occurs, 1-2 shift valve or No. 2 solenoid is stuck.

If no 2nd-3rd gear upshift occurs, 2-3 shift valve or No. 1 solenoid is stuck.

If no 3-OD gear upshift occurs, 3-4 shift valve is stuck.

If all shift points are incorrect, throttle, 1-2 shift, 2-3 shift and 3-OD shift valves are defective.

If all lock-up points are incorrect, lock-up control valve, lock-up signal valve or lock-up solenoid is stuck.

2. Use procedure outlined in step 1) to check shock and slip between 1-2 gear, 2-3 gear and 3-OD gear upshifts. Excessive shock can be caused by excessive line pressure, defective accumulator or defective check ball.

3. Run in OD or lock-up in "D" range. Check for abnormal noise and vibration. Noise and vibration may be caused by unbalanced drive shaft, differential, torque converter or other drive train components.

4Runner4-Cyl. A-340E & A-340F 700V6 A-340E & A-340F 700

(1) Plus or minus 50 RPM.

(2) Check idle speed in Neutral range with A/C off.

CAUTION: Perform test at normal operating fluid temperature of 122-176°F (50-80°C).

1998 Lexus LX 470


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4. While running in "D" range, 2nd, 3rd and OD gears, check correct kickdown speed for 2-1, 3-2 and OD-3 gears. Check for abnormal shock and slip at kickdown.

5. Check lock-up mechanism. Drive in OD gear of "D" range, at steady speed (lock-up ON) of 47 MPH for 4Runner, Tacoma and T100 models, and 59 MPH for Land Cruiser, LX 450 and LX 470 models. Lightly depress accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates there is no lock-up.

"2" Range Test

1. Shift to "2" range. Drive with accelerator pedal held constant at full throttle. Push in one pattern selection button. Ensure 1-2 upshift points at each accelerator opening take place and are operating properly.

2. While driving in "2" range, 2nd gear, release accelerator pedal and check engine braking. If there is no engine braking, second coast brake is defective. Check for abnormal noise and shock at acceleration and deceleration.

"L" Range Test

While running in "L" range, ensure there is no upshift to 2nd gear. While running in "L" range, release accelerator pedal. If there is no engine braking effect, 1st and reverse brake is defective. Note abnormal noise at acceleration and deceleration.

"R" Range Test

Shift into "R" range. Accelerate vehicle from a stop at full throttle. Ensure slipping does not occur.

"P" Range Test

Stop vehicle on 5 degree or more gradient. Shift transmission into "P". Release parking brake. Ensure parking pawl holds vehicle.

SHIFT SPEED SPECIFICATIONS

LAND CRUISER & LX 450 A-343F (1997) SHIFT SPEED SPECIFICATIONS (1)

NOTE: There is no OD upshift and lock-up in "2" range. To prevent overrun, transmission upshifts into 3rd gear at 62 MPH for 4Runner.

Application MPH"D" Range

1st-2nd 35-392nd-3rd 64-713rd-OD 94-101OD-3rd 90-973rd-2nd 59-632nd-1st 26-29

1998 Lexus LX 470


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LAND CRUISER & LX 450 A-343F (1997) LOCK-UP SPEED SPECIFICATIONS (1)

LAND CRUISER & LX 470 A-343F (1998-99) SHIFT SPEED SPECIFICATIONS (1)

LAND CRUISER & LX 470 A-343F (1998-99) LOCK-UP SPEED SPECIFICATIONS (1)

"2" Range (2) 3rd-2nd 72-79

"L" Range2nd-1st 38-39

(1) Wide open throttle.

(2) No 1-2 upshift or 2-1 downshift with 2nd start switch on.

Application MPH

"D" Range (2) (NORM Or PWR)Lock-Up ON 48-52Lock-Up OFF 42-46

(1) Throttle valve opened 5 percent.

(2) No lock-up in "L" or "2" range.


1st-2nd 34-372nd-3rd 63-693rd-OD 95-103OD-3rd 91-983rd-2nd 58-622nd-1st 27-30

"2" Range (2) 3rd-2nd 70-76

"L" Range2nd-1st 34-39


(2) No 1-2 upshift or 2-1 downshift with 2nd start switch on.

Application MPH

"D" Range (2) (NORM Or PWR)Lock-Up ON 38-41Lock-Up OFF 34-39


1998 Lexus LX 470


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4RUNNER 2.7L 2WD A-340E (1997-99) SHIFT SPEED SPECIFICATIONS

4RUNNER 2.7L 2WD A-340E (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

4RUNNER 3.4L 2WD A-340E (1997-99) SHIFT SPEED SPECIFICATIONS


Application MPH"D" Range (NORM or PWR)

1st-2nd (1) 36-40

2nd-3rd (1) 66-72

3rd-OD (1) 88-94

3rd-OD (2) 21-24

OD-3rd (2) 16-19

OD-3rd (1) 84-90

3rd-2nd (1) 61-67

2nd-1st (1) 29-32

"2" Range (NORM or PWR)

1st-2nd (1) 36-40

3rd-2nd (1) 70-75

2nd-1st (1) 29-32

"L" Range (NORM or PWR)

2nd-1st (1) 34-37


(2) Fully closed throttle.

Application MPH

"D" Range (NORM) (2) Lock-Up ON In OD 48-52Lock-Up OFF In OD 43-47

"D" Range (PWR)Lock-Up ON In OD 52-55Lock-Up OFF In OD 43-47




1998 Lexus LX 470


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4RUNNER 3.4L 2WD A-340E (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

4RUNNER 2.7L 4WD A-340F (1997-99) SHIFT SPEED SPECIFICATIONS

1st-2nd (1) 37-40

2nd-3rd (1) 70-75

3rd-OD (1) 94-99

3rd-OD (2) 27-30

OD-3rd (2) 14-17

OD-3rd (1) 89-94

3rd-2nd (1) 64-69

2nd-1st (1) 29-32


1st-2nd (1) 37-40

3rd-2nd (1) 74-79

2nd-1st (1) 29-32


2nd-1st (1) 36-39



Application MPH

"D" Range (NORM or PWR) (2) Lock-Up ON in OD 47-50Lock-Up OFF in OD 42-45




1st-2nd (1) 34-38

2nd-3rd (1) 63-69

3rd-OD (1) 83-90

3rd-OD (2) 20-23

OD-3rd (2) 15-18

OD-3rd (1) 79-86

3rd-2nd (1) 58-64

1998 Lexus LX 470


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4RUNNER 2.7L 4WD A-340F (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

4RUNNER 3.4L 4WD A-340F (1997-99) SHIFT SPEED SPECIFICATIONS

2nd-1st (1) 27-30


1st-2nd (1) 34-38

3rd-2nd (1) 65-72

2nd-1st (1) 27-30


2nd-1st (1) 32-35



Application MPH





1st-2nd (1) 35-39

2nd-3rd (1) 66-73

3rd-OD (1) 89-97

3rd-OD (2) 25-29

OD-3rd (2) 14-17

OD-3rd (1) 85-93

3rd-2nd (1) 61-68

2nd-1st (1) 28-32


1st-2nd (1) 35-39

3rd-2nd (1) 71-78

2nd-1st (1) 28-32


2nd-1st (1) 34-38

1998 Lexus LX 470


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4RUNNER 3.4L 4WD A-340F (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 2.7L (P255/75R15 TIRES) A-340E (1997-98) SHIFT SPEED SPECIFICATIONS

TACOMA 2.7L (P225/75R15 TIRES) A-340E (1999) SHIFT SPEED SPECIFICATIONS



Application MPH





1st-2nd (1) 33-36

2nd-3rd (1) 60-65

3rd-OD (1) 84-89

3rd-OD (2) 21-23

OD-3rd (2) 15-18

OD-3rd (1) 80-86

3rd-2nd (1) 55-59

2nd-1st (1) 26-29


1st-2nd (1) 33-36

3rd-2nd (1) 66-72

2nd-1st (1) 26-29


3rd-2nd (1) 57-62

2nd-1st (1) 32-35




1st-2nd (1) 35-38

1998 Lexus LX 470


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TACOMA 2.7L (P255/75R15 TIRES) A-340E (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 2.7L (P225/75R15 TIRES) A-340E (1999) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 2.7L (31X10.5R15 TIRES) A-340E (1997-98) SHIFT SPEED SPECIFICATIONS

2nd-3rd (1) 63-68

3rd-OD (1) 89-94

3rd-OD (2) 22-24

OD-3rd (2) 16-19

OD-3rd (1) 85-90

3rd-2nd (1) 59-62

2nd-1st (1) 28-30


1st-2nd (1) 35-38

3rd-2nd (1) 71-75

2nd-1st (1) 28-30


3rd-2nd (1) 60-65

2nd-1st (1) 34-37



Application MPH

"D" Range (NORM or PWR) (2) Lock-Up ON In OD 48-52Lock-Up OFF In OD 45-48



Application MPH





1998 Lexus LX 470


Microsoft


TACOMA 2.7L (31X10.5R15 OR P265/70R16 TIRES) A-340E (1999) SHIFT SPEED SPECIFICATIONS

1st-2nd (1) 32-35

2nd-3rd (1) 58-63

3rd-OD (1) 82-87

3rd-OD (2) 20-22

OD-3rd (2) 15-17

OD-3rd (1) 78-83

3rd-2nd (1) 54-57

2nd-1st (1) 25-28


1st-2nd (1) 32-35

3rd-2nd (1) 65-70

2nd-1st (1) 25-28


3rd-2nd (1) 55-60

2nd-1st (1) 31-34




1st-2nd (1) 34-37

2nd-3rd (1) 62-67

3rd-OD (1) 88-93

3rd-OD (2) 21-24

OD-3rd (2) 16-19

OD-3rd (1) 84-88

3rd-2nd (1) 58-61

2nd-1st (1) 27-30


1st-2nd (1) 34-37

3rd-2nd (1) 70-74

2nd-1st (1) 27-30


3rd-2nd (1) 59-64

1998 Lexus LX 470


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TACOMA 2.7L (31X10.5R15 TIRES) A-340E (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 2.7L (31X10.5R15 OR P265/70R16 TIRES) A-340E (1999) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 3.4L A-340E (1997-98) SHIFT SPEED SPECIFICATIONS

2nd-1st (1) 34-36



Application MPH




Application MPH





1st-2nd (1) 40-43

2nd-3rd (1) 75-81

3rd-OD (1) 101-107

3rd-OD (2) 29-32

OD-3rd (2) 16-19

OD-3rd (1) 96-102

3rd-2nd (1) 69-75

2nd-1st (1) 32-35


1st-2nd (1) 40-43

3rd-2nd (1) 80-85

2nd-1st (1) 32-35

1998 Lexus LX 470


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TACOMA 3.4L (P225/75R15 TIRES) A-340E (1999) SHIFT SPEED SPECIFICATIONS

TACOMA 3.4L (31X10.5R15 TIRES) A-340E (1999) SHIFT SPEED SPECIFICATIONS


3rd-2nd (1) 68-73

2nd-1st (1) 38-42




1st-2nd (1) 35-38

2nd-3rd (1) 65-71

3rd-OD (1) 88-94

3rd-OD (2) 25-29

OD-3rd (2) 14-16

OD-3rd (1) 84-90

3rd-2nd (1) 60-66

2nd-1st (1) 27-30


1st-2nd (1) 35-38

3rd-2nd (1) 70-75

2nd-1st (1) 27-30


3rd-2nd (1) 59-65

2nd-1st (1) 34-37




1st-2nd (1) 36-39

2nd-3rd (1) 68-73

3rd-OD (1) 91-97

3rd-OD (2) 26-29

OD-3rd (2) 14-18

87-93

1998 Lexus LX 470


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TACOMA 3.4L A-340E (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 3.4L (P225/75R15 TIRES) A-340E & A-340F (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 3.4L (31X10.5R15 TIRES) A-340E & A-340F (1997-99) LOCK-UP SPEED SPECIFICATIONS (1)

OD-3rd (1)

3rd-2nd (1) 62-68

2nd-1st (1) 29-31


1st-2nd (1) 36-39

3rd-2nd (1) 72-78

2nd-1st (1) 29-31


3rd-2nd (1) 62-68

2nd-1st (1) 35-38



Application MPH




Application MPH




Application MPH


1998 Lexus LX 470


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TACOMA 2.7L (P225/75R15 TIRES) A-340F (1999) SHIFT SPEED SPECIFICATIONS

TACOMA 2.7L (31X10.5R15 TIRES) A-340F (1999) SHIFT SPEED SPECIFICATIONS




1st-2nd (1) 33-36

2nd-3rd (1) 60-65

3rd-OD (1) 84-89

3rd-OD (2) 21-23

OD-3rd (2) 15-18

OD-3rd (1) 80-86

3rd-2nd (1) 55-59

2nd-1st (1) 26-29


1st-2nd (1) 33-36

3rd-2nd (1) 66-72

2nd-1st (1) 26-29


3rd-2nd (1) 57-62

2nd-1st (1) 32-35




1st-2nd (1) 32-35

2nd-3rd (1) 58-63

3rd-OD (1) 82-87

3rd-OD (2) 20-22

OD-3rd (2) 15-17

OD-3rd (1) 78-83

3rd-2nd (1) 54-57

2nd-1st (1) 25-28

1998 Lexus LX 470


Microsoft


TACOMA 2.7L (P225/75R15 TIRES) A-340F (1999) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 2.7L (31X10.5R15 TIRES) A-340F (1999) LOCK-UP SPEED SPECIFICATIONS (1)

TACOMA 3.4L (P225/75R15 TIRES) A-340F (1997-99) SHIFT SPEED SPECIFICATIONS


1st-2nd (1) 32-35

3rd-2nd (1) 65-70

2nd-1st (1) 15-28


3rd-2nd (1) 55-60

2nd-1st (1) 31-34



Application MPH




Application MPH





1st-2nd (1) 35-38

2nd-3rd (1) 65-71

3rd-OD (1) 88-94

3rd-OD (2) 25-29

OD-3rd (2) 14-16

OD-3rd (1) 84-90

3rd-2nd (1) 60-66

1998 Lexus LX 470


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TACOMA 3.4L (31X10.5R15 TIRES) A-340F (1997-99) SHIFT SPEED SPECIFICATIONS

T100 2.7L 2WD A-340E (1997-98) SHIFT SPEED SPECIFICATIONS

2nd-1st (1) 27-30


1st-2nd (1) 35-38

3rd-2nd (1) 70-75

2nd-1st (1) 27-30


3rd-2nd (1) 59-65

2nd-1st (1) 34-37




1st-2nd (1) 36-39

2nd-3rd (1) 68-73

3rd-OD (1) 91-97

3rd-OD (2) 26-29

OD-3rd (2) 14-18

OD-3rd (1) 87-93

3rd-2nd (1) 62-68

2nd-1st (1) 29-31


1st-2nd (1) 36-39

3rd-2nd (1) 72-78

2nd-1st (1) 29-31


3rd-2nd (1) 62-68

2nd-1st (1) 35-38




1st-2nd (1) 34-37

1998 Lexus LX 470


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T100 2.7L 2WD A-340E (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

T100 3.4L 2WD A-340E (1997-98) SHIFT SPEED SPECIFICATIONS

2nd-3rd (1) 62-67

3rd-OD (1) 79-85

3rd-OD (2) 21-24

OD-3rd (2) 16-19

OD-3rd (1) 75-81

3rd-2nd (1) 57-61

2nd-1st (1) 27-30

"2" Range

1st-2nd (1) 34-37

3rd-2nd (1) 68-75

2nd-1st (1) 27-30

"L" Range

2nd-1st (1) 33-36



Application MPH

"D" Range (2) Lock-Up ON In OD 52-55Lock-Up OFF In OD 44-47




1st-2nd (1) 35-39

2nd-3rd (1) 67-73

3rd-OD (1) 91-96

3rd-OD (2) 27-30

OD-3rd (2) 14-17

OD-3rd (1) 86-92

3rd-2nd (1) 62-67

2nd-1st (1) 29-32

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T100 3.4L 2WD A-340E (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

T100 3.4L 4WD A-340F (1997-98) SHIFT SPEED SPECIFICATIONS

"2" Range

1st-2nd (1) 35-39

3rd-2nd (1) 71-77

2nd-1st (1) 29-32

"L" Range

2nd-1st (1) 32-36



Application MPH





1st-2nd (1) 34-37

2nd-3rd (1) 64-69

3rd-OD (1) 86-91

3rd-OD (2) 26-29

OD-3rd (2) 13-16

OD-3rd (1) 83-88

3rd-2nd (1) 59-64

2nd-1st (1) 27-30

"2" Range

1st-2nd (1) 34-37

3rd-2nd (1) 68-73

2nd-1st (1) 27-30

"L" Range

2nd-1st (1) 33-36


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T100 3.4L 4WD A-340F (1997-98) LOCK-UP SPEED SPECIFICATIONS (1)

STALL SPEED TEST

Test Procedure

1. Operate engine and transmission at normal operating temperature. Connect scan tool to DLC3, located under instrument panel. Apply parking brake and block front wheels.

2. On Tacoma, 4Runner and T100 4WD models, place transfer case in "H2" position. On all models, start engine, apply brake pedal and place transmission in "D". Accelerate engine to full throttle and note maximum RPM obtained. Repeat test in "R". Compare reading obtained to specification. See STALL SPEED SPECIFICATIONS table.

Stall Test Results

1. If stall speed is the same for both ranges but lower than specification, engine output may be insufficient or stator one-way clutch may not be operating properly.

2. Stall speed exceeding specification in "D" range may be caused by a slipping forward clutch, defective No. 2 or overdrive one-way clutch, low main line pressure or transfer case direct clutch slipping.

3. Stall speeds exceeding specification in "R" range may be caused by a low main line pressure, direct clutch slipping, 1st and reverse brake slipping, overdrive one-way clutch defective or transfer case direct clutch slipping.

4. Stall speeds exceeding specification in both ranges may be caused by a low main line pressure, improper fluid level or defective overdrive one-way clutch.

STALL SPEED SPECIFICATIONS


Application MPH




CAUTION: DO NOT maintain stall RPM for more than 5 seconds. Allow engine to idle for one minute between tests to allow fluid to cool.

NOTE: If stall RPM is more than 600 RPM below specifications, torque converter may be faulty.

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HYDRAULIC PRESSURE TEST

1. Ensure transmission fluid is at normal operating temperature. Remove plug from right side of transmission case and install appropriate pressure gauge.

2. Apply parking and service brakes. Start engine. Ensure idle speed is within manufacturer's specifications. Place transmission in "D" range.

3. Check main line pressure at engine idle. Repeat procedure in "R" range. Compare all readings to specification. See appropriate A-340 SERIES LINE PRESSURE SPECIFICATIONS table.

4. Check main line pressure at full throttle (stall speed). Read highest pressure when engine reaches stall speed. Repeat procedure in "R" range. Compare all readings to specification. See appropriate A-340 SERIES LINE PRESSURE SPECIFICATIONS table.

Main Line Pressure Test Results

1. If line pressure in all ranges exceeds specification, check for defective regulator valve, defective throttle valve or throttle cable out of adjustment.

2. If line pressure is below specification in all ranges, check for defective oil pump, defective regulator valve, defective throttle valve, throttle cable out of adjustment or defective OD direct clutch.

3. If line pressure is below specification in "D" range only, check for defective forward clutch, fluid leak in "D" range circuit or defective OD clutch.

Vehicle Transmission Stall RPMLexus

LX 450 A-343F 1800-2100LX 470 A-343F 2150-2450

ToyotaLand Cruiser

1997 A-343F 1800-21001998 A-343F 2150-2450

Tacoma & T1001997

4-Cyl. A-340E 1800-2100V6 A-340E & A-340F 2000-2300

19984-Cyl. A-340E 1800-2100V6 A-340E & A-340F 2100-2400

4Runner4-Cyl. A-340E & A-340F 1850-2150V6 A-340E & A-340F 2100-2400

NOTE: Hydraulic pressure test should be performed with transmission fluid temperature of 122-176°F (50-80°C).

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4. If line pressure is low in "R" range only, check for defective direct clutch, fluid leak in "R" range or defective 1st and reverse brake.

A-340 SERIES LINE PRESSURE SPECIFICATIONS (LAND CRUISER)

A-340 SERIES LINE PRESSURE SPECIFICATIONS (LX 450 - 1997)

A-340 SERIES LINE PRESSURE SPECIFICATIONS (LX 470 - 1998-99)

A-340 SERIES LINE PRESSURE SPECIFICATIONS (TACOMA & T100)

A-340 SERIES LINE PRESSURE SPECIFICATIONS (4RUNNER)

Application"D" Range - psi

(kg/cm2 )"R" Range - psi

(kg/cm2 )1997

Idle Speed 61-70 (4.3-4.9) 74-88 (5.2-6.2)Stall Speed 186-222 (13.1-15.6) 229-280 (16.1-19.7)

1998-99Idle Speed 70-78 (4.9-5.5) 101-115 (7.1-8.1)Stall Speed 188-208 (13.2-14.6) 240-287 (16.9-20.2)

Application "D" Range - psi (kg/cm2 ) "R" Range - psi (kg/cm2 )Idle Speed 61-70 (4.3-4.9) 74-88 (5.2-6.2)Stall Speed 186-222 (13.1-15.6) 229-280 (16.1-19.7)

Application "D" Range - psi (kg/cm2 ) "R" Range - psi (kg/cm2 )Idle Speed 70-78 (4.3-4.9) 101-115 (7.1-8.1)Stall Speed 188-208 (13.2-14.6) 240-287 (16.9-20.2)

Application"D" Range - psi

(kg/cm2 )"R" Range - psi

(kg/cm2 )4-Cyl. (A-340E)

Idle Speed 53-61 (3.7-4.3) 71-85 (5.0-6.0)Stall Speed 135-171 (9.5-

12.0)188-238 (13.2-16.7)

V6 (A-340E & A-340F)Idle Speed 53-61 (3.7-4.3) 88-101 (6.2-7.1)Stall Speed 131-166 (9.2-

11.7)208-282 (14.6-19.8)

Application "D" Range - psi (kg/cm2 )

"R" Range - psi (kg/cm2 )

4-CylinderIdle Speed 53-61 (3.7-4.3) 88-102 (6.2-7.2)Stall Speed 135-171 (9.5-12.0) 228-277 (16.0-

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TORQUE CONVERTER

ONE-WAY CLUTCH CHECK

1. Install turner and stopper of One-Way Clutch Tester (09350-30020) in torque converter. See Fig. 4 . Turner fits in inner race of one-way clutch. Stopper fits in notch of converter hub and outer race of one-way clutch.

2. Clutch should lock when turned counterclockwise, but should turn freely when rotated clockwise. Torque required to turn clutch clockwise should be less than 22 INCH lbs. (2.5 N.m). If necessary, clean converter and retest clutch. Replace converter if clutch still fails test.

Fig. 4: Checking Condition Of Torque Converter One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

19.5)V6

Idle Speed 53-61 (3.7-4.3) 88-101 (6.2-7.1)Stall Speed 131-166 (9.2-11.7) 208-282 (14.6-

19.8)

NOTE: Torque converter is a sealed unit and is serviced as complete assembly. Perform following tests to check for defective converter. Torque converter and transmission cooler must be thoroughly cleaned and flushed if transmission is contaminated.

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DRIVE PLATE (FLYWHEEL) RUNOUT CHECK

Using dial indicator, measure drive plate runout. See Fig. 5 . If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace drive plate. If installing a new drive plate, note position of spacers.

Fig. 5: Measuring Drive Plate Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONVERTER SLEEVE RUNOUT CHECK

Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on converter sleeve. See Fig. 6 . Rotate converter. If runout exceeds .012" (.30 mm), reposition converter on drive plate and recheck runout.

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Fig. 6: Measuring Converter Sleeve Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.


TRANSMISSION DISASSEMBLY

1. Remove wire harness and throttle cable clamp. Remove transmission shaft lever and park/neutral position switch. Remove cooler line side unions. On A-340E and A-340F models, remove speedometer driven gear or No. 1 and No. 2 speed sensors (if equipped) from extension housing. On A-340F and A-343F models, remove transmission fluid temperature sensor from right side of transmission case.

2. On A-340F and A-343F models, remove breather hose from transfer upper cover and transmission shifter control retainer. Remove engine rear mounting. Remove dynamic damper (vibration damper) from transfer case. Remove drive shaft upper dust cover. Unbolt and remove transfer case from transmission.

NOTE: For transmission removal procedure, see appropriate AUTOMATIC TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

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DO NOT damage adapter rear oil seal with transfer input gear spline.

3. Remove speed sensor snap ring, sensor rotor and key. Remove transmission housing from transmission case. On A-340E models, remove extension housing. Remove speedometer drive gear snap ring, drive gear and lock ball from output shaft. Remove sensor rotor and key (if equipped). On A-340F and A-343F models, remove transfer case from transmission. On all models, remove transmission oil pan. To prevent contamination of valve body, DO NOT turn transmission over.

4. Remove oil filter and solenoid wiring. Remove oil tubes. Disconnect throttle cable from cam. Remove valve body. Remove check ball body and spring. See Fig. 7 . Remove accumulator piston springs. Apply air pressure to proper passages of transmission case to remove accumulator pistons. See Fig. 8 -Fig. 10 . Remove throttle cable from transmission case.

Fig. 7: Locating Check Ball & Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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5. Remove parking lock pawl bracket. Disconnect parking rod from manual valve lever. Remove "E" ring from shaft. Carefully remove lock pawl, spring and shaft. Using chisel and hammer, cut and remove spacer from shaft. Drive out roll pin. Remove manual valve lever shaft through transmission case. Remove manual valve lever.

6. Remove oil pump from transmission case using appropriate puller. Remove overdrive planetary gear unit with overdrive direct clutch from case. Remove bearing and race. See Fig. 11 . Remove overdrive planetary ring gear. Remove bearing and race.

7. Check overdrive brake piston stroke. Install dial indicator on overdrive (OD) brake piston. Measure stroke by applying 57-114 psi (4-8 kg/cm2 ) compressed air to opening in case. See Fig. 12 . See OD BRAKE PISTON STROKE SPECIFICATIONS table. If piston stroke is not within specifications, inspect clutch discs.

OD BRAKE PISTON STROKE SPECIFICATIONS

8. Remove snap ring. Remove OD brake clutch pack flanges, plates and discs. Note number and location of all components. Place reference mark on 2nd coast brake piston rod. Apply 57-114 psi (4.8 kg/cm2 ) of air at opening of transmission case. Using wire gauge, measure clearance between reference mark and case. See Fig. 13 and Fig. 14 . See 2ND COAST BRAKE PISTON STROKE SPECIFICATIONS table. If stroke is not within specification, inspect brake band.

2ND COAST BRAKE PISTON STROKE SPECIFICATIONS

Model & Transmission Piston Stroke - In. (mm)Lexus

LX 450 & LX 470 A-343F

.069-.081 (1.75-2.05)

ToyotaLand Cruiser A-343F

.069-.081 (1.75-2.05)

Tacoma & 4RunnerA-340E .055-.067 (1.40-1.70)A-340F .052-.064 (1.32-1.62)

T1002WD A-340E

.055-.067 (1.40-1.70)

4WD A-340F

.055-.067 (1.40-1.70)


LX 450 & LX 470 A-

.059-.118 (1.50-3.00)

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9. Remove 2nd coast brake cover snap ring. Carefully apply air pressure to oil hole as in step 13) to remove cover, piston and spring. Remove thrust bearing and race from overdrive support assembly. Remove overdrive support-to-case bolts. Remove snap ring. Using appropriate puller, remove overdrive support assembly. Remove race from rear of support assembly. Remove direct clutch with forward clutch from case. Remove bearings and race from clutch assembly.

10. Remove "E" ring from 2nd coast brake band pin and remove pin. Remove 2nd coast brake band. Remove race from front planetary ring gear. Remove front planetary ring gear. Remove thrust bearing and race from inside ring gear. Remove race from front planetary gear. Place transmission on end and support output shaft on wooden blocks. Remove snap ring located above front planetary gear. Remove front planetary gear. See Fig. 11 .

11. Remove sun gear drum and one-way clutch. Check clutch pack clearance of second brake. See Fig. 16 . See 2ND BRAKE CLUTCH PACK CLEARANCE SPECIFICATIONS table. If clearance is not within specifications, inspect condition of clutch discs. Remove flange snap ring.

12. Remove the flange, plates and discs. Note the number and location of all components. Check clutch pack clearance of 1st and reverse brakes. See Fig. 15 . See 1ST & REVERSE BRAKE PACK CLEARANCE SPECIFICATIONS table. If clearance is not within specifications, inspect condition of clutch discs.

2ND BRAKE CLUTCH PACK CLEARANCE SPECIFICATIONS

343FToyota

Land Cruiser A-343F

.059-.118 (1.50-3.00)

Tacoma & 4Runner A-340E & A-340F

.059-.118 (1.50-3.00)

T100 A-340E & A-340F

.059-.118 (1.50-3.00)


LX 450 & LX 470 A-343F

.024-.078 (.61-1.98)


.024-.078 (.61-1.98)

Tacoma & 4RunnerA-340E .024-.078 (.61-1.98)

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1ST & REVERSE BRAKE PACK CLEARANCE SPECIFICATIONS

13. Remove 2nd brake piston sleeve. Remove rear planetary gear unit snap ring. Remove rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft as an assembly. Remove thrust bearing and race from case. Remove 2nd brake drum assembly. See Fig. 11 .

14. Remove 1st and reverse brake cushion plate, flange, plates and discs. Note number and location of all components. Remove leaf spring from case. Remove brake drum gasket from case.

15. Ensure 1st and reverse brake pistons move smoothly when applying compressed air into case. See Fig. 17 . Disassemble 1st and reverse brake piston. Install appropriate compressor on spring retainer and compress return spring. See Fig. 18 . Remove snap ring. Remove piston return spring. Using compressed air, remove 1st and reverse brake piston No. 2. See Fig. 17 .

16. Insert Sleeve Remover (09350-07080) behind reaction sleeve. Remove reaction sleeve from case. See Fig. 19 and Fig. 20 . Insert Piston Remover (09350-07090) behind No. 1 brake piston. Remove No. 1 brake piston from case. On A-340E model, remove manual valve lever spacer from shaft. Remove pin. Pull shaft out through case and remove lever. Remove 2 oil seals.

A-340F .020-.069 (.50-1.76)T100

2WD A-340E

.024-.078 (.61-1.98)

4WD A-340F

.024-.078 (.61-1.98)

Model & Transmission Clearance - In. (mm)Lexus

LX 450 & LX 470 A-343F

.028-.048 (.71-1.22)


.028-.048 (.71-1.22)

Tacoma & 4RunnerA-340E .024-.044 (.61-1.12)A-340F .020-.040 (.50-1.02)

T1002WD A-340E

.024-.044 (.61-1.12)

4WD A-340F

.024-.044 (.61-1.12)

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Fig. 8: Removing 2nd Brake & Direct Clutch Accumulator Pistons & Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 9: Removing Overdrive Brake Accumulator Pistons & Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Removing Overdrive Direct Clutch Accumulator Pistons & SpringsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 11: Exploded View Of A-340E, A-340F & A-343F Internal Components

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 12: Measuring Overdrive Brake Piston Stroke

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Fig. 13: Identifying 2nd Coast Brake Piston Rod Reference Mark Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 14: Checking 2nd Coast Brake Piston Stroke Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 15: Checking 1st & Reverse Brake Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 16: Checking 2nd Brake Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 17: Checking 1st & Reverse Brake Piston Travel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 18: Compressing 1st & Reverse Brake Return Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 19: Removing Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 20: Removing Reaction Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP

Disassembly

1. Place oil pump on torque converter while working on pump. Remove seal rings from rear of oil pump. Remove bolts from rear of pump assembly. Remove stator shaft from pump housing. See Fig. 21 .

2. Place reference mark on drive and driven gears for reassembly reference and remove from pump housing. If oil seal requires replacement, pry seal from housing with a screwdriver.

Cleaning & Inspection

1. Clean all components in solvent. Dry with compressed air. Inspect contact surfaces between housing and driven gear for wear. Check gears for wear and body crescent for damage. Check pump gear contact surface on stator shaft for damage and wear.

2. Measure inside diameter of oil pump housing and stator shaft bushings. Measure driven gear-to-housing clearance and gear tip clearance. Using feeler gauge and straightedge, measure gear side clearance between pump housing face and top of gears. See Fig. 22 . See OIL PUMP CLEARANCE SPECIFICATIONS table.

3. If clearance(s) are not within specifications, replace worn component(s). Pump gears must be replaced as

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a matched set. If bushing diameter exceeds specification, oil pump housing or stator shaft must be replaced.

OIL PUMP CLEARANCE SPECIFICATIONS

Reassembly

1. Install oil seal until seal is even with outer edge of pump housing. Place stator shaft in torque converter while working on pump. Coat all components with ATF. See Fig. 21 .

2. Align reference marks on gears during installation. To complete reassembly, reverse disassembly procedure. Tighten bolts to specification. DO NOT over expand seal rings during installation. Ensure seal rings move smoothly after installation. Ensure drive gear rotates smoothly when installed in torque converter.

Application In. (mm)Gear-To-Housing

Standard .003-.006 (.07-.15)Maximum .012 (.30)

Gear Tip ClearanceStandard .004-.006 (.11-.14)Maximum .012 (.30)

Gear Side ClearanceStandard .0008-.0020 (.020-.050)Maximum .004 (.10)

Housing Bushing 1.504 (38.19)Stator Shaft Bushing (Maximum)

Front .850 (21.58)Rear 1.066 (27.08)

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Fig. 21: Exploded View Of Oil Pump Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 22: Measuring Oil Pump Clearances Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OD PLANETARY GEAR, OD DIRECT CLUTCH & OD ONE-WAY CLUTCH

Disassembly

1. One-way clutch operation should be checked prior to disassembly. Hold clutch drum and rotate input shaft clockwise. See Fig. 23 . Input shaft should rotate freely clockwise and lock counterclockwise.

2. Remove clutch drum from planetary gear. Remove thrust bearing from clutch drum. Remove snap ring, flange, discs and plates from clutch drum. Note number and location of components.

3. Using appropriate compressor, compress piston return spring and remove snap ring. Carefully release press and remove piston return spring. Place oil pump on torque converter. Place clutch drum on pump. Hold clutch piston and carefully apply air pressure to oil pump port. See Fig. 24 . Remove direct clutch piston.

4. Remove snap ring and ring gear flange from planetary ring gear. Remove bearing race from rear of planetary gear. Remove snap ring, retaining plate, one-way clutch assembly and thrust washer from planetary gear. Remove one-way clutch from outer race. Remove thrust washer.

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Inspection

1. Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas. Ensure check ball does not allow air to bleed through piston.

2. Measure inside diameter of clutch drum bushing and planetary gear bushing. Maximum diameter for overdrive direct clutch drum bushing is 1.067" (27.11 mm). Maximum diameter for overdrive planetary gear bushing is .444" (11.27 mm). Replace components if damaged or not within specifications.

3. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-.024" (.20-.61 mm). Maximum clearance is .039" (1.00 mm). If clearance is not within specifications, replace planetary gear assembly. Check OD direct clutch return spring free length. Include spring seat in measurement. Standard free length is .622" (15.80 mm).

Fig. 23: Checking OD One-Way Clutch Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CAUTION: Clutch discs should be soaked in ATF for 15 minutes prior to installation. Coat all parts with ATF prior to installation. Coat thrust bearings and races with petroleum jelly prior to installation.

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Reassembly

1. Position planetary gear with input shaft pointing upward. Install thrust washer in planetary gear with grooved side facing upward. Install one-way clutch into outer race with flanged side facing upward. See Fig. 25 .

2. Install one-way clutch assembly on planetary gear. Install retaining plate and snap ring. Install race on back of planetary gear. Race tabs must be engaged in planetary gear. See Fig. 26 .

3. Install ring gear flange and snap ring. Install thrust bearing and race in planetary ring gear. Race tabs must be engaged in ring gear. Coat "O" rings with ATF and install on clutch piston. Carefully install clutch piston in clutch drum. Install piston return spring. Using appropriate compressor, compress return spring and install snap ring. Ensure ring is fully seated.

4. With clutch drum open area facing upward, install plates and discs, starting with plate. Install flange with flat end facing toward disc. Install snap ring. Place oil pump on torque converter. Place clutch drum on oil pump. Measure piston stroke while applying 57-114 psi (4-8 kg/cm2 ) to oil pump port. See Fig. 24 . See OVERDRIVE DIRECT CLUTCH PISTON STROKE SPECIFICATIONS table. If piston stroke is not within specifications, check for incorrectly assembled components. Recheck piston stroke.

OVERDRIVE DIRECT CLUTCH PISTON STROKE SPECIFICATIONS

5. If piston stroke exceeds specification, install different thickness flange. Flanges are available in thicknesses of .122" (3.09 mm) to .142" (3.60 mm) in .004" (.10 mm) increments.

6. Remove clutch assembly from oil pump. Install thrust bearing and race in clutch drum with race toward clutch drum. Align tabs of clutch discs. See Fig. 26 . Install direct clutch drum on planetary gear. Hold clutch drum and rotate input shaft clockwise. Input shaft should rotate freely clockwise and lock counterclockwise.

CAUTION: Ensure ends of snap ring do not align with claw area on spring retainer of piston return spring.

Application In. (mm)Lexus

LX 450 & LX 470

.073-.085 (1.85-2.15)

ToyotaA-340E .073-.085 (1.85-2.15)A-340F (T100)

.073-.085 (1.85-2.15)

A-340F (Except T100)

.070-.082 (1.77-2.07)

A-343F .073-.085 (1.85-2.15)

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Fig. 24: Removing Clutch Piston & Measuring Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 25: Installing Overdrive One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 26: Exploded View Of Overdrive Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OVERDRIVE BRAKE

Disassembly

Remove all thrust washers from overdrive support. Using appropriate compressor, compress piston return spring and remove snap ring. Place support on direct clutch assembly. Hold brake piston in a level position. Carefully apply air pressure to piston supply port and remove piston. Remove oil seal rings from rear of

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support. See Fig. 27 .

Inspection

Clean all components with solvent. Dry with compressed air. Inspect components for damage. Measure return spring free length. Free length should be .678" (17.23 mm). Replace components as necessary.

Reassembly

1. To reassemble, reverse disassembly procedure. Coat seal rings with ATF prior to installation. DO NOT over expand seal rings during piston installation. Ensure seal rings move smoothly after installation.

2. Install NEW "O" rings on OD brake piston. Use care not to damage "O" rings during piston installation. Install snap ring in support and ensure end of snap ring is not aligned with cutout portion of support.

3. Ensure tabs on all races are aligned with areas on support. Coat races and thrust bearings with petroleum jelly prior to installation. Place support on direct clutch assembly and apply air pressure to piston supply port. Ensure piston operates smoothly in support. See Fig. 27 .

Fig. 27: Exploded View Of Overdrive Support & Brake Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DIRECT CLUTCH

Disassembly

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1. Remove direct clutch drum from forward clutch assembly. Remove thrust washer from inside of clutch drum. Remove snap ring from clutch drum. Remove flange, discs and plates. Note number and location of components. See Fig. 28 .

2. Using appropriate compressor, compress piston return spring and remove snap ring or oil seal ring. Place clutch drum on overdrive support and carefully apply air pressure to piston supply port and remove clutch piston. See Fig. 29 .

Inspection

1. Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas.

2. Ensure check ball is free in clutch piston. Apply air pressure to check ball area. Ensure check ball does not allow air to bleed through piston. Measure free length of piston return spring. Length should be .839" (21.32 mm).

3. Measure inside diameter of clutch drum bushing. Replace the clutch drum if bushing diameter exceeds specification. See DIRECT CLUTCH DRUM BUSHING SPECIFICATIONS table.

DIRECT CLUTCH DRUM BUSHING SPECIFICATIONS

Reassembly

1. Coat "O" rings with ATF. To complete reassembly, reverse disassembly procedure. Ensure piston return spring snap ring or oil seal ring is fully seated and ring ends do not align with claw area on spring retainer of piston return spring.

2. With clutch drum open area facing upward, install plates and discs, starting with a plate and then alternating with a disc. Install appropriate number of plates and discs.

3. Install flange with flat end facing toward disc. Install snap ring. Place clutch drum on overdrive support. Measure piston stroke with a dial indicator while applying 57-114 psi (4-8 kg/cm2 ) to piston supply port. See Fig. 29 .

4. See DIRECT CLUTCH PISTON STROKE SPECIFICATIONS table. If piston stroke is not within specifications, check for incorrectly assembled components. Recheck piston stroke measurement.

DIRECT CLUTCH PISTON STROKE SPECIFICATIONS

Application In. (mm)Lexus LX 450 & LX 470 2.126 (53.99)Toyota (All Models) 2.126 (53.99)

CAUTION: Clutch discs should be soaked in ATF for 15 minutes prior to installation. Thrust washers and races should be coated with petroleum jelly prior to installation.

Application In. (mm)Lexus LX 450 & LX 470

.054-.063 (1.37-1.60)

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5. If piston stroke is not within specifications, install different thickness flange. Flanges for Toyota A-340E, A-340F and A-343F are available in thicknesses of .118" (2.99 mm) to .146" (3.70 mm) in .004" (.10 mm) increments. Flanges for Lexus A-340E are available in thicknesses of .126 (3.20 mm) to .157" (4.00 mm) in .004" (.10 mm) increments.

6. Install thrust washer in clutch drum. Align tabs of clutch discs. Install direct clutch assembly on forward clutch assembly. Measure distance from end of direct clutch to shaft end of forward clutch. Distance should be 2.803" (71.2 mm). See Fig. 30 . If distance is not within specifications, components may be incorrectly assembled.

Fig. 28: Exploded View Of Direct Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ToyotaA-340E .054-.063 (1.37-1.60)A-340F (T100)

.054-.063 (1.37-1.60)

A-340F (Except T100)

.041-.052 (1.03-1.33)

A-343F .054-.063 (1.37-1.60)

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Fig. 29: Measuring Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 30: Checking Direct Clutch Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FORWARD CLUTCH

Disassembly

1. Separate forward clutch assembly from direct clutch. Place overdrive support on wooden blocks and install forward clutch in overdrive support. Remove snap ring from clutch drum. Remove flange, discs, plates and cushion plate. See Fig. 31 . Note number and location of components.

2. Using appropriate compressor, compress piston return spring and remove snap ring. Place clutch drum on overdrive support. Carefully apply air pressure to piston supply port and remove clutch piston. Remove "O" rings from clutch piston and clutch hub. Remove oil seal rings.

Inspection

Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas. Ensure check ball is free in clutch piston. Apply air pressure to check ball area. Ensure check ball does not allow air to bleed through piston. Measure inside diameter of clutch drum bushing. Replace clutch

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drum if bushing diameter exceeds .948" (24.08 mm).

Reassembly

1. Coat "O" rings with ATF. To complete reassembly, reverse disassembly procedure. Ensure piston return spring snap ring is fully seated and ends do not align with claw area on spring retainer of piston return spring.

2. Install cushion plate with rounded end toward inside of clutch drum. Install plates and discs, starting with a plate. Install appropriate number of plates and discs. See Fig. 31 .

3. Install flange with rounded edge toward disc. Install snap ring. Ensure end gap of snap ring is not aligned with forward clutch drum cut out portion. Place clutch drum on overdrive support. Measure piston stroke while applying 57-114 psi (4-8 kg/cm2 ) to piston supply port. See Fig. 32 . See FORWARD CLUTCH PISTON STROKE SPECIFICATIONS table.

4. If clearance is not within specifications, install different thickness flange. Flanges are available in thicknesses of .118" (3.0 mm) to .173" (4.4 mm) in .008" (.20 mm) increments. Install thrust bearing and race. Align tabs of the clutch discs.

FORWARD CLUTCH PISTON STROKE SPECIFICATIONS

CAUTION: Clutch disc should be soaked in ATF for 15 minutes prior to installation.

Application In. (mm)Lexus LX 450 & LX 470 .024-.039 (.61-.100)Toyota

A-340E .020-.035 (.50-.90)A-340F (T100) .020-.035 (.50-.90)A-340F (Except T100) .016-.031 (.40-.80)A-343F .024-.039 (.61-.100)

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Fig. 31: Exploded View Of Forward Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 32: Checking Forward Clutch Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT PLANETARY GEAR

Disassembly & Inspection

Remove thrust bearings and races from planetary gear and front planetary ring gear. Note direction of race installation. Measure front planetary ring gear bushing inside diameter. Replace planetary ring gear if bushing diameter exceeds .948" (24.08 mm). Measure planetary pinion gear thrust clearance. Clearance should be .008-.024" (.20-.61 mm). Maximum clearance is .039" (1.00 mm). If clearance is not within specifications, replace planetary gear assembly.

Reassembly

Coat thrust bearings and races with petroleum jelly. Install thrust bearings and races, ensuring tabs on race align with planetary gear. Install races in planetary ring gear and planetary gear with the flat side against the gear surface. See Fig. 33 .

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Fig. 33: Exploded View Of Front Planetary Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PLANETARY SUN GEAR & NO. 1 ONE-WAY CLUTCH

Disassembly

Hold sun gear input drum and check rotation of one-way clutch. Clutch should turn freely clockwise and lock counterclockwise. See Fig. 35 . Remove one-way clutch assembly. Note direction of clutch installation. Remove thrust washer and oil seal rings from sun gear input drum and sun gear. Support sun gear input drum on wooden block and remove snap ring from sun gear. Separate sun gear from sun gear input drum. See Fig. 36 .

Inspection

Clean components in solvent. Dry with compressed air. Measure inside diameter of sun gear bushing. Replace sun gear if diameter exceeds 1.066" (27.08 mm).

Reassembly

To reassemble, reverse disassembly procedure. See Fig. 36 . Ensure ends of oil seal rings are properly locked together and seal rings move smoothly. Install one-way clutch assembly in proper direction. Check one-way clutch operation. See Fig. 34 and Fig. 35 .

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Fig. 34: Installing No. 1 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 35: Checking No. 1 One-Way Clutch Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 36: Exploded View Of Planetary Sun Gear & No. 1 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2ND COAST BRAKE (BAND)

Disassembly

Compress spring and remove "E" ring from piston rod. Remove 2nd coast brake piston, spring and retainer from piston rod. Remove oil seal ring.

Inspection

1. Replace brake band if lining is peeled off or discolored or printed numbers are defaced. Before assembling NEW band, soak band in ATF for at least 15 minutes.

2. If brake band is serviceable but piston rod stroke is not within specification, select replacement rod. Rods are available in lengths of 2.78" (70.7 mm), 2.81" (71.4 mm), 2.84" (72.2 mm), 2.87" (72.9 mm) and 2.09" (73.1 mm).

Reassembly

Install oil seal ring on piston. Install retainer, spring and piston to piston rod. Install "E" ring. See Fig. 37 .

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Fig. 37: Exploded View Of 2nd Coast Brake Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2ND BRAKE

Disassembly

Remove thrust washer. Using appropriate compressor, compress piston return spring with an arbor press. Remove snap ring. Remove spring retainer and piston return spring. Hold 2nd brake piston and apply compressed air to 2nd brake drum to remove piston.

Inspection

Check all parts for wear and damage. Soak NEW discs in ATF for 15 minutes before installation. Measure return spring free length. Free length should be .773" (19.64 mm). Replace components as necessary.

Reassembly

Coat NEW "O" rings with ATF and install. Carefully press 2nd brake piston into 2nd brake drum. Install piston return spring and spring retainer. See Fig. 38 . Compress return spring and install snap ring. Apply compressed air to 2nd brake drum. Ensure 2nd brake piston moves smoothly. Install thrust washer. Ensure cutout portions of thrust washer match teeth of spring retainer.

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Fig. 38: Exploded View Of 2nd Brake Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR PLANETARY GEAR, NO. 2 ONE-WAY CLUTCH & OUTPUT SHAFT

Disassembly

1. Remove output shaft from rear planetary gear assembly. Remove oil seal from output shaft. Remove rear planetary gear from rear planetary ring gear. Hold planetary gear and check operation of No. 2 one-way clutch. Clutch should turn freely counterclockwise and lock clockwise. See Fig. 39 and Fig. 40 . Remove No. 2 one-way clutch inner race from rear planetary gear.

2. Remove snap ring and No. 2 one-way clutch with retainers from planetary gear. Note direction of one-way clutch in planetary gear. Remove No. 1 and 2 thrust washers from planetary gear. Remove bearings and races from ring gear. Remove snap ring and ring gear flange from ring gear. See Fig. 41 .

Inspection

Clean all components with solvent. Dry with compressed air. Inspect all components for damage. Replace if

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necessary. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-.024" (.20-.61 mm). Maximum clearance is .039" (1.00 mm). If clearance is not within specifications, replace planetary gear assembly.

Reassembly

1. To reassemble, reverse disassembly procedure. Coat all thrust bearings and races with petroleum jelly. When installing thrust bearings and races in ring gear, flat side of race must be placed against ring gear.

2. Ensure No. 1 and 2 thrust washer tangs align with cutout area of planetary gear. Install No. 2 one-way clutch with open ends facing upward. See Fig. 39 and Fig. 40 .

3. Rotate one-way clutch inner race counterclockwise during installation into rear planetary gear. Ensure No. 2 one-way clutch turns freely counterclockwise and locks clockwise. See Fig. 39 and Fig. 40 .

4. Install rear planetary gear on rear planetary ring gear. Install oil seal ring. DO NOT spread oil seal ring too much. After installing oil seal ring, ensure seal ring rotates smoothly. Install output shaft into rear planetary gear assembly. See Fig. 41 .

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Fig. 39: Installing No. 2 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 40: Checking No. 2 One-Way Clutch Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 41: Exploded View Of Output Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VALVE BODY ASSEMBLY

Disassembly

CAUTION: All valve body components must be installed in original location. Lay all components in sequence during removal for reassembly reference. Note diameter and check ball location. Throttle pressure is changed according to number of adjusting rings. When assembling valve body, install same number of adjusting rings as removed. Some valve bodies do not have adjusting rings.

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Remove detent spring and manual valve from valve body assembly. Remove solenoids and lock plate (if applicable), oil strainer and pressure relief valve. Remove lower valve body-to upper valve body bolts. Note bolt length and location. Separate upper valve body and valve body plate from lower valve body. See Fig. 42 .

Fig. 42: Exploded View Of A-340 Series Control Valve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.

Inspection

1. Clean all parts in solvent. Dry with compressed air. Ensure all valve body passages are clear. Ensure strainers are not damaged or clogged. Inspect valves for scoring or roughness.

2. Ensure valves slide freely in bores. Inspect valve springs for damage, squareness and collapsed coils. Measure spring free length. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS table. Ensure valve body springs correspond with appropriate valve. Ensure retainers are installed in appropriate locations.

CAUTION: DO NOT allow valve body plate to separate from upper valve body during removal, or check balls and strainer may fall out.

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VALVE BODY SPRING SPECIFICATIONS

A-340E UPPER VALVE BODY SPRING SPECIFICATIONS

A-343F UPPER VALVE BODY SPRING SPECIFICATIONS (LAND CRUISER, LX 450 & LX 470)

A-340 SERIES LOWER VALVE BODY SPRING SPECIFICATIONS

Spring (1) Free Length - In. (mm) Diameter - In. (mm) Color1 1.075 (27.30) .343 (8.70) Yellow2 .811 (20.60) .362 (9.20) Blue2 (Optional) .917 (23.30) .362 (9.20) White3 1.213 (30.80) .382 (9.70) Purple4 .996 (25.30) .339 (8.60) Orange5 .843 (21.40) .217 (5.50) Light Gray6 1.217 (30.90) .441 (11.20) Blue7 .858 (21.80) .236 (6.00) Red8 1.213 (30.80) .382 (9.70) Blue9 1.197 (30.40) .327 (8.30) Yellow(1) For spring locations, see Fig. 43 .

Spring (1) Free Length - In. (mm) Diameter - In. (mm) Color1 1.075 (27.30) .343 (8.70) Yellow2 .811 (20.60) .362 (9.20) Blue2 (Optional) .917 (23.30) .362 (9.20) White3 1.213 (30.80) .382 (9.70) Purple4 1.217 (30.90) .327 (8.30) Purple5 .843 (21.40) .217 (5.50) Light Gray6 1.177 (29.90) .433 (11.00) Green7 .858 (21.80) .236 (6.00) Red8 1.213 (30.80) .382 (9.70) Blue9 1.197 (30.40) .327 (8.30) Light Green(1) For spring locations, see Fig. 43 .

Spring (1) Free Length - In. (mm) Diameter - In. (mm) Color1 .796 (20.20) .476 (12.10) None2 .441 (11.20) .252 (6.40) None3 1.213 (30.80) .382 (9.70) Purple4 2.453 (62.30) .732 (18.60) Purple5 1.335 (33.90) .346 (8.80) Pink(1) For spring locations, see Fig. 44 .

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Fig. 43: Exploded View Of A-340 Series Upper Valve Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 44: Exploded View Of A-340 Series Lower Valve Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Reassembly

1. Coat all components with ATF. To reassemble, reverse disassembly procedure. Ensure check balls in upper and lower valve body are installed correctly. See Fig. 47 .

2. Position NEW No. 1 gasket, plate and NEW No. 2 gasket on upper valve body. Place lower valve body on upper valve body with plate and gaskets. DO NOT let components separate. Align each bolt hole in valve bodies with gaskets and plate.

3. Install and finger tighten bolts in upper valve body. Ensure proper bolt length is used. See Fig. 48 . Tighten bolts to 56 INCH lbs. (6.4 N.m). Install oil strainer, pressure relief valve and solenoids (as applicable). Install manual valve and detent spring. Tighten bolts to 89 INCH lbs. (10 N.m). Ensure manual valve moves freely.

NOTE: Valves may be held in with pins or retainers and plugs. Remove components and note locations. Arrange parts in order for reassembly reference.

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Fig. 45: Identifying Upper Valve Body Check Ball Locations (Tacoma, T100 & 4Runner A-340E, Land Cruiser, LX 450 & LX 470 A-343F) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 46: Identifying Upper Valve Body Check Ball Locations (Tacoma, T100 & 4Runner A-340F) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 47: Identifying Lower Valve Body Check Ball Locations (A-340 Series) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 48: Identifying A-340 Series Valve Body Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSMISSION REASSEMBLY

1. Before transmission reassembly, inspect case bushing and extension housing bushing (if equipped). Maximum transmission case bushing inside diameter is 1.504" (38.19 mm). Maximum extension housing bushing inside diameter is 1.578" (40.09 mm). If bushings are not within specifications, manufacturer recommends replacing transmission case and/or extension housing.

2. Install 1st and reverse brake No. 1 piston to reaction sleeve. Install No. 1 piston with reaction sleeve on No. 2 piston. Align No. 2 piston teeth into proper grooves. Carefully press No. 1 and No. 2 brake pistons

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts as necessary. Clutch discs should be soaked in ATF for 15 minutes before installation.

NOTE: For thrust bearing and race identification and installation positions, see Fig. 52 and Fig. 53 .

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into case. Position piston return spring on No. 2 piston. Using Spring Compressor (09350-07050), compress return spring. See Fig. 18 .

3. Install snap ring. Ensure snap ring end-gap is not aligned with spring retainer claw. Ensure 1st and reverse brake pistons move smoothly by applying compressed air to case. See Fig. 17 .

4. Install leaf spring (if equipped). Install rear planetary gear unit with 1st and reverse brake pack and output shaft. Install flange with rounded edge toward planetary ring gear. Install flange. Install plates and discs, starting with disc. Install correct number of plates and discs.

5. Install 2nd brake drum assembly. Install thrust bearing in case. Align teeth of 2nd brake drum, flange, discs and plates. Align splines of transmission case, assembled rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft into case.

6. Support output shaft on wooden blocks. Install snap ring in case with chamfered edge toward front of transmission. Ensure ends of snap ring are not aligned with cutout area of case. Measure 1st and reverse brake clearance between 2nd brake drum and plate. See Fig. 15 . See 1ST & REVERSE BRAKE PACK CLEARANCE SPECIFICATIONS table.

7. If clearance is not within specification, select a different thickness flange. Flanges are available in thicknesses of .157" (4.0 mm) to .213" (5.4 mm) in .008" (.20 mm) increments.

8. Install 2nd brake piston sleeve. Install NEW brake drum gasket in case. Install No. 1 one-way clutch. On all models except A-340F, install .071" (1.8 mm) flange plate with rounded edge side of plate facing disc. Install plates and discs starting with disc. Install end flange with rounded edge facing disc. Install snap ring.

9. On A-340F, install .098" (2.5 mm) flange plate with rounded edge side of plate facing disc. Install plates and discs. Install end flange with rounded edge facing disc. Install snap ring.

10. On all models, measure 2nd brake clearance between snap ring and flange. See Fig. 16 . See 2ND BRAKE CLUTCH PACK CLEARANCE SPECIFICATIONS table. If clearance is not within specifications, check for incorrect assembly.

11. Install planetary sun gear. Turn planetary sun gear clockwise into No. 1 one-way clutch. Ensure all thrust washers are correctly installed. Install front planetary gear bearing and race. Install front planetary gear into sun gear. Install snap ring. Remove wooden block from under output shaft. Install race on front of planetary gear so race tabs align with planetary gear holes.

12. Install 2nd coast brake band and pin. Pin must be installed so "E" ring is toward front of transmission. Install "E" ring. Coat thrust bearing and race with petroleum jelly and install on forward clutch. Raised portion of race must be toward front.

13. Install race on front planetary ring gear. Smooth flat surface must be toward front. Align disc tabs of forward clutch. Install front planetary gear in forward clutch. Ensure gear is aligned with all clutch discs.

14. Install bearing race and thrust bearing on ring gear. Raised portion of race must be toward rear. Install forward and direct clutch assembly and front planetary ring gear in transmission case. Measure distance between sun gear input drum and direct clutch drum. Clearance should be .209-.287" (5.30-7.30 mm). See Fig. 49 . If clearance is not within specifications, check for incorrect installation.

15. Install thrust bearing and race on forward clutch assembly with flat side toward clutch assembly. Install NEW "O" ring on 2nd coast brake cover. Install spring, 2nd coast brake piston assembly and cover to

NOTE: For thrust bearing and race identification and installation positions, see Fig. 52 and Fig. 53 .

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case. Install snap ring.

16. Place reference mark on 2nd coast brake piston rod. Apply 57-114 psi (4.8 kg/cm2 ) of air at opening of transmission case. Using wire gauge, measure clearance between reference mark and case. See Fig. 13 and Fig. 14 . See 2ND COAST BRAKE PISTON STROKE SPECIFICATIONS table.

17. If stroke is not within specification, install replacement piston rod. Rods are available in lengths of 2.78" (70.7 mm), 2.81" (71.4 mm), 2.84" (72.2 mm) and 2.87" (72.9 mm). If stroke is not within specification, install NEW brake band. Install race on overdrive support. Install bolt and oil holes of overdrive support toward valve body side and align with bolt holes of case. Install support.

18. Ensure support is properly aligned. Install support snap ring with chamfered edge toward front of transmission. End of snap ring must be positioned to valve body side of case within .94" (23.9 mm) from center line of valve body as viewed from front of transmission.

19. Using dial indicator, check output shaft end play. End play should be .011-.034" (.27-.86 mm). If end play is not within specifications, check for incorrect assembly. Ensure output shaft rotates smoothly.

20. Install a .157" (4.00 mm) thick flange with rounded edge facing disc. Install correct number of discs and plates, beginning with plate. Install end flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are not located at cutout areas of case.

21. Install dial indicator on case and measure piston stroke. Apply 57-114 psi (4-8 kg/cm2 ) at opening of transmission case and note piston stroke. See Fig. 12 . See OD BRAKE PISTON STROKE SPECIFICATIONS table.

22. If piston stroke is not within specifications, check for incorrect installation. Recheck piston stroke. If piston stroke is not within specifications, install different thickness flange. Flanges are available in thicknesses of .130" (3.3 mm) to .157" (4.0 mm) in .008" (.20 mm) increments.

23. Install thrust bearing and races on overdrive support. Ensure race tabs align with hole support. Install overdrive planetary ring gear. Install thrust bearing and race in ring gear. Install race on rear of overdrive planetary gear, aligning race tabs with holes of gear.

24. Install overdrive planetary gear with overdrive direct clutch and one-way clutch. Install thrust bearing and race onto OD direct clutch with race flat side toward direct clutch.

25. Install race on rear of oil pump with raised side toward oil pump. Install NEW "O" ring on outer diameter of oil pump. Ensure oil seal rings are installed on rear of oil pump. Align holes of oil pump and transmission case. Install oil pump while holding input shaft and lightly pressing on oil pump.

26. Install oil pump bolts and tighten to specification. See TORQUE SPECIFICATIONS . Ensure input shaft rotates smoothly. Install throttle cable. Apply air pressure to specified oil passage to check operating components. See Fig. 50 . When air checking OD direct clutch, overdrive accumulator piston hole must be plugged.

CAUTION: DO NOT apply excessive pressure on oil pump during installation, or oil seal rings will stick to direct clutch drum.

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Fig. 49: Measuring Input Drum & Direct Clutch Drum Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 50: Air Testing Transmission Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

27. Assemble NEW spacer-to-manual valve lever. Install manual lever shaft to case through manual valve lever. Install pin to shaft. Align spacer hole with lever hole and stake spacer to lever. Ensure manual valve lever shaft turns smoothly.

28. Install "E" ring, parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl bracket on case and install.

29. Install accumulator pistons with NEW "O" rings and springs. See Fig. 51 . Accumulator pistons and springs must be correct diameter and height. Accumulator pistons are stamped with identification codes. Determine correct spring free length. See appropriate ACCUMULATOR SPRING SPECIFICATIONS table.

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Fig. 51: Identifying Accumulator Piston Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ACCUMULATOR SPRING SPECIFICATIONS (A-340E) Component, Code & Color

Free Length - In. (mm)

Diameter - In. (mm)

2nd Brake (B2) - Yellow

2.776 (70.50) .776 (19.70)

Direct Clutch (C2)Inner - Pink

1.657 (42.10) .579 (14.70)

Outer - Purple

2.764 (70.20) .795 (20.20)

OD Brake (B0) - Green

2.441 (62.00) .630 (16.00)

OD Direct Clutch (C0)Inner - Yellow

1.811 (46.00) .551 (14.00)

Outer - Orange

2.937 (74.60) .823 (20.90)

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ACCUMULATOR SPRING SPECIFICATIONS (A-340F)

ACCUMULATOR SPRING SPECIFICATIONS (1) (A-343F)

30. Install check ball body and spring. See Fig. 7 . Install valve body. See TRANSMISSION VALVE BODY under ON-VEHICLE SERVICE. Install sensor rotor and key on output shaft with snap ring. Install speedometer drive gear and lock ball and snap ring on output shaft. Install extension housing and NEW gasket. Shorter mounting bolts go to bottom of extension housing.

31. On A-340F and A-343F models, install transfer case assembly. Install transfer and drive shaft upper dust cover to transmission. Install engine rear mounting. Install dynamic damper. Install breather hose. Hose depth is .51" (13 mm).

32. Install transmission housing. On A-340E models, install speed sensor and speedometer driven gear. Install front and rear cooler line unions. Install No. 1 and No. 2 speed sensors (if applicable).

33. Install speed sensor and fluid temperature sensor (if applicable). Install park/neutral position switch. Tighten nut to 61 INCH lbs. (6.9 N.m). Align neutral basic line and switch groove. Bend at least 2 lock washer tabs.

34. Install control shaft lever. If throttle cable is new, stake stopper on inner cable. Install wire harness and throttle cable clamp. Install torque converter. Using straightedge and depth gauge, measure distance from front of converter to front mounting surface of transmission housing. See TORQUE CONVERTER DISTANCE SPECIFICATIONS table to determine if converter is fully installed.

Component, Code & ColorFree Length -

In. (mm)Diameter - In.

(mm)2nd Brake (B2) - Yellow 2.776 (70.50) .776 (19.70)Direct Clutch (C2) - Blue 2.697 (68.50) .795 (20.20)OD Brake (B0) - Lt. Green 2.744 (69.70) .657 (16.70)OD Direct Clutch (C0) - White

2.638 (67.00) .701 (17.80)

Spring (Color) Free Length - In. (mm)2nd Brake (Light Gray)

2.858 (72.60)

Direct ClutchInner (Pink) 1.657 (42.10)Outer (White/Red)

2.886 (73.30)

OD Brake (Green)

2.441 (62.00)

OD Direct ClutchInner (Yellow)

1.811 (46.00)

Outer (Orange)

2.937 (74.60)

(1) Spring diameter is not available.

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TORQUE CONVERTER DISTANCE SPECIFICATIONSApplication Distance - In. (mm)Lexus

LX 450 A-343F .618 (15.70)LX 470 A-343F .673 (17.10)


1997 .618 (15.70)1998-99 .673 (71.10)

Tacoma & 4Runner4-Cylinder A-340E & A-340F 1.250 (31.75)V6 A-340E & A-340F .707 (17.95)

T100A-340E

4-Cylinder 1.250 (31.75)V6 .707 (17.95)

A-340F .707 (17.95)

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Fig. 52: Identifying Thrust Bearing & Race Installation Positions (Land Cruiser, Lexus LX 450 & LX 470 A-343F) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 53: Identifying Thrust Bearing & Race Installation Positions (All Other A-340 Series Models) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

THRUST BEARING & RACE SPECIFICATIONS A-340 SERIES (ALL EXCEPT A-343F)

ApplicationOuter Diameter - In.

(mm)Inner Diameter - In.

(mm)"A"

Front Race 1.86 (47.3) 1.11 (28.1)

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THRUST BEARING & RACE SPECIFICATIONS (LAND CRUISER, LX 450 & LX 470 A-343F)

Bearing 1.98 (50.2) 1.14 (28.9)"B"

Front Race 1.65 (41.8) 1.07 (27.3)Rear Race 1.88 (47.8) .953 (24.2)Bearing 1.84 (46.8) 1.02 (26.0)

"C"Front Race 2.31 (58.8) 1.46 (37.2)Bearing 2.01 (51.1) 1.33 (33.7)

"D"Front Race 2.00 (50.9) 1.45 (36.8)Bearing 1.87 (47.6) 1.33 (33.7)

"E"Front Race 1.93 (48.9) 1.02 (26.0)Rear Race 1.85 (47.0) 1.06 (26.8)Bearing 1.84 (46.7) 1.02 (26.0)

"F"Front Race 2.11 (53.6) 1.20 (30.6)Rear Race 1.88 (47.8) 1.35 (34.3)Bearing 1.88 (47.8) 1.28 (32.6)

"G"Front Race 1.87 (47.6) 1.33 (33.7)Bearing 1.88 (47.8) 1.40 (35.5)

"H"Front Race 1.76 (44.8) 1.13 (28.8)Rear Race 1.76 (44.8) 1.13 (28.8)Bearing 1.76 (44.8) 1.19 (30.1)

"I"Bearing 2.27 (57.7) 1.54 (39.2)

ApplicationOuter Diameter - In.

(mm)Inner Diameter - In.

(mm)"A"

Front Race 1.87 (47.5) 1.11 (28.1)Bearing 1.98 (50.4) 1.13 (28.8)

"B"Front Race 1.65 (42.0) 1.07 (27.2)Rear Race 1.89 (48.0) .94 (24.0)Bearing 1.85 (47.0) 1.02 (26.0)

"C"Front Race 2.32 (59.0) 1.46 (37.0)

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CLUTCH DISC & PLATE SPECIFICATIONS

CLUTCH DISC & PLATE QUANTITY (TACOMA, T100 & 4RUNNER A-340E)

CLUTCH DISC & PLATE QUANTITY (TACOMA, T100 & 4RUNNER A-340F)

CLUTCH DISC & PLATE QUANTITY (LAND CRUISER, LX 450 & LX 470 A-343F)

Bearing 1.98 (50.4) 1.32 (33.5)"D"

Front Race 2.01 (51.0) 1.46 (37.0)Bearing 1.88 (47.8) 1.32 (33.5)

"E"Rear Race 2.11 (53.7) 1.04 (26.5)Bearing 1.69 (43.0) 1.02 (26.0)

"F"Rear Race 2.50 (63.6) 2.10 (53.3)Bearing 2.55 (64.7) 1.96 (49.7)

"G"Front Race 1.88 (47.8) 1.32 (33.5)Bearing 1.89 (48.0) 1.39 (35.4)

"H" (2-piece)Front Race 1.74 (44.2) 1.12 (28.5)Bearing 1.74 (44.2) 1.08 (27.5)

"I"Bearing 2.27 (57.7) 1.54 (39.2)

Component Disc PlateOD Direct Clutch 2 2Forward Clutch 5 5Direct Clutch 4 42nd Brake 5 51st & Reverse Brake 6 6OD Brake 4 3

Component Disc PlateOD Direct Clutch 1 1Forward Clutch 4 4Direct Clutch 3 32nd Brake 4 41st & Reverse Brake 5 5OD Brake 3 2

Component Disc Plate

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OD Direct Clutch 2 2Forward Clutch

1997 6 61998-99 7 7

Direct Clutch1997 4 41998-99 5 5

2nd Brake 5 51st & Reverse Brake 7 7OD Brake 5 4

Application Ft. Lbs. (N.m)Cooler Union 21 (29)Dynamic Damper 27 (37)Extension Housing Bolt 27 (37)No. 1 Speed Sensor Bolt 12 (16)Oil Cooler Pipe Union Nut 25 (34)Oil Pump-To-Case Bolt 16 (22)Overdrive-To-Case Bolt 18 (25)Rear Mounting-To-Extension Housing Bolt 18 (25)Shift Lever Nut 12 (16)Speedometer Driven Gear Bolt 12 (16)Support Crossmember-To-Body Bolt 18 (25)Torque Converter-To-Drive Plate Bolt 30 (41)Transmission Housing Bolt

10-mm 25 (34)12-mm 42 (57)14-mm 25 (34)17-mm 42 (57)

INCH Lbs. (N.m)Detent Spring Bolt 89 (10)Park/Neutral Position Switch

Adjusting Bolt 115 (13)Retaining Nut 61 (6.9)

No. 2 Speed Sensor Bolt 48 (5.4)Oil Pan Bolt 65 (7.3)Oil Pump-To-Stator Shaft Bolt 89 (10)Oil Strainer Bolt 89 (10)

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TRANSMISSION SPECIFICATIONS

TRANSMISSION SPECIFICATIONS (LAND CRUISER, LX 450 & LX 470)

TRANSMISSION SPECIFICATIONS (TACOMA & 4RUNNER)

Parking Lock Pawl Bracket Bolt 65 (7.3)Solenoid-To-Valve Body Bolt 89 (10)Throttle Cable-To-Transmission Case Bolt 48 (5.4)Upper Valve Body-To-Lower Valve Body Bolt 57 (6.4)Valve Body-To-Case Bolt 89 (10)

Application In. (mm)Bushing Diameter (Maximum)

Direct Clutch Drum 2.126 (53.99)Extension Housing 1.578 (40.09)Forward Clutch Drum .948 (24.08)OD Direct Clutch Drum 1.067 (27.11)OD Planetary Gear .444 (11.27)Sun Gear 1.066 (27.08)Transmission Case 1.504 (38.19)

Clutch Pack Clearance1st & Reverse Brake .028-.048 (.70-1.22)2nd Brake Clutch .024-.078 (.61-1.98)

Output Shaft End Play .011-.034 (.27-.86)Piston Stroke

Direct Clutch .054-.063 (1.37-1.60)Forward Clutch .024-.039 (.61-1.00)OD Brake .069-.081 (1.75-2.05)OD Direct Clutch

Land Cruiser .073-.085 (1.85-2.15)LX 450 & LX 470 .057-.067 (1.45-1.70)

2nd Coast Brake .059-.118 (1.50-3.00)Planetary Pinion Gear Clearance .008-.024 (.20-.61)


Direct Clutch Drum 2.126 (53.99)Extension Housing 1.578 (40.09)Forward Clutch Drum .948 (24.08)OD Direct Clutch Drum 1.067 (27.11)OD Planetary Gear .444 (11.27)Planetary Ring Gear .948 (24.08)

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TRANSMISSION SPECIFICATIONS (T100)

Sun Gear 1.066 (27.08)Transmission Case 1.504 (38.19)

Clutch Pack Clearance1st & Reverse Brake

A-340E .024-.044 (.61-1.12)A-340F .020-.040 (.50-1.02)

2nd Brake ClutchA-340E .024-.078 (.61-1.98)A-340F .020-.069 (.50-1.76)


Direct ClutchA-340E .054-.063 (1.37-1.60)A-340F .041-.052 (1.03-1.33)

Forward ClutchA-340E .020-.035 (.50-.90)A-340F .016-.031 (.40-.80)

OD BrakeA-340E .055-.067 (1.40-1.70)A-340F .052-.064 (1.32-1.62)

OD Direct ClutchA-340E .073-.085 (1.85-2.15)A-340F .070-.082 (1.77-2.07)

2nd Coast BrakeA-340E .059-.118 (1.50-3.00)A-340F .059-.118 (1.50-3.00)

Planetary Pinion Gear Clearance .008-.024 (.20-.61)


Direct Clutch Drum 2.126 (53.99)Extension Housing 1.578 (40.09)Forward Clutch Drum .948 (24.08)OD Direct Clutch Drum 1.067 (27.11)OD Planetary Gear .444 (11.27)Planetary Ring Gear .948 (24.08)Sun Gear 1.066 (27.08)Transmission Case 1.504 (38.19)

Clutch Pack Clearance1st & Reverse Brake

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2WD A-340E .024-.044 (.61-1.12)4WD A-340F .024-.044 (.61-1.12)

2nd Brake Clutch2WD A-340E .024-.078 (.61-1.98)4WD A-340F .024-.078 (.61-1.98)


Direct Clutch2WD A-340E .054-.063 (1.37-1.60)4WD A-340F .054-.063 (1.37-1.60)

Forward Clutch2WD A-340E .020-.035 (.50-.90)4WD A-340F .020-.035 (.50-.90)

OD Brake2WD A-340E .055-.067 (1.40-1.70)4WD A-340F .055-.067 (1.40-1.70)

OD Direct Clutch2WD A-340E .073-.085 (1.85-2.15)4WD A-340F .073-.085 (1.85-2.15)

2nd Coast Brake2WD A-340E .059-.118 (1.50-3.00)4WD A-340F .059-.118 (1.50-3.00)

Planetary Pinion Gear Clearance .008-.024 (.20-.61)

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1997 STEERING

Steering Column - LX 450


Fig. 1: Exploded View Of Steering Column (1 Of 2)

1997 Lexus LX 450

1997 STEERING Steering Column - LX 450

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Fig. 2: Exploded View Of Steering Column (2 Of 2)

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DISABLING & ACTIVATING AIR BAG SYSTEM

ADJUSTMENTS

SPIRAL CABLE

Ensure front wheels are in straight-ahead position. Turn spiral cable counterclockwise until it is hard to turn. Turn spiral cable clockwise about 3 turns until Red mating mark is aligned. See Fig. 3 .

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

CAUTION: Never use air bag parts from another vehicle. when replacing parts, replace with new parts.

NOTE: If the air bag connector is disconnected with the ignition switch at ON, or ACC, DTCs will be recorded.

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Fig. 3: Aligning Marks On Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.


IGNITION KEY CYLINDER, IGNITION SWITCH & KEY INTERLOCK SOLENOID

For component replacement, see INSPECTION& REPLACEMENT under STEERING COLUMN in OVERHAUL.

STEERING COLUMN

WARNING: To avoid injury from accidental air bag deployment, read and carefully

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Removal

1. Place the front wheels facing straight ahead. Remove the steering wheel lower number 2 and number 3 cover from the steering wheel. Using a Torx socket wrench, loosen the 2 Torx screws. See Fig. 4 .

Fig. 4: Removing Steering Wheel Pad& Torx Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. Pull out the wheel pad from the steering wheel and disconnect the air bag connector. See Fig. 5 .

follow all SERVICE PRECAUTIONS. Deactivate air bag system before performing any repairs. See DISABLING & ACTIVATING AIR BAG SYSTEMin AIR BAG RESTRAINT SYSTEM article.

WARNING: When removing the wheel pad, take care not to pull the AIRBAG wire harness.

CAUTION: When storing the wheel pad, keep the upper surface of the pad facing upward. Never disassemble the wheel pad.

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Fig. 5: Disconnecting The Air Bag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Disconnect the connector. Remove the steering wheel set nut. Place marks on the steering wheel and main

1997 Lexus LX 450


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shaft assembly. Using Special Tool 09950-50010 (09951-05010, 09952-05010, 09953-05020, 09954-05020), remove the steering wheel. See Fig. 6 .

Fig. 6: Removing Steering Wheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. Disconnect the hood lock control cable and fuel lid control cable. Remove the 4 panel set screws. Remove the instrument lower finish panel.

5. Remove number 2 heater to register duct.

6. Remove the 5 screws. Remove upper and lower column covers.

7. Disconnect the combination switch and sprial cable connectors. Disconnect the air bag connector. Remove the 4 screws and lift out air bag spiral cable.

8. Remove 4 column hole cover set bolts.

9. Working at lower end of steering column at steering gear, remove the 2 bolts and link joint protector. See Fig. 1 .

10. Place match marks on the yoke sub assembly and steering gear worm gear valve body shaft. Loosen bolt A and remove bolt B. Disconnect sliding yoke sub assembly. See Fig. 7 .

CAUTION: Do not disassemble the cable or apply oil to it.

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11. Remove the bolt A. Remove sliding yoke sub assembly. See Fig. 7 .

Fig. 7: Disconnect Sliding Yoke Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. Disconnect the 3 connectors. Remove the 2 column assembly set nuts and 2 set bolts. Remove tilt steering column assembly.

Installation

1. Install steering column assembly to vehicle. Torque the 2 column assembly set nuts and 2 set boltsto 18 ft. lbs. (25 N.m). Connect the 3 connectors.

2. Install sliding yoke sub assembly at steering gear. Temporarily tighten the bolt A. See Fig. 7 .

3. Connect sliding yoke assembly. Align the match marks on the yoke sub assembly and worm gear valve body shaft. Torque the bolt B. Torque the bolt A. See Fig. 8 .See TORQUE SPECIFICATIONS .

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Fig. 8: Installing Sliding Yoke Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. Install sliding yoke link joint protector. Torque the 2 bolts. See TORQUE SPECIFICATIONS .

5. Torque 4 column hole cover set bolts. See TORQUE SPECIFICATIONS .

6. Install combination switch with spiral cable. Tighten the 4 screws. Connect the air bag connector. Connect the 2 connectors.

7. Install upper and lower column covers. Tighten the 5 screws.

8. Install number 2 heater to register duct.

9. Install instrument lower finish panel. Tighten the 4 panel set screws. Connect the hood lock control cable and fuel lid control cable.

NOTE: The cable will rotate about 3 turns to either the left or right of the center.

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Fig. 9: Adjusting Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

10. Center the spiral cable. Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes harder to turn the cable. Then rotate the cable clockwise about 3 turns to align the red marks. See Fig. 9 .

11. Install steering wheel. Align the match marks on the wheel and main shaft assembly. Torque the wheel set nut. See TORQUE SPECIFICATIONS . Connect the electrical connector.

CAUTION: Make sure the wheel pad is installed to the specified torque. If the wheel pad has been dropper, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts.

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12. Install sterling wheel pad. Connect the air bag connector. Install the wheel pad after confirming that the circumference groove of the Torx screws is caught on the screw case. Using a Torx socket wrench, torque the 2 screws. See TORQUE SPECIFICATIONS . Install the steering wheel lower number 3 and 3 cover. See Fig. 10 .

13. Check steering wheel center point.

Fig. 10: Installing Steering Wheel Pad Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OVERHAUL

STEERING COLUMN

Disassembly

1. Place match marks on the universal joint, intermediate number 2 shaft and main shaft. Remove the 2 bolts. Disconnect universal joint. See Fig. 11 .

CAUTION: When mounting steering column in a vise, do not overtighten it.

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Fig. 11: Disconnecting Universal Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. Remove the 2 bolts from the dust seal. Remove the hole shield from the hole cover. Remove lower dust seal, column hole cover and column hole shield. See Fig. 2 .

3. Remove the boltand wiring harness clamp.

4. Using a punch, mark the center of the 2 tapered-head bolts that secure the column upper bracket and upper clamp. See Fig. 2 . Using a 3-4 mm drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts. See Fig. 12 . Remove column upper bracket and column upper clamp.

1997 Lexus LX 450


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Fig. 12: Removing Column Upper Bracket & Upper Clamp Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5. Remove the compression spring bolt. Remove the 2 bushings from the spring. Remove compression spring. See Fig. 2 .

6. Remove 3 tension springs. See Fig. 2 .

7. Remove the E-ring from the tilt lever lock shaft. See Fig. 2 . Remove the nut from the tilt number 2 bolt. Remove 2 tilt lever retainers and tilt pawl stoppers. See Fig. 2 .

8. Remove the nut and 2 washers from the tilt pawl bolt. Pull out the bolt. Remove the tilt lever assembly set bolt. Remove the collar from the tilt pawl. Remove 2 tilt pawls.

9. Remove tilt lever, tilt sub lever, tilt lever assembly and tilt lever lock shaft. See Fig. 2 .

10. Position Special Tool 09910-00015 (09911-00011, 09912-00010), the nut (10 mm nominal diameter, 1.25 mm pitch), plate washer (36 mm outer diameter) and bolt (10 mm nominal diameter, 1.25 mm pitch, 50 mm length). See Fig. 13 . Remove the 2 tilt number 2 bolts by using the sliding hammer on the special tool. Remove the upper tube with shaft assembly from the column lower tube.

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Fig. 13: Removing Column Upper Tube With Main Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

11. Remove the 2 bolts and turn signal bracket.

CAUTION: Do not bend the sliding yoke of the main shaft assembly more than 20 degrees.

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Fig. 14: Removing Main Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. Using Special Tool 09950-40010 (09957-04010, 09958-04010), compress the compression spring. Using a snap ring expander, remove the snap ring. Remove the shaft assembly from the column upper tube. Remove the compression spring, bearing thrust collar and bearing from the shaft assembly. See Fig. 14 .

13. Remove the snap ring and collar from the column lower tube. See Fig. 15 .

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Fig. 15: Removing Snap Ring Collar Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspection& Replacement

1. Inspect steering lock operation. Check that the steering lock mechanism operates properly. See Fig. 16 .

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Fig. 16: Inspecting Steering Lock Operation. Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE: Make sure the key is at the ACC position.

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Fig. 17: Replacing Key Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. If necessary, replace key cylinder. Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder. Install a new cylinder. See Fig. 17 .

3. Inspect ignition switch. Inspect key unlock warning switch. See STEERING COLUMN SWITCHES article in ACCESSORIES & ELECTRICAL.

4. If necessary, replace ignition switch with key unlock warning switch. Remove the 2 screws. Install a new switch with the 2 screws.

5.

6. Inspect key interlock solenoid. If necessary, replace key interlock solenoid. Remove the 2 screws. Remove the solenoid, spring and lock pin. Install a new solenoid with the spring and lock pin, with the 2 screws. See Fig. 18 .

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Fig. 18: Inspecting Key Interlock Solenoid Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

7. If necessary, replace bushing. Using a screwdriver, remove the bushing from the column lower tube. Coat a new bushing with molybdenum disulfide lithium base grease. Align the holes of the tube and projections of the bushings. See Fig. 19 .

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Fig. 19: Replacing The Bushings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Reassembly

1. Coat specifed parts with with molybdenum disulfide lithium base grease. See Fig. 2 .

CAUTION: When using a vise to hold steering column, do not overtighten it.

CAUTION: Do not bend the universal joint of the main shaft more than 20degrees.

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Fig. 20: Installing Main Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. Install a new bearing, bearing thrust collar and compression spring to the shaft assembly. Install the shaft assembly into the column upper tube. Using Special Tool 09950-40010 (09957-04010, 09950-04010), compress the compression spring. Using a snap ring expander, install a new snap ring. Install the main shaft assembly. See Fig. 20 .

3. Install turn signal bracket. Torque the 2 boltsto 50 INCH lbs. (5.7 N.m).

CAUTION: Select the bolt type to match each number marked in the squares on the upper tube.

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Fig. 21: Selecting Tilt Number 2 Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. Select the bolt with plain thread end when the column upper tube mark is 2, and the bolt with the hollow tipped thread end when the mark is 1. See Fig. 21 .

5. Install the collar to the shaft assembly. Install a new snap ring. Install the upper tube with the shaft assembly into the column lower tube. See Fig. 22 . Using a plastic hammer, drive in the 2 tilt number 2 bolts. See Fig. 23 .

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Fig. 22: Installing Column Upper Tube With Main Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 23: Driving In The Tilt No. 2 Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. Install tilt lever lock shaft, tilt lever assembly, tilt sub lever and tilt lever.

7. Install 2 tilt pawls. Coat the collar with molybdenum disulfide lithium base grease. Install the collar to the tilt pawl. See Fig. 2 . Install the pawl. Install the bolt through the pawls and tilt lever assembly. Temporarily install the 2 washers and nut. Torque the tilt lever assembly set boltto 26 INCH lbs. (2.9 N.m).

8. Engage the tilt sub lever side pawl to the center of the ratchet. While turning the tilt lever side tilt pawl collar, completely engage the tilt lever side pawl to the ratchet. See Fig. 24 .Torque the nut to 52 INCH lbs. (5.9 N.m).

NOTE: Install the pawl pin into long hole of the tilt lever/tilt sub lever.

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Fig. 24: Adjusting The Tilt Pawls Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. With the tilt pawl and ratchet engaged, install the stopper. Check that the alignment marks on the stopper and pawl align when the stopper is rotated to the pawl side. See Fig. 25 .

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Fig. 25: Installing Tilt Pawl Stoppers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

10. If the alignment marks do not align, select stopper according to the table. See Fig. 26 . After selecting the stoppers, check that on both sides the pawl and ratchet are fully engaged. See Fig. 27 .

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Fig. 26: Tilt Pawl Stoppers Assembly Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 27: Inspecting Engagement Of Pawl & Ratchet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

11. Install 2 tilt lever retainers. Install a new E-ring. torque the nutto 11 ft. lbs. (15 N.m).

12. Install 3 tension springs.

13. Install compression spring. Install the 2 bushings to the spring. Torque the boltto 69 INCH lbs. (7.8 N.m).

14. Install column upper bracket and column upper camp. Tighten 2 new tapered head bolts until the bolt head brakes off. See Fig. 28 .

1997 Lexus LX 450


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Fig. 28: Installing Column Upper Bracket & Upper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. Install wiring harness clamp. Tighten the bolt.

16. Install column hole shield, column hole cover and lower dust seal. Install the hole shield to the hole cover. Install the dust seal to the hole cover. Torque 2 bolts to 52 INCH lbs. (5.9 N.m).

17. Connect universal joint. Align the match marks on the intermediate number 2 shaft and universal joint then torque the bolt. Align the match marks on the universal joint and the main shaft then torque the boltto 25 ft. lbs. (34 N.m). See Fig. 29 .

18. Check tilt steering column operation. Check that there is no axial play at the end of the main shaft. With the main shaft in the neutral position, raise the tilt lever and check that the main shaft raises to the uppermost position. Lower the main shaft, and check that it locks in the lowermost position.

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Fig. 29: Installing Intermediate Shaft Universal Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.


TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)Intermediate Shaft-To-Main Shaft Universal Joint Bolt 25 (34)Link Joint Protector Bolts 9 (12)Steering Column Assembly-To-Support Set Nuts & Bolts 18 (25)Steering Column Hole Cover Set Bolts 9 (13)Steering Wheel Set Nut 25 (34)

Steering Column-To-Steering Gear Sliding Yoke Sub-Assembly (1) Bolt A 25 (34)Bolt B 25 (34)

Tilt Lever Retainer Nut 11 (15)INCH Lbs. (N.m)

Compression Spring Bolt 69 (7.8)Dust Seal Bolt 52 (5.9)Steering Wheel Pad Screws 78 (9.0)Tilt Lever Assembly Set Bolt 26 (2.9)Tilt Lever Side Pawl Nut 52 (5.9)

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SPECIAL TOOLS

Fig. 30: Identifying Special Tools Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Turn Signal Bracket Bolt 50 (5.7)(1) See Fig. 7 for bolt identification.

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SUN ROOF - POWER

1997 ACCESSORIES & EQUIPMENT Toyota - Power Sun Roofs


The ignition switch must be in ON position for sun roof to operate. If all doors are closed and ignition switch is turned off, sun roof will still operate for 60 seconds. The sun roof has a tilt mode and sliding mode. When closing sun roof in sliding mode, sun roof will stop part way until sun roof switch is pressed a second time.

ADJUSTMENTS

SUN ROOF HEIGHT

Close sun roof fully. Measure sun roof height. Roof panel should be even with glass weatherstrip within 0.06" (1.5 mm). If adjustment is required, install or remove shims between bracket and sun roof. Recheck sun roof height.

SUN ROOF CLEARANCE & ALIGNMENT

Closing Clearance

If sun roof closing clearances are unequal between right and left sides, loosen sun roof slider mount nuts. Move either side forward or backward as required. Tighten sun roof slider mount nuts. Recheck sun roof alignment and operation.

Front-To-Rear Alignment

If front-to-rear position of sun roof is incorrect, loosen sun roof slider mount nuts. Move sun roof to front or rear as necessary. Tighten sun roof slider mount nuts.

Side-To-Side Alignment

If sun roof is mounted to right or left of center line in roof opening, loosen sun roof slider mount nuts. Move sun roof right or left as necessary. Tighten sun roof slider mount nuts.

TROUBLE SHOOTING

NOTE: This article also applies to Lexus LX450. Refer to Land Cruiser, unless otherwise indicated.

NOTE: Remove sun roof trim plates from top of sun roof opening before making adjustments.

NOTE: Ensure all component terminals and ground connections are clean and tight.

1997 Lexus LX 450

SUN ROOF - POWER 1997 ACCESSORIES & EQUIPMENT Toyota - Power Sun Roofs

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Microsoft


POWER SUN ROOF

Sun Roof Does Not Operate, Power Door Locks Normal

Defective GAUGE fuse. Defective ignition switch. Defective POWER fuse. Defective main relay. Defective sun roof switch. See SUN ROOF SWITCH TEST under COMPONENT TESTS. Defective sun roof control relay. See CONTROL RELAY TEST under COMPONENT TESTS. Defective motor. See SUN ROOF MOTOR TEST under COMPONENT TESTS. Defective wiring harness.

Sun Roof & Power Door Locks Do Not Operate

Defective AM1 fuse. Defective POWER fuse. Defective power door lock control relay. Defective wiring harness.

Sun Roof Operates Abnormally

Defective sun roof control relay. See CONTROL RELAY TEST under COMPONENT TESTS. Defective limit switch. See LIMIT SWITCH TEST under COMPONENT TESTS. Defective sun roof switch. See SUN ROOF SWITCH TEST under COMPONENT TESTS.

Sun Roof Stops Halfway When Opening

Defective sun roof control relay. See CONTROL RELAY TEST under COMPONENT TESTS. Defective limit switch. See LIMIT SWITCH TEST under COMPONENT TESTS. Defective sun roof switch. See SUN ROOF SWITCH TEST under COMPONENT TESTS. Defective motor. See SUN ROOF MOTOR TEST under COMPONENT TESTS.

Sun Roof Power Reserve Does Not Operate

Defective POWER fuse. Defective door lock control relay. Defective GAUGE fuse. Defective ignition switch. Defective door courtesy switch. Defective wiring harness.

COMPONENT TESTING

CONTROL RELAY TEST

See CONTROL RELAY LOCATION table for relay location. Unplug relay connector. Check for continuity or voltage as indicated at control relay connector terminals with sun roof switch or limit switch in specified positions. See CONTROL RELAY TEST table. If test results are as specified, replace control relay. If test results are not as specified, repair or replace appropriate switch or wire. See Fig. 1 .

CONTROL RELAY LOCATION

Check possible faults in order listed. Repair or replace components and circuits as necessary.

Model Location

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CONTROL RELAY TEST

Land Cruiser To Left Of Motor

Terminal No. & Switch Position Condition

1: Slide (1) Off Or Close No ContinuityOpen Continuity

2: Slide (1) Off Or Open No ContinuityClose Continuity

3: Tilt (1) Off Or Down No ContinuityUp Continuity

4 (1) No Continuity

4 & 5 Continuity

5 (1) No Continuity

6 (1) Ignition Switch LOCK Or ACC No VoltageIgnition Switch ON Battery Voltage

7: Tilt (1) Off Or Up No ContinuityDown Continuity

8: No. 1 Limit Switch (1) Off No ContinuityOn Continuity

9: No. 2 Limit Switch (1) Off No ContinuityOn Continuity

11 (1) Continuity

12 (1) Battery Voltage

(1) Terminal connected to ground.

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Fig. 1: Identifying Control Relay Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SUN ROOF MOTOR TEST

Unplug sun roof motor connector. Using fused jumper wires, connect positive battery lead to sun roof motor terminal No. 1 and negative lead to terminal No. 3. See Fig. 2 . Motor should rotate smoothly. Transpose jumper wires. Motor should rotate smoothly in opposite direction. Replace motor if operation is not as specified.

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Fig. 2: Identifying Sun Roof Motor Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LIMIT SWITCH TEST

1. Unplug switch connector. See Fig. 3 . For limit switch No. 1, continuity should not exist between terminals No. 1 and 5 with switch pin released. With pin pressed in, continuity should exist between terminals No. 1 and 5.

2. For limit switch No. 2, continuity should not exist between terminals No. 4 and 5 with switch pin released. With pin pressed in, continuity should exist between terminals No. 4 and 5. Replace switch if continuity is not as specified.

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Fig. 3: Identifying Limit Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SUN ROOF SWITCH TEST

Remove power sun roof switch. Check for continuity between switch terminals with switch in specified positions. If continuity is not as specified, replace switch. See SUN ROOF SWITCH CONTINUITY TEST table. See Fig. 4 .

SUN ROOF SWITCH CONTINUITY TEST Position Terminal ContinuitySlide

Off (1) *Open 3 & 4Close 4 & 6

TiltOff (1) *Up 4 & 5Down 2 & 4

(1) No continuity.

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Fig. 4: Identifying Sun Roof Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.


DRIVE CABLES


See SUN ROOF .

DRIVE MOTOR


See SUN ROOF .

SUN ROOF SWITCH


Disconnect negative battery cable. Remove screw from sun roof switch assembly (if equipped). Pry sun roof switch assembly from roof panel. Remove screws and switch from switch panel. Unplug switch connector. To install, reverse removal procedure.

NOTE: Tape the end of a flat-blade screwdriver to protect switch and trim panels during removal.

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SUN ROOF


1. Disconnect negative battery cable. Remove back door scuff plate. Remove No. 2 rear seat (if equipped). Carefully remove left and right quarter trim panels by releasing clips along outer edges. Remove rear seat side trim. Remove rear door scuff plate. Remove cowl side trim. Remove front and rear door opening trim. Remove center pillar lower trim.

2. Remove front seat shoulder belt outer anchor. Remove center pillar upper trim. Remove front seat shoulder belt adjuster. Remove rear seat shoulder belt outer anchor. Remove No. 2 rear seat shoulder belt outer anchor (if equipped). Remove quarter pillar trim. Remove rear pillar trim. Remove assist grips.

3. Remove front pillar trim. Remove sun visors, rear view mirror, and interior lights. Remove back door trim. Remove sun roof opening trim moldings. Remove sun roof switch. See SUN ROOF SWITCH . Release 7 clips and remove headliner. Remove drive gear assembly. Remove side trim plates. Remove sun roof mounting nuts and shims. Pull upward on sun roof glass and remove.

4. Remove drip channel. Remove wind deflector. Remove cable guide casing assembly. Remove sunshade trim. Remove drive rail. To install, reverse removal procedure.

WIND DEFLECTOR


See SUN ROOF .

WIRING DIAGRAMS

NOTE: For installation reference, note number and position of shims when removing sun roof.

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Fig. 5: Power Sun Roof System Wiring Diagram

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I - SYSTEM/COMPONENT TESTS

1997 ENGINE PERFORMANCE Toyota - System & Component Testing - 6-Cyl.

INTRODUCTION

Before testing separate components or systems, perform basic diagnostic procedures in BASIC TESTING article. Since many computer-controlled and monitored components set a diagnostic trouble code if they malfunction, also perform self-diagnostics in TESTS W/CODES article.

COMPUTERIZED ENGINE CONTROLS

ENGINE CONTROL MODULE

Power & Ground Circuits

For testing of Engine Control Module (ECM) power and ground circuits, see PIN VOLTAGE CHARTS article. See ECM LOCATION table for identifying ECM mounting locations.

ECM LOCATION

ENGINE SENSORS & SWITCHES

AIRFLOW METER

1. Turn ignition off. Disconnect electrical connector from airflow meter. Airflow meter is located at passenger's side front corner of engine compartment, between air intake hose and the upper cap on air cleaner assembly.

2. Note airflow meter terminal identification. See Fig. 1 . Using ohmmeter, check resistance between terminals E2 and THA. Resistance should be within specification in relation to the temperature. See AIRFLOW METER RESISTANCE table. Replace airflow meter if resistance is not within specification.

3. To check airflow meter operation, ensure electrical connector is installed on airflow meter. Connect voltmeter leads between proper terminals on airflow meter with electrical connector installed. See Fig. 2 .

NOTE: Testing individual components does not isolate short or open circuits. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate shorted or open wiring harness.

Model LocationLX 450/Land Cruiser Above Glove Box, Near Passenger's Side Of

Instrument Panel

NOTE: Airflow meter may be referred to as Mass Airflow (MAF) meter.

1997 Lexus LX 450

I - SYSTEM/COMPONENT TESTS 1997 ENGINE PERFORMANCE Toyota - System & Component Testing - 6-Cyl.

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4. Turn ignition on. Apply air into airflow meter and note voltage reading. See Fig. 2 . While air is being applied, voltage reading should fluctuate. Replace airflow meter if voltage does not fluctuate. Turn ignition off. Remove voltmeter.

AIRFLOW METER RESISTANCE

Fig. 1: Identifying Airflow Meter Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Application & Terminals OhmsE2-THA

-4°F (-20°C) 10,000-20,00032°F (0°C) 4000-700068°F (20°C) 2000-3000104°F (40°C) 900-1300140°F (60°C) 400-700176°F (80°C) 200-400

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Fig. 2: Testing Airflow Meter Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CAMSHAFT POSITION SENSOR

Camshaft position sensor is a pick-up coil located in the distributor. For checking of pick-up coil, see PICK-UP COIL RESISTANCE and PICK-UP COIL AIR GAP under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) in BASIC TESTING article.

CRANKSHAFT POSITION SENSOR

For testing crankshaft position sensor, see CRANKSHAFT POSITION SENSOR under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) in BASIC TESTING article.

EGR GAS TEMPERATURE SENSOR

1. Remove EGR gas temperature sensor. The EGR gas temperature is screwed into a gas passage, near the EGR valve. Place threaded end of EGR gas temperature sensor and thermometer in container of oil.

2. Attach ohmmeter between electrical terminals on EGR gas temperature sensor. Heat oil and note resistance at specified temperature. See EGR GAS TEMPERATURE SENSOR RESISTANCE table. Replace EGR gas temperature sensor if resistance is not within specification. Reinstall EGR gas temperature sensor and tighten to 15 ft. lbs. (20 N.m).

EGR GAS TEMPERATURE SENSOR RESISTANCE Temperature °F (°C) Ohms122 (50) 64,000-97,000212 (100) 11,000-16,000

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ENGINE COOLANT TEMPERATURE (ECT) SENSOR

1. Ensure ignition is off. Disconnect electrical connector from ECT sensor. See ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION table. To verify wire colors for proper sensor identification, see appropriate wiring diagram in WIRING DIAGRAMS article.

2. Drain cooling system and remove ECT sensor. Place probe end of ECT sensor and thermometer in container of water. Attach ohmmeter between electrical terminals on ECT sensor. Heat water and note that resistance is within specification in relation to temperature. See Fig. 3 . Replace ECT sensor if resistance is not within specification.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION

302 (150) 2000-4000

NOTE: The ECT sensor may be also identified using appropriate illustration in THEORY/OPERATION article.

Model LocationLX 450/Land Cruiser Rear Sensor On Cylinder Head, Just Below Intake

Manifold, Above Oil Filter & Contains Green 2-Pin Electrical Connector

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Fig. 3: Checking Engine Coolant Temperature (ECT) Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HEATED OXYGEN SENSOR

1. Two heated oxygen sensors are used. A heated oxygen sensor is used on exhaust pipe in front of front catalytic converter. This oxygen sensor is referred to as the No. 1 oxygen sensor or front oxygen sensor. Another heated oxygen sensor is located on exhaust pipe behind rear catalytic converter. This oxygen sensor is referred to as the No. 2 oxygen sensor or the rear oxygen sensor.

2. If a problem exists with No. 1 or 2 heated oxygen sensors, a diagnostic trouble code will be stored in Engine Control Module (ECM). For diagnostic trouble code diagnosis, see TESTS W/CODES article.

3. To test the heater on the No. 1 or 2 oxygen sensors, disconnect electrical connector for appropriate heated oxygen sensor. See Fig. 4 . Note terminals on heated oxygen sensor. See Fig. 4 .

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4. Using ohmmeter, check resistance between heated oxygen sensor terminals +B and HT. See Fig. 4 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68°F (20°C).

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Fig. 4: Checking Heater On Heated Oxygen Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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KNOCK SENSOR

1. Knock sensor(s) are located on driver's side of the cylinder block, just below cylinder head. See Fig. 5 . Manufacturer recommends removing knock sensor from cylinder block before testing. See KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVE/INSTALL/OVERHAUL article.

2. Using ohmmeter, check that no continuity exists between electrical terminal on knock sensor and body of knock sensor. Replace knock sensor if continuity exists.

Fig. 5: Locating Knock Sensors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PARK/NEUTRAL POSITION SWITCH CIRCUIT

If problem exists with Park/Neutral Position (PNP) switch or circuit, a diagnostic trouble Code P1780 will be stored in the Engine Control Module (ECM). For diagnostic trouble code diagnosis, see TESTS W/CODES article.

PARK/NEUTRAL POSITION (PNP) SWITCH

1. Disconnect electrical connector from Park/Neutral Position (PNP) switch. PNP switch is mounted on side of transmission. Note terminal identification. See Fig. 6 .

2. Using ohmmeter, check for continuity between specified terminals with shift lever in proper positions. See PARK/NEUTRAL POSITION SWITCH SPECIFICATIONS table. If proper continuity cannot

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obtained, adjust or replace switch as necessary.

PARK/NEUTRAL POSITION SWITCH SPECIFICATIONS

Fig. 6: Identifying Typical Park/Neutral Position Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PICK-UP COILS

See PICK-UP COIL AIR GAP and PICK-UP COIL RESISTANCE under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) in BASIC TESTING article.

THROTTLE POSITION SENSOR

1. Ensure ignition is off. Disconnect electrical connector from Throttle Position (TP) sensor. TP sensor is located on throttle body. Note terminal identification on TP sensor. See Fig. 7 .

Shift Lever Position Terminal ContinuityPark 5 & 6; 4 & 7Reverse 4 & 8Neutral 5 & 6; 4 & 10Drive 4 & 92 2 & 4Low 3 & 4

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2. Apply vacuum to throttle opener. Insert specified thickness feeler gauge between throttle stop screw and throttle lever, and check resistance or continuity. See TP SENSOR RESISTANCE SPECIFICATIONStable. Replace or adjust TP sensor if not within specification.

TP SENSOR RESISTANCE SPECIFICATIONS (1)

Fig. 7: Testing Throttle Position Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VEHICLE SPEED SENSOR

Application Type Clearance In. (mm) Terminals Tested Ohmmeter Reading4.5L Fully Closed VTA & E2 200-5700" .020 (.50) IDL & E2 2300 Or Less" .030 (.75) IDL & E2 No Continuity" Fully Open VTA & E2 2000-10,200" " VC & E2 2500-5900(1) Apply vacuum to throttle opener before testing TP sensor.

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1. Vehicle speed sensor is located on transmission and contains a 3-pin electrical connector. Connect voltmeter and battery voltage to vehicle speed sensor terminals. See Fig. 8 .

2. While rotating vehicle speed sensor shaft, ensure voltage changes from zero to at least 11 volts. Voltage should change 4 times per revolution of the shaft. Replace vehicle speed sensor if voltage does not change as specified.

Fig. 8: Testing Vehicle Speed Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

RELAYS

CIRCUIT OPENING RELAY

1. Turn ignition off. Remove circuit opening relay from relay box behind driver's side kick panel. See Fig. 9 .

2. To check circuit opening relay continuity, use ohmmeter to check continuity between specified terminals. Perform STEP 1. See Fig. 10 .

3. To check circuit opening relay operation, apply battery voltage and ground to specified terminals on relay and use ohmmeter to check continuity between specified terminals. Perform STEP 2. See Fig. 10 . Replace circuit opening relay if defective.

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Fig. 9: Locating Circuit Opening Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Testing Circuit Opening Relay Or EFI Main RelayCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EFI MAIN RELAY

1. Ensure ignition is off. Remove EFI main relay from fuse/relay box at driver's side front corner of engine compartment, near the battery.

2. To test EFI main relay continuity, use ohmmeter to check continuity between specified terminals. See Fig. 10 .

3. To test EFI main relay operation, apply battery voltage and ground to specified terminals on EFI main relay and use ohmmeter to check continuity between specified terminals. See Fig. 10 . Replace EFI main relay if defective.

FUEL PUMP RELAY

1. Ensure ignition is off. Remove fuel pump relay. Fuel pump relay is bolted to fender on driver's side of engine compartment, just above fenderwell and contains a Black 4-pin electrical connector.

2. To check fuel pump relay continuity, use ohmmeter to check continuity between specified terminals. See Fig. 11 .

3. To test fuel pump relay operation, apply battery voltage and ground to specified terminals on fuel pump relay and use ohmmeter to check continuity between specified terminals. See Fig. 11 . Replace fuel pump relay if defective.

NOTE: Fuel pump relay may be identified using appropriate illustration in THEORY/OPERATION article.

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Fig. 11: Testing Fuel Pump Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FUEL SYSTEM

FUEL DELIVERY

Circuit Opening Relay

See CIRCUIT OPENING RELAY under RELAYS.

EFI Main Relay

See EFI MAIN RELAY under RELAYS.

Fuel Pump Pressure

For fuel pump pressure testing, see BASIC TESTING article.

Fuel Pump Resistance & Operation

1. Remove second seat, scuff plate, step plate, floor mats and cover plate on floor panel for access to electrical connector at fuel pump. Disconnect electrical connector for fuel pump.

2. To test fuel pump resistance, use ohmmeter to check resistance between specified terminals on electrical connector for fuel pump. See Fig. 12 . Replace fuel pump if resistance is not .20-3.00 ohms at 68°F (20°C).

3. To test fuel pump operation, apply battery voltage and ground to (+) and (-) terminals on electrical connector for fuel pump. See Fig. 12 . DO NOT apply battery voltage to fuel pump for more than 10 seconds. Keep fuel pump away from battery as far as possible. Replace fuel pump if fuel pump does not operate.

CAUTION: When testing fuel pump operation, DO NOT apply battery voltage to fuel pump for more than 10 seconds, or fuel pump may be damaged. When testing fuel pump operation, keep fuel pump away from battery as far as possible.

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Fig. 12: Testing Fuel Pump Resistance & Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fuel Pump Relay

See FUEL PUMP RELAY under RELAYS.

Fuel Pump Resistor

1. Ensure ignition is off. Disconnect electrical connector at fuel pump resistor. Fuel pump resistor is located on passenger's side of engine compartment, near fenderwell and cruise control actuator. See Fig. 13 . Fuel pump resistor contains a Dark Gray 2-pin electrical connector.

2. Using ohmmeter, check resistance between terminals on electrical connector for fuel pump resistor. Replace fuel pump resistor if resistance is not .70-.76 ohms at 68°F (20°C).

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Fig. 13: Locating Fuel Pump Resistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FUEL CONTROL

Fuel Injectors

1. Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See FUEL INJECTOR RESISTANCE table.

2. To check fuel injector volume, remove fuel injector. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEM in REMOVE/INSTALL/OVERHAUL article. Disconnect fuel hose from fuel filter outlet. Use Delivery Hose (09268-41046) to install fuel injector between fuel filter and fuel pressure regulator. See Fig. 14 .

3. Place fuel injector into a clean graduated container. Place vinyl tube on end of fuel injector to prevent fuel

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spillage.

4. Use scan tool to operate the fuel pump to pressurize the fuel system. See FUEL PRESSURE under FUEL SYSTEM in BASIC TESTING article.

5. Connect Fuel Injector Tester (09842-30070) to fuel injector for 15 seconds. See Fig. 15 . Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table.

6. Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector is one drop or less per minute. Replace fuel injector if leakage exceeds specification. Remove test equipment.

FUEL INJECTOR RESISTANCE

FUEL INJECTOR VOLUME SPECIFICATIONS

NOTE: Fuel pump may also be operated to pressurize fuel system by applying battery voltage to electrical terminals on fuel pump. For operating of fuel pump, see FUEL PUMP RESISTANCE & OPERATION under FUEL DELIVERY under FUEL SYSTEM.

NOTE: Ensure difference between fuel injector volume on all fuel injectors is within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table.

Application Ohms @ 68°F (20°C)LX 450/Land Cruiser 13.4-14.2

Application Cu. In. (cc)LX 450/Land Cruiser 4.2-5.4 (69-88)

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Fig. 14: Connections For Testing Fuel Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 15: Connecting Fuel Injector Tester Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fuel Pressure Control System

1. Fuel pressure control system uses a fuel pressure control Vacuum Switching Valve (VSV). Fuel pressure control VSV is supplied voltage through EFI main relay.

2. The Engine Control Module (ECM) will activate VSV by controlling ground circuit for approximately 90-180 seconds when restarting engine at normal operating temperature. Locate and remove fuel pressure control VSV. See FUEL PRESSURE CONTROL VSV LOCATION table. See Fig. 16 .

FUEL PRESSURE CONTROL VSV LOCATION

NOTE: Fuel pressure control system may also be referred to as fuel pressure-up system.

NOTE: Fuel pressure control VSV may also be identified by using proper wire color. See appropriate wiring diagram in WIRING DIAGRAMS article.

Application LocationLX 450/Land Cruiser Below Air Intake Chamber At

Front Lower Side Of Intake Manifold, Near Dipstick &

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Fig. 16: Locating Fuel Pressure Control VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Using ohmmeter, ensure continuity exists between electrical terminals on fuel pressure control VSV and resistance is within specification. See FUEL PRESSURE CONTROL VSV RESISTANCE table. Replace fuel pressure control VSV if no continuity exists or resistance is not within specification.

4. Ensure no continuity exists between each electrical terminal and body of fuel pressure control VSV. Replace fuel pressure control VSV if continuity exists between electrical terminal and body of fuel pressure control VSV.

5. To test fuel pressure control VSV operation, apply air pressure to port "E". Ensure air flows from port "G" and not from the filter. Perform STEP 1. See Fig. 17 .

6. Apply battery voltage and ground to electrical terminals on fuel pressure control VSV. Apply air pressure to port "E". Ensure air flows from filter and not from port "G". Perform STEP 2. See Fig. 17 . Replace fuel pressure control VSV if defective.

FUEL PRESSURE CONTROL VSV RESISTANCE

Contains Brown 2-Pin Electrical Connector

Application Ohms @ 68°F (20°C)LX 450/Land Cruiser 37-44

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Fig. 17: Testing Fuel Pressure Control VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fuel Cut System

1. When checking fuel cut system, engine RPM must be monitored. Scan tool is connected to data link connector No. 3 for monitoring engine RPM. For connecting of scan tool, see IDLE SPEED & MIXTURE in ADJUSTMENTS article.

2. Start and warm engine to normal operating temperature. Ensure the A/C and all accessories are off. Gradually increase engine RPM to maintain at least specified engine speed. See FUEL CUT SYSTEM TESTING SPECIFICATIONS table.

FUEL CUT SYSTEM TESTING SPECIFICATIONS

3. Using stethoscope, check for fuel injector operating sound. Ensure when throttle lever is released, fuel injector stops operating momentarily and then resumes operating (fuel return RPM).

4. Ensure fuel return RPM is within specification. See FUEL CUT SYSTEM SPECIFICATIONS table. Shut engine off. Remove test equipment.

FUEL CUT SYSTEM SPECIFICATIONS (1)

IDLE CONTROL SYSTEM

IDLE AIR CONTROL (IAC) VALVE

1. Listen for clicking sound at IAC valve immediately after engine is shut off. If no clicking sound is heard, check IAC valve resistance and operation.

2. To test IAC valve resistance, ensure ignition is off. Disconnect electrical connector from IAC valve. Using ohmmeter, check resistance between specified terminals. See IAC VALVE RESISTANCE SPECIFICATIONS table. See Fig. 18 . Replace IAC valve if resistance is not within specification.

IAC VALVE RESISTANCE SPECIFICATIONS

Application Engine RPMLX 450/Land Cruiser 3500

Application Fuel Return RPMLX 450/Land Cruiser 1200(1) Check with engine at normal operating temperature and with A/C and all accessories off.

NOTE: IAC valve is located on side of throttle body, near throttle position sensor. See Fig. 18 .

Terminals OhmsB1 To S1 & S3

Cold (1)

15-25

Hot (2) 20-30

B2 To S2 & S4

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3. To test IAC valve operation, remove IAC valve. Apply battery voltage to terminals B1 and B2. See Fig. 19 . Repeatedly ground terminals in sequence, and ensure IAC valve closes and opens. See IAC VALVE GROUNDING SEQUENCE table. See Fig. 19 . Replace IAC valve if defective.

IAC VALVE GROUNDING SEQUENCE

4. If IAC valve resistance is within specification and IAC valve operates correctly, check wiring between Engine Control Module (ECM) and IAC valve. See appropriate wiring diagram in WIRING DIAGRAMS article.

5. ECM is located above glove box, near passenger's side of instrument panel.

Cold (1)

15-25

Hot (2) 20-30

(1) Cold is with temperature of 14-122°F (-10-50°C).

(2) Hot is with temperature of 122-212°F (50-100°C).

ApplicationTerminal Grounding

SequenceTo Close IAC Valve S1-S2-S3-S4-S1To Open IAC Valve S4-S3-S2-S1-S4

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Fig. 18: Locating IAC Valve & Identifying IAC Valve Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 19: Testing IAC Valve Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IGNITION SYSTEM

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TIMING CONTROL SYSTEMS

Knock Sensor

See KNOCK SENSOR under ENGINE SENSORS & SWITCHES.

EMISSION SYSTEMS & SUB-SYSTEMS

EXHAUST GAS RECIRCULATION (EGR) SYSTEM TEST

1. Ensure EGR vacuum modulator filter is clean and in good condition. Clean filter with compressed air (if necessary).

2. Using 3-way connector, install vacuum gauge in line with vacuum hose between top of EGR valve and EGR vacuum modulator. Start engine. Ensure engine runs idles smoothly to ensure proper seating of EGR valve.

3. Ensure engine coolant temperature is less than 117°F (47°C). Start and operate engine at 2500 RPM. Ensure no vacuum reading is obtained with engine at 2500 RPM. The EGR pipe should not be hot.

4. Warm engine so engine coolant temperature is greater than 127°F (53°C). Operate engine at 2500 RPM and note vacuum reading. Ensure low vacuum reading is now obtained.

5. Disconnect vacuum hose from port "R" on EGR vacuum modulator. See Fig. 21 . Using additional hose, connect port "R" on EGR vacuum modulator directly to intake manifold. High vacuum reading should be now be obtained with engine at 2500 RPM.

6. Remove vacuum hose and reconnect original vacuum hose to EGR vacuum modulator. To check EGR valve operation, remove and plug vacuum hose at top of EGR valve.

7. Using vacuum pump, apply vacuum directly to EGR valve with engine idling. Engine should run rough or stall. If EGR system does not operate as described, each individual component should be tested.

NOTE: For basic ignition checks, see BASIC TESTING article.

NOTE: EGR systems contain different components depending on application. See Fig. 20 . When testing EGR system and components, use proper illustration to determine component location.

NOTE: When testing EGR vacuum modulator, it may be necessary to monitor engine RPM by using scan tool. For scan tool connections, see IDLE SPEED & MIXTURE in ADJUSTMENTS article.

NOTE: EGR vacuum modulator filter must be installed with coarse side facing upward, away from EGR vacuum modulator.

NOTE: Engine should misfire due to large amounts of exhaust gas being injected into intake manifold.

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Reconnect vacuum hose at EGR valve.

8. Diagnostic trouble code may have been set in Engine Control Module (ECM) while testing EGR system and Malfunction Indicator Light (MIL) on instrument panel may have come on. Clear DTC from ECM. See TESTS W/CODES article.

Fig. 20: Locating Emission System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 21: Identifying Ports & Testing EGR Vacuum Modulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR

See EGR GAS TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES.

EGR VACUUM MODULATOR

1. Mark vacuum hose locations and disconnect vacuum hoses from EGR vacuum modulator. Block ports "P" and "R" on EGR vacuum modulator. See Fig. 21 .

2. Apply air pressure to port "Q". See Fig. 21 . Air should flow freely through air filter side of EGR vacuum

NOTE: When testing EGR vacuum modulator, it may be necessary to monitor engine RPM by using scan tool. For scan tool connections, see IDLE SPEED & MIXTURE in ADJUSTMENTS article.

NOTE: Ports "P" and "R" are the double ports on side of EGR vacuum modulator. Port "Q" is single port on side of EGR vacuum modulator.

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modulator.

3. Start and operate engine at specified RPM. See EGR VACUUM MODULATOR TESTING SPECIFICATIONS table. Repeat test procedures in steps 1) and 2). Strong resistance of airflow should be felt. Replace EGR vacuum modulator if resistance is not felt. Reconnect vacuum hoses to proper locations.

EGR VACUUM MODULATOR TESTING SPECIFICATIONS

EGR VACUUM SWITCHING VALVE (VSV)

1. Disconnect vacuum hoses and electrical connector from EGR VSV. EGR VSV is located on intake manifold, below air intake chamber and contains a Dark Blue 2-pin electrical connector. See Fig. 20 and Fig. 22 . It may be necessary to remove air intake chamber to access EGR VSV.

2. Using ohmmeter, check that continuity exists between electrical terminals on EGR VSV and that resistance is within specification. See EGR VSV RESISTANCE table. Replace EGR VSV if no continuity exists or resistance is not within specification.

3. Using ohmmeter, ensure no continuity exists between each electrical terminal and body of the EGR VSV. Replace EGR VSV if continuity exists between any electrical terminal and body of EGR VSV.

4. To test EGR VSV operation, apply air pressure to port "G". Ensure air flows from port "E". Perform STEP 1. See Fig. 23 . Apply battery voltage and ground to electrical terminals on EGR VSV. Apply air pressure to port "G". Ensure air does not flow from port "E". Perform STEP 2. See Fig. 23 . Replace EGR VSV if defective.

Application Engine RPMLX 450/Land Cruiser 2500

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Fig. 22: Locating EGR VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 23: Testing EGR VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EGR VSV RESISTANCE

FUEL EVAPORATION SYSTEM

Charcoal Canister

1. Disconnect hoses from charcoal canister. Check for clogged filter and/or stuck check valve by applying low air pressure to port "A". See Fig. 24 . Ensure air flows freely from other ports on charcoal canister.

2. Apply low air pressure to port "B" while holding port "C" closed. See Fig. 24 . Ensure air flows freely from port "A". Replace charcoal canister if defective.

3. To clean charcoal canister filter, apply 43 psi (3 kg/cm2 ) air pressure to port "A" while holding port "B" closed. Air should flow from port "C". Ensure no activated carbon comes out of charcoal canister. DO NOT attempt to wash out charcoal canister.

Application Ohms @ 68°F (20°C)LX 450/Land Cruiser 30-34

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Fig. 24: Identifying Charcoal Canister Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EVAP Check Valve

1. Remove EVAP check valve from vacuum hose to EVAP Vacuum Control Valve (VCV). The EVAP VCV is located on bracket, below air intake chamber, near engine oil dipstick. See Fig. 20 .

2. Apply air pressure to Orange colored side of EVAP check valve. Air should flow through EVAP check valve. Apply air pressure to Black colored side of EVAP check valve. Air should not flow through EVAP check valve. Replace EVAP check valve if defective. The EVAP check valve should be installed with Black colored side toward the EVAP vacuum control valve.

EVAP Thermal Vacuum Valve

1. Drain cooling system. Remove EVAP Thermal Vacuum Valve (EVAP TVV). The EVAP TVV is located in coolant passage on cylinder head. See Fig. 20 .

2. Use cool water to cool threaded end of EVAP TVV to less than 113°F (45°C). Apply air pressure to lower vacuum hose port on EVAP TVV. Ensure EVAP TVV is closed and air flows from the air filter

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located on top of EVAP TVV.

3. Heat water to greater than 147°F (64°C). Apply air pressure to lower vacuum hose port on EVAP TVV. Ensure EVAP TVV is open and air flows through upper vacuum hose port and not through air filter. Replace EVAP TVV if defective. Apply thread sealant to threads of EVAP TVV and reinstall. Tighten EVAP TVV to 21 ft. lbs. (29 N.m). Fill cooling system.

EVAP Vacuum Control Valve

1. Warm engine to normal operating temperature. Disconnect vacuum hose from union pipe at EVAP Vacuum Control Valve (VCV). See Fig. 25 . With engine idling, ensure no suction exists on union pipe at EVAP VCV.

2. Gradually increase engine to 3000 RPM. Ensure suction now exists on union pipe. If suction does not exist, remove EVAP VCV. Using vacuum pump, apply 2.8 in. Hg of vacuum to port "S" on EVAP VCV. See Fig. 25 .

3. Apply air pressure to port "Y". Ensure air flows from port "Z". Remove vacuum pump. Apply air pressureto port "Y". Ensure air does not flow from port "Z". Replace EVAP VCV if defective and recheck operation.

Fig. 25: Testing EVAP Vacuum Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

POSITIVE CRANKCASE VENTILATION (PCV)

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1. Remove PCV valve. Apply air pressure to PCV valve at cylinder head side of PCV valve. Ensure air flows easily through PCV valve.

2. Apply air pressure to PCV valve at intake manifold side of PCV valve. Ensure air flows through PCV valve with some resistance. Replace PCV valve if valve does not function as described.

THROTTLE CONTROLS

DASHPOT CONTROL SYSTEM

1. Warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ADJUSTMENTS article.

2. With engine idling, open throttle valve on throttle body until throttle lever separates from end of dashpot. Dashpot is located on throttle body, just below the throttle cables. See Fig. 26 . Gradually release throttle valve and note dashpot setting RPM when throttle lever contacts dashpot.

3. Dashpot setting RPM should be 1900-2500 RPM. If dashpot setting RPM is not within specification, shut engine off. Loosen lock nut and rotate stopper bolt. See Fig. 26 .

4. Repeat step 2) until proper adjustment is obtained. Tighten lock nut. To check throttle body Vacuum Transmitting Valve (VTV) operation, operate engine at 3500 RPM. Release throttle. Ensure engine returns to proper idle speed in a few seconds.

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Fig. 26: Locating Dashpot & Adjusting Stopper Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

THROTTLE OPENER

1. Warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ADJUSTMENTS article.

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2. Disconnect and plug vacuum hose at throttle opener located on throttle body. See Fig. 27 . Start engine and note engine speed. Engine speed should be 700-1000 RPM.

3. Replace throttle body if engine speed is not within specification. Shut engine off. Reinstall vacuum hose on throttle opener. Start engine and ensure engine returns to proper idle speed.

Fig. 27: Locating Throttle Opener & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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M - VACUUM DIAGRAMS

1997 ENGINE PERFORMANCE Toyota - Vacuum Diagrams

VACUUM DIAGRAMS

Fig. 1: Vacuum Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1997 Lexus LX 450

M - VACUUM DIAGRAMS 1997 ENGINE PERFORMANCE Toyota - Vacuum Diagrams

1997 Lexus LX 450

M - VACUUM DIAGRAMS 1997 ENGINE PERFORMANCE Toyota - Vacuum Diagrams

Microsoft


Microsoft


WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

1997-98 WHEEL ALIGNMENT Toyota - Specifications & Procedures

RIDING HEIGHT

RIDING HEIGHT ADJUSTMENT

Before adjusting alignment, measure riding height. Riding height must be measured with vehicle on level floor and tires properly inflated. Bounce vehicle several times to allow suspension to settle.

Visually inspect vehicle for signs of abnormal height from front to rear or side to side. Check passenger and luggage compartments for extra heavy items, and remove them if present. If riding height is not within specification, inspect and repair or replace suspension components. See RIDING HEIGHT SPECIFICATIONS .

RIDING HEIGHT MEASUREMENT POINTS

Avalon, Camry, Celica & Corolla

Measure front riding height from ground to center of lower control arm mounting bolt/nut. Measure rear riding height from ground to center of forward strut rod mounting bolt. Strut rod is parallel to side body panel.

Land Cruiser/LX470

On 1997 models, measure riding height at specified locations. See Fig. 1 . Dimension "A" is follow spring clearance. Dimension "B" is bumper stopper clearance.

On 1998 models, front riding height specification is difference between spindle center height and lower control mounting bolt center height. Rear riding height specification is difference between rear axle shaft center height and trailing arm front mount bolt center height.

1998 Lexus LX 470

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES 1997-98 WHEEL ALIGNMENT Toyota - Specifications & Procedures

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Fig. 1: Riding Height Measurement Points (1997 Land Cruiser) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Paseo, Sienna & Tercel

Measure front riding height from ground to center of lower arm mounting bolt. Measure rear riding height from ground to center of rear lower control arm forward mounting bolt.

RAV4

Measure front riding height from ground to center of lower arm mounting bolt. Measure rear riding height from ground to center of body side No. 1 suspension arm mounting bolt.

Supra

Measure front riding height from ground to center of lower suspension arm mounting bolt. Measure rear riding height from ground to center of No. 2 lower suspension arm mounting bolt.

Tacoma, T100 & 4Runner

1. Measure front riding height by subtracting height at center of lower arm adjuster cam bolt from height at center tip of spindle. See Fig. 2 .

2. Measure rear riding height by subtracting height at center of front leaf spring mounting bolt from height at center line of rear axle shaft. The difference between measurements is riding height.

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Fig. 2: Riding Height Measurement Points (Tacoma Shown; T100 & 4Runner Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

RIDING HEIGHT SPECIFICATIONS

RIDING HEIGHT SPECIFICATIONS (CARS) Application Front: In. (mm) Rear: In. (mm)Avalon 8.43 (214) 10.47 (266)Camry

P195/70R14 8.35 (212) 10.39 (264)

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RIDING HEIGHT SPECIFICATIONS (LAND CRUISER/LX470)

RIDING HEIGHT SPECIFICATIONS (PREVIA)

RIDING HEIGHT SPECIFICATIONS (RAV4)

RIDING HEIGHT SPECIFICATIONS (SIENNA)

RIDING HEIGHT SPECIFICATIONS (TACOMA 2WD)

P205/65R15 8.46 (215) 10.49 (266)Celica

P185/70R14 7.39 (187.6) 10.07 (255.8)P205/75R15 7.19 (182.6) 9.84 (250)

Corolla175/65R14 7.28 (185) 9.65 (245)185/65R14 (85S) 7.48 (190) 9.84 (250)

Paseo (185/60R14) 7.40 (188) 9.80 (249)Supra

Non-Turbo 7.32 (186) 9.68 (246)Turbo 7.40 (188) 10.00 (254)

Tercel155SR13 7.63 (194) 9.92 (252)175/65R14 7.76 (197) 9.96 (253)185/60R14 7.56 (192) 9.84 (250)

Application Front: In. (mm) Rear: In. (mm)1997 1.42 (36) 4.09 (104)1998 2.80 (71) 2.01 (51)

Application Front: In. (mm) Rear: In. (mm)P205/75R14 9.37 (238) 11.06 (281)P215/65R15 9.33 (237) 10.98 (279)

Application Front: In. (mm) Rear: In. (mm)2WD (215/70R16) 8.94 (227) 13.90 (353)4WD

215/70R16 9.33 (237) 14.17 (360)235/60R16 8.58 (218) 13.62 (346)

Application Front: In. (mm) Rear: In. (mm)205/70R15 9.06 (230) 12.76 (324)215/65R15 8.90 (226) 12.60 (320)

Application Front: In. (mm) Rear: In. (mm)1997-98

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RIDING HEIGHT SPECIFICATIONS (TACOMA 4WD)

RIDING HEIGHT SPECIFICATIONS (T100 2WD)

2.4L Reg Cab 1.73 (44) 2.40 (61)2.4L Xtra Cab 1.69 (43) 2.68 (68)3.4L Xtra Cab 1.69 (43) 2.40 (61)

Application Front: In. (mm) Rear: In. (mm)1997

RZN161L-TRMDKAB 1.89 (48) 1.50 (38)RZN161L-TRPDKAB 1.89 (48) 1.50 (38)VZN160L-TRMDKAB 1.89 (48) 1.50 (38)RZN171L-CRMDKAB 1.73 (44) 1.34 (34)RZN171L-CRPDKAB 1.73 (44) 1.34 (34)VZN170L-CRMDKAB 1.73 (44) 1.38 (35)VZN170L-CRPDKAB 1.73 (44) 1.38 (35)VZN170L-CRMGKAB 1.73 (44) 1.34 (34)VZN170L-CRPGKAB 1.73 (44) 1.34 (34)

19982.7L Reg Cab 1.90 (49) 1.38 (35)2.7L Xtra Cab 1.89 (48) 1.89 (48)3.4L Xtra Cab 1.89 (48) 1.97 (50)


RCK10L-TRMRKAP215/75R15 1.79 (45.4) 2.40 (60.9)P235/75R15 1.79 (45.4) 2.36 (59.9)

RCK10L-TRSRKAP215/75R15 1.79 (45.4) 2.43 (61.8)P235/75R15 1.79 (45.4) 2.40 (60.9)

VCK11L-TRMDKAP215/75R15 1.89 (48.0) 2.43 (61.8)P235/75R15 1.89 (48.0) 2.39 (60.7)

VCK11L-THMDKA1-Ton 1.94 (49.3) 1.37 (34.9)

VCK11L-TRSDKAP215/75R15 1.97 (49.9) 2.48 (62.9)P235/75R15 1.97 (49.9) 2.44 (62.0)

VCK11L-THSDKA1-Ton 1.97 (49.9) 1.41 (35.7)

VCK11L-CRMDKA

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RIDING HEIGHT SPECIFICATIONS (T100 4WD)

RIDING HEIGHT SPECIFICATIONS (4RUNNER)

JACKING & HOISTING

FLOOR JACK

Avalon, Camry, Celica & Corolla

To raise vehicle front, place floor jack under center of front longitudinal engine crossmember. For vehicle rear, place floor jack under rear suspension crossmember.

Land Cruiser/LX470

P215/75R15 1.53 (38.8) 1.78 (45.3)P235/75R15 1.53 (38.8) 1.77 (44.3)

VCK11L-CRMSKAP235/75R15 1.53 (38.8) 1.80 (45.6)

VCK11L-CRSDKAP215/75R15 1.53 (38.8) 1.82 (46.2)P235/75R15 1.53 (38.8) 1.78 (45.3)

VCK11L-CRSSKAP235/75R15 1.53 (38.8) 1.83 (46.5)


VCK21L-TRMDKAP235/75R15 1.52 (38.5) 2.85 (72.3)P265/75R16 1.52 (38.5) 2.91 (74.0)

VCK21L-TRSDKAP235/75R15 1.58 (40.2) 2.80 (71.1)P265/75R16 1.58 (40.2) 2.87 (72.8)

VCK21L-CRMKAP235/75R15 1.28 (32.5) 3.13 (79.4)P265/75R16 1.28 (32.5) 3.21 (81.6)

VCK21L-CRSKAP235/75R15 1.28 (32.5) 3.08 (78.3)P265/75R16 1.28 (32.5) 3.17 (80.6)


P225/75R15 2.74 (69.6) 1.95 (49.6)P265/70R16 1.87 (47.5) 1.16 (29.4)

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Place floor jack under front and/or rear differential to raise vehicle.

RAV4

To raise vehicle, place floor jack under front undercover support and/or rear suspension crossmember.

Paseo & Tercel

To raise vehicle, place floor jack under front crossmember and/or center of rear axle beam.

Previa, Sienna, Tacoma, T100 & 4Runner

To raise vehicle, place floor jack under front crossmember and/or rear axle housing/differential.

Supra

To raise vehicle, place floor jack under front suspension crossmember and/or rear differential carrier.

EMERGENCY JACKING

Avalon, Camry, Celica, Corolla, Paseo, RAV4, Supra & Tercel

Place emergency jack on reinforced support points of side body panel (between front and rear wheels). Safety stands may also be placed at these points. See Fig. 3 .

Land Cruiser/LX470

To raise vehicle, place emergency jack under front and/or rear axle.


Place emergency jack under front suspension crossmember and/or rear axle housing/differential.

Sienna

To raise vehicle, place emergency jack under frame support points between front and/or rear wheels.

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Fig. 3: Identifying Jacking & Hoisting Support Points (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LIFTING VEHICLE WITH HOIST

Avalon, Camry, Celica, Corolla, Paseo, RAV4, Supra & Tercel

Place lift blocks on reinforced support points of side body panel (between front and rear wheels). Safety stands may also be placed at these points. See Fig. 3 .

Land Cruiser/LX470

Place lift blocks under front and rear axles to raise vehicle.


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On 2WD models, place lift blocks under frame side rail and rear axle housing to raise vehicle. On 4WD models, place lift blocks under front suspension crossmember and rear axle housing to raise vehicle.

Previa & Sienna

Place lift blocks under frame side rail supports.

ADJUSTMENTS

TURNING ANGLE

On Land Cruiser/LX470, Previa, T100 and 4Runner, remove steering knuckle stopper bolt caps. On all models, turn steering wheel fully right and then left, and observe turning radius on both wheels. If turning radius is incorrect, inspect and replace any damaged or worn front suspension components. See ALIGNMENT SPECIFICATIONS .

CAMBER ADJUSTMENT

Front Suspension (Avalon, Camry, Celica, Corolla, Land

Cruiser, Paseo, Previa, RAV4, Sienna & Tercel)

1) Check tires for wear and improper inflation. Inspect front wheel bearings for looseness. Check wheel runout. Wheel runout should not exceed .039" (1.0 mm) on Avalon, Camry, Celica, Corolla and RAV4, .055" (1.4 mm) on Paseo, Previa and Tercel, or .118" (3.0 mm) on Land Cruiser/LX470.

2) Inspect front suspension components for looseness. Ensure front shock absorbers work properly. Measure vehicle riding height. See RIDING HEIGHT ADJUSTMENT .

3) Measure camber of both front wheels. See ALIGNMENT SPECIFICATIONS . If camber is not within specification, inspect and replace any damaged or worn front suspension components. Camber is not adjustable on all models listed except Sienna. On Sienna, loosen lower strut mounting bolts and move steering knuckle until camber is within specification. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Front Suspension (Tacoma, T100 & 4Runner)

1. Check tires for wear and improper inflation. Inspect front wheel bearings for looseness. Check wheel runout. Wheel runout should not exceed .118" (3.0 mm).

2. Inspect front suspension components for looseness. Ensure front shock absorbers work properly. Measure vehicle riding height. See RIDING HEIGHT ADJUSTMENT .

3. Measure camber of both front wheels. If camber is not within specification, add or remove shims on upper suspension arms on 2WD models. On 4WD models, loosen and rotate adjuster cams. See ALIGNMENT SPECIFICATIONS . See Fig. 4 .

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Fig. 4: Adjusting Front Camber & Caster (T100 & 4Runner Shown; Tacoma Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Front Suspension (Supra)

1. Check tires for wear and improper inflation. Inspect front wheel bearings for looseness. Check wheel runout. Wheel runout should not exceed .055" (1.4 mm).

2. Inspect front suspension components for looseness. Ensure front shock absorbers work properly. Measure vehicle riding height. See RIDING HEIGHT ADJUSTMENT .

3. Measure camber of both front wheels. If camber is not within specification, remove engine undercover. Remove front lower arm bracket strut. Loosen adjuster cam lock nuts. Rotate adjuster cams as necessary. See ALIGNMENT SPECIFICATIONS . See Fig. 5 . Tighten lock nuts to specification. See TORQUE SPECIFICATIONS .

Fig. 5: Adjusting Front Camber & Caster (Supra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Rear Suspension (Avalon, Camry, Celica & Corolla)

Check tires for wear and improper inflation. Measure camber of both rear wheels. See ALIGNMENT SPECIFICATIONS . If camber is not within specification, inspect and replace any damaged or worn rear suspension components. Camber is not adjustable.

Rear Suspension (RAV4)

Check tires for wear and improper inflation. Check camber of both rear wheels. See ALIGNMENT SPECIFICATIONS . If camber is not within specification, adjust camber by rotating adjuster cams.

Rear Suspension (Supra)

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Check tires for wear and improper inflation. Ensure lengths of left and right No. 1 and No. 2 lower suspension arms are equal. See Fig. 6 . Check camber of both rear wheels. See ALIGNMENT SPECIFICATIONS . If camber is not within specification, adjust camber by rotating adjuster cams.

Fig. 6: Identifying Rear Camber & Toe Adjuster Cams (Supra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CASTER ADJUSTMENT

Front Suspension (Avalon, Camry, Celica, Corolla, Land

Cruiser, Paseo, Previa, RAV4, Sienna & Tercel)

Measure caster of both front wheels. If caster is not within specification, inspect and replace any damaged or worn front suspension components. Caster is not adjustable.

Front Suspension (Tacoma, T100 & 4Runner)

1. Measure riding height, camber, and steering axis inclination. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure.

2. Measure caster of both front wheels. If caster is not within specification, add or remove shims on upper control arms on 2WD models. On T100 2WD, adjust shim thickness between front and rear locations to within .16" (4 mm). If measurement cannot be met, adjust strut rod length by adjusting strut rod nuts. See Fig. 7 . On 4WD models, loosen and rotate adjuster cams. See Fig. 4 .

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Fig. 7: Identifying Caster Adjuster Nut (T100 2WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Front Suspension (Supra)

1. Measure riding height, camber, and steering axis inclination. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure.

2. Measure caster of both front wheels. If caster is not within specification, remove engine undercover. Remove front lower arm bracket strut. Loosen adjuster cam lock nuts. Rotate adjuster cams as necessary. See ALIGNMENT SPECIFICATIONS . See Fig. 5 . Tighten lock nuts to specification. See TORQUE SPECIFICATIONS .

STEERING AXIS/KING PIN INCLINATION

Except Supra

Measure riding height and camber. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure. Measure steering axis inclination of both front wheels. If steering axis inclination is not within specification, inspect and replace any damaged or worn front suspension components.

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See ALIGNMENT SPECIFICATIONS . Steering axis/king pin inclination is not adjustable.

Supra

Measure riding height, camber, and caster. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure. Measure steering axis inclination of both front wheels. If steering axis inclination is not within specification, inspect wheel bearing for looseness, or replace steering knuckle. See ALIGNMENT SPECIFICATIONS . Steering axis/king pin inclination is not adjustable.

TOE-IN ADJUSTMENT

Front Suspension

Measure riding height, camber, steering axis inclination, and caster. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure. Set front wheels to straight-ahead position. Bounce both ends of vehicle several times to settle suspension. Measure toe-in. If necessary, adjust toe-in by changing length of tie rods.

Rear Suspension (Avalon, Camry, Celica & Corolla)

1. Measure rear camber. See ALIGNMENT SPECIFICATIONS . If adjustment is necessary, see appropriate adjustment procedure.

2. Bounce both ends of vehicle several times to settle suspension. Measure length of left and right No. 2 suspension arms. See Fig. 8 . Ensure lengths of both arms are equal within .039" (1.0 mm).

3. If toe-in is not within specification, adjust toe-in by rotating rear toe adjuster sleeves, located on No. 2 suspension arms. See ALIGNMENT SPECIFICATIONS . Tighten lock nuts to specification after adjustment. See TORQUE SPECIFICATIONS .

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Fig. 8: No. 2 Suspension Arm (Avalon, Camry, Celica & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Rear Suspension (Land Cruiser/LX470, Paseo, Previa, Sienna,

Tercel, T100 & 4Runner)

Measure rear wheel toe-in. If toe-in is not within specification, inspect and replace any damaged or worn suspension components. See ALIGNMENT SPECIFICATIONS . Rear toe-in is not adjustable.

Rear Suspension (Supra)

1. Measure rear camber. See CAMBER ADJUSTMENT under ADJUSTMENTS. Bounce both ends of vehicle several times to settle suspension.

2. Measure toe-in. If toe-in is not within specification, adjust by rotating adjuster cams. See ALIGNMENT SPECIFICATIONS . See Fig. 6 .

ALIGNMENT SPECIFICATIONS

AVALON

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WHEEL ALIGNMENT SPECIFICATIONS (AVALON)

CAMRY

WHEEL ALIGNMENT SPECIFICATIONS (CAMRY)

Application Preferred Range

Camber (1) Front -0.62 -1.37 To 0.13Rear -0.77 -1.52 To -0.02

Caster (1) Front 2.18 1.43 To 2.93Rear N/A N/A

Steering Axis Inclination (1) 13.07 N/A

Toe-In (2) Front 0 (0) -0.08 To 0.08

(-2 To 2)Rear 0.16 (4) 0.08 To 0.24

(2 To 6)

Toe-In (1) Front 0 -0.2 To 0.2Rear 0.4 0.2 To 0.6

Toe-Out On Turns (1) Inner 35.78 N/AOuter 31.42 N/A

(1) Measurement in degrees.

(2) Measurement in inches (mm).

Application Preferred Range4-Cylinder

Camber (1) Front -0.6 -1.35 To

0.15Rear -0.7 -1.45 To

0.05

Caster (1) Front 2.17 1.42 To

2.92Rear N/A N/A


Toe-In (2)

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CELICA

Front 0 (0) -0.08 To 0.08 (-2 To

2)Rear 0.16 (4) 0.08 To

0.24 (2 To 6)


Toe-Out On Turns (1) (3) Inner 37.20 N/AOuter 32.35 N/A

V6


0.13Rear -0.75 -1.5 To 0

Caster (1) Front 2.18 1.43 To

2.93Rear N/A N/A


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.16 (4) 0.08 To 0.24 (2 To

6)





(3) If vehicle is equipped with P205/65R15 tires, inner is 35.78 degrees, outer is 31.42 degrees.

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WHEEL ALIGNMENT SPECIFICATIONS (CELICA)Application Preferred Range1.8L

Camber (1) Front -0.85 -1.6 To -0.1Rear -1.27 -2.02 To

0.52

Caster (1) 2.12 1.37 To 2.87


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.14 (3.5) 0.06 To 0.22 (1.5 To

5.5)

Toe-In (1) Front 0 -0.2 To 0.2Rear 0.35 0.15 To

0.55


2.2L

Camber (1) Front -0.77 -1.52 To -

0.02Rear -1.17 -1.92 To

0.42

Caster (1) 2.08 1.33 To 2.83


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.14 (3.5) 0.06 To 0.22 (1.5 To

5.5)

Toe-In (1) Front 0 -0.2 To 0.2Rear 0.35 0.15 To

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COROLLA

WHEEL ALIGNMENT SPECIFICATIONS (COROLLA)

LAND CRUISER/LX470

WHEEL ALIGNMENT SPECIFICATIONS (LAND CRUISER/LX470)

0.55





Camber (1) Front -0.18 -0.93 To 0.57Rear -0.92 -1.67 To 0.17

Caster (1) 1.32 0.57 To 2.07


Toe-In (2) Front 0.04 (1) -0.04 To 0.12

(-1 To 3)Rear 0.16 (3) 0.08 To 0.24

(2 To 6)

Toe-In (1) Front 0.10 -0.1 To 0.3Rear 0.4 0.2 To 0.6




(3) If vehicle is equipped with manual steering, inner is 39.02 degrees, outer is 33.37 degrees.

Application Preferred Range1997

Camber (1) Front 1 0.25 To

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PASEO

WHEEL ALIGNMENT SPECIFICATIONS (PASEO)

1.75

Caster (1) 3 2 To 4

Steering Axis Inclination (1) 13 N/A

Toe-In (2) 0.08 (2) 0.04 To 0.12 (1 To 3)

Toe-In (1) 0.2 0.1 To 0.3

Toe-Out On Turns (1) Inner 35.5 N/AOuter 31 N/A

1998

Camber (1) Front .08 -0.67 To

0.83

Caster (1) 2.5 1.75 To 3.25


Toe-In (2) 0.04 (1) -0.04 To 0.12 (-1 To 3)

Toe-In (1) 0.1 -0.1 To 0.3






Caster (1) 1.5 0.75 To 2.25


Toe-In (2) Front 0.04 (1) -0.04 To 0.12

(-1 To 3)Rear 0.13 (3) 0 To 0.26 (0

To 7)

1998 Lexus LX 470


Microsoft


PREVIA

WHEEL ALIGNMENT SPECIFICATIONS (PREVIA)

RAV4 - 2-DOOR 2WD

WHEEL ALIGNMENT SPECIFICATIONS (RAV4 - 2 DOOR 2WD)

Toe-In (1) Front 0.1 -0.1 To 0.3Rear 0.33 0 To 0.66





Camber (1) 0.08 -0.42 To 0.58

Caster (1) 5.5 5 To 6


Toe-In (2) 0.08 (2) 0 To 0.16 (0 To 4)

Toe-In (1) 0.16 0 To 0.32





Camber (1) Front -0.33 -1.08 To 0.42Rear

2-Door -1.33 -2.08 To -0.58

4-Door -1.25 -2 To -0.5

Caster (1) 1.42 0.67 To 2.17


Toe-In (2) Front 0 (0) -0.08 To 0.08

1998 Lexus LX 470


Microsoft


RAV4 - 4-DOOR 2WD

WHEEL ALIGNMENT SPECIFICATIONS (RAV4 - 4 DOOR 2WD)

(-2 To 2)Rear

2-Door 0.16 (4) 0.08 To 0.24 (2 To

6)4-Door 0.12 (3) 0.04 To 0.2

(1 To 5)

Toe-In (1) Front 0 -0.2 To 0.2Rear

2-Door 0.4 0.2 To 0.64-Door 0.3 0.1 To 0.5





Camber (1) Front -0.33 -1.08 To 0.42Rear

2-Door -1.33 -2.08 To -0.58

4-Door -1.25 -2 To -0.5

Caster (1) 1.42 0.67 To 2.17


Toe-In (2) Front 0 (0) -0.08 To 0.08

(-2 To 2)Rear

2-Door 0.16 (4) 0.08 To 0.24 (2 To

6)4-Door 0.12 (3) 0.04 To 0.2

(1 To 5)

Toe-In (1)

1998 Lexus LX 470


Microsoft


RAV4 - 2-DOOR 4WD

WHEEL ALIGNMENT SPECIFICATIONS (RAV4 - 2-DOOR 4WD)

Front 0 -0.2 To 0.2Rear

2-Door 0.4 0.2 To 0.64-Door 0.3 0.1 To 0.5




Application Preferred Range215/70R16

Camber (1) Front -0.25 -1.0 To 0.5Rear -1.08 -1.83 To -

0.33

Caster (1) 1.33 0.58 To 2.08


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.12 (3) 0.04 To 0.2 (1 To 5)


Toe-Out On Turns (1) Inner 33.25 N/A

Outer 28.08 N/A235/60R16


0.42Rear -1.42 -2.17 To -

0.671.42 0.67 To 2.17

1998 Lexus LX 470


Microsoft


RAV4 - 4-DOOR 4WD

WHEEL ALIGNMENT SPECIFICATIONS (RAV4 - 4-DOOR 4WD)

Caster (1)


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.16 (4) 0.08 To 0.24 (2 To

6)





Application Preferred Range215/70R16


0.17

Caster (1) 1.33 0.58 To 2.08


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.12 (3) 0.04 To 0.2 (1 To 5)


Toe-Out On Turns (1)

1998 Lexus LX 470


Microsoft


SIENNA

WHEEL ALIGNMENT SPECIFICATIONS (SIENNA)

Inner 33.25 N/AOuter 28.08 N/A

235/60R16


0.42Rear -1.33 -2.08 To -

0.58

Caster (1) 1.42 0.67 To 2.17


Toe-In (2) Front 0 (0) -0.08 To

0.08 (-2 To 2)

Rear 0.12 (3) 0.4 To 0.2 (1 To 5)






Camber (1) Front -0.53 -1.28 To 0.22Rear -0.92 -1.67 To -0.17

Caster (1) 1.53 0.78 To 2.28


Toe-In (2) Front 0.1 (2.5) .02 To .18 (.5

To 4.5)Rear 0.09 (2) -.03 To .21 (-1

To 5)

1998 Lexus LX 470


Microsoft


SUPRA

WHEEL ALIGNMENT SPECIFICATIONS (SUPRA)

Toe-In (1) Front 27 0.07 To 0.47Rear 0.22 -0.8 To 0.52




Application Preferred RangeNon-Turbo


1.08

Caster (1) 3.33 2.83 To 3.83


Toe-In (2) Front 0 (0) -0.04 To

0.04 (-1 To 1)

Rear 0.12 (3) 0.08 To 0.16 (2 To

4)


Toe-Out On Turns (1) Inner 35 N/AOuter 30.75 N/A

Turbo

Camber (1) Front -0.5 -1 To 0Rear -1.5 -2 To -1

Caster (1) 3.5 3 To 4


1998 Lexus LX 470


Microsoft


TACOMA - 2WD

WHEEL ALIGNMENT SPECIFICATIONS (TACOMA - 2WD)

TACOMA - 4WD

WHEEL ALIGNMENT SPECIFICATIONS (TACOMA - 4WD)

Toe-In (2) Front 0 (0) -0.04 To

0.04 (-1 To 1)

Rear 0.12 (3) 0.08 To 0.16 (2 To

4)






Camber (1) 0.08 -0.67 To 0.83

Caster (1) 2.4L Reg Cab .58 0.17 To 1.332.4L Xtra Cab .83 0.08 To 1.583.4L Xtra Cab .67 -0.08 To 1.42


Toe-In (2) 0.08 (2) -0 To 0.16 (0 To 4)

Toe-In (1) 0.2 0 To 0.4

Toe-Out On Turns (1) Inner 36 N/AOuter 31 N/A




1998 Lexus LX 470


Microsoft


1997

Camber (1) 2.7L Reg Cab 0.25 -0.5 To 13.4L Reg Cab 0.25 -0.5 To 12.7L Xtra Cab 0.33 -0.42 To

1.083.4L Xtra Cab 0.33 -0.42 To

1.08

Caster (1) 2.7L Reg Cab 1.58 0.83 To

2.333.4L Reg Cab 1.58 0.83 To

2.332.7L Xtra Cab 1.75 1 To 2.53.4L Xtra Cab 1.75 1 To 2.5


Toe-In (2) 0.08 (2) 0 To 0.16 (0 To 4)

Toe-In (1) 0.2 0 To 0.4


1998

Camber (1) 2.7L Reg Cab 0.17 -0.58 To 12.7L Xtra Cab 0.25 -0.5 To 13.4L Xtra Cab 0.25 -0.5 To 1

Caster (1) 2.7L Reg Cab 1.67 0.92 To

2.422.7L Xtra Cab 1.5 .75 To 2.253.4L Xtra Cab 1.42 0.67 To

2.17


Toe-In (2) 0.08 (2) 0 To 0.16 (0 To 4)

Toe-In (1) 0.2 0 To 0.4


1998 Lexus LX 470


Microsoft


TERCEL

WHEEL ALIGNMENT SPECIFICATIONS (TERCEL)

T100 - REGULAR CAB

WHEEL ALIGNMENT SPECIFICATIONS (T100 - REGULAR CAB)





Caster (1) 1.33 0.58 To 2.08


Toe-In (2) Front 0.04 (1) -0.04 To 0.12

(-1 To 3)Rear 0.12 (3) 0 To 0.24 (0

To 6)

Toe-In (1) Front 0.1 -0.1 To 0.3Rear 0.3 0 To 0.6




Application Preferred Range2WD

Camber (1) 0.4 -0.35 To 1.15

Caster (1) 2.4 1.65 To 3.15


Toe-In (2) 0.09 (2.5) -0.01 To 0.19 (-0.5 To 4.5)

Toe-In (1) 0.18 -0.02 To 0.38

Toe-Out On Turns (1)

1998 Lexus LX 470


Microsoft


T100 - XTRA CAB

WHEEL ALIGNMENT SPECIFICATIONS (T100 - XTRA CAB)

Inner 40.67 N/AOuter 35.1 N/A

4WD

Camber (1) 0.67 -0.08 To 1.42

Caster (1) 1.08 0.33 To 1.83


Toe-In (2) 0.1 (2.5) 0 To 0.2 (0 To 5)

Toe-In (1) 0.2 0 To 0.4





Camber (1) .47 -0.28 To 1.22

Caster (1) 2.07 1.32 To 2.82


Toe-In (2) 0.17 (4) 0.07 To 0.27 (1.5 To 7)

Toe-In (1) 0.33 0.13 To 0.53


4WD

Camber (1) 0.58 -0.17 To 1.33

Caster (1) 0.92 0.17 To 1.67


Toe-In (2) 0.07 (2) -0.03 To 0.17 (-1 To 4)

Toe-In (1) 0.13 -0.07 To 0.33

Toe-Out On Turns (1) Inner 33.12 N/A

1998 Lexus LX 470


Microsoft


4RUNNER

WHEEL ALIGNMENT SPECIFICATIONS (4RUNNER)


TORQUE SPECIFICATIONS (CARS)

Outer 30.52 N/A(1) Measurement in degrees.



Camber (1) -0.25 -1 To 0.5

Caster (1) 3.08 2.33 To 3.83


Toe-In (2) 0.08 (2) 0 To 0.16 (0 To 4)

Toe-In (1) 0.2 0 To 0.4


4WD

Camber (1) 0.17 -0.58 To 0.92

Caster (1) 2.42 1.67 To 3.17


Toe-In (2) 0.08 (2) 0 To 0.16 (0 To 4)

Toe-In (1) 0.2 0 To 0.4




Application Ft. Lbs. (N.m)Avalon & Camry

Rear Toe Adjuster Sleeve Lock Nuts 41 (56)Tie Rod Lock Nuts 55 (75)

1998 Lexus LX 470


Microsoft


TORQUE SPECIFICATIONS (LIGHT TRUCKS)

Wheel Lug Nuts 76 (103)Celica

Rear Toe Adjuster Sleeve Lock Nuts 55 (75)Tie Rod Lock Nuts 41 (56)Wheel Lug Nuts 76 (103)

CorollaRear Toe Adjuster Sleeve Lock Nuts 41 (56)Tie Rod Lock Nuts 41 (56)Wheel Lug Nuts 76 (103)

Paseo & TercelTie Rod Lock Nuts 35 (47)Wheel Lug Nuts 76 (103)

SupraFront Adjuster Cam Lock Nuts 167 (226)Rear Adjuster Cam Lock Nuts 136 (184)Tie Rod Lock Nuts 41 (56)Wheel Lug Nuts 76 (103)

Application Ft. Lbs. (N.m)Land Cruiser/LX470

Steering Knuckle Stopper Bolts 32 (44)Tie Rod Clamp Nuts 27 (37)Wheel Lug NutsAluminum Wheel 76 (103)Steel Wheel 108 (147)

Previa & SiennaLower Strut Mounting Bolts 155 (210)Steering Knuckle Stopper Bolts 24 (33)Tie Rod Lock Nuts 67 (91)Wheel Lug Nuts 76 (103)

RAV4Tie Rod Lock Nuts 41 (56)Wheel Lug Nuts 76 (103)

T100 2WDTie Rod Lock Nuts 41 (56)Upper Control Arm Bolts 71 (96)Wheel Lug Nuts 76 (103)

T100 4WDFront Suspension Adjuster Cams 167 (226)Steering Knuckle Stopper Bolts 35 (47)

1998 Lexus LX 470


Microsoft


Tie Rod Clamp Nuts 16 (22)Wheel Lug Nuts 76 (103)

4RunnerFront Suspension Adjuster Cams 96 (130)Tie Rod Clamp Nuts 41 (55)Wheel Lug Nuts 81 (110)

1998 Lexus LX 470


Microsoft


WIPER/WASHER SYSTEM

1997 ACCESSORIES & EQUIPMENT Toyota - Wiper/Washer Systems


For Land Cruiser, see AIR BAG RESTRAINT SYSTEM .

For Lexus LX450, see AIR BAG RESTRAINT SYSTEM .

Vehicles are equipped with 2-speed wiper motors. An intermittent wiper system is optional. Front wiper motors are protected by an internal circuit breaker. Vehicles are equipped with rear wipers.

COMPONENT TESTING

FRONT WIPER MOTOR TEST

1. Using 12-volt battery, connect jumper wire from positive battery terminal to wiper motor terminal No. 3. See Fig. 1 . Connect another jumper wire between negative battery terminal and wiper motor terminal No. 1. Motor should operate at low speed.

2. Remove jumper wire from terminal No. 3. Reconnect positive battery terminal jumper wire to wiper motor terminal No. 2. Motor should operate at high speed.

3. Remove jumper wire from terminal No. 2 and reconnect jumper wire to wiper motor terminal No. 3. With motor running at low speed, stop motor at any position except PARK position by disconnecting jumper wire from terminal No. 3. Install another jumper wire between wiper motor terminals No. 3 and 5.

4. Ensure motor terminal No. 1 (ground terminal) is still connected to battery negative terminal. Connect positive battery terminal jumper wire to wiper motor terminal No. 6. Motor should start running and then stop at the PARK position. Replace motor if operation is not as described.

NOTE: This article also applies to Lexus LX450. Refer to Land Cruiser, unless otherwise indicated.

WARNING: Deactivate air bag system before performing any service operation. See appropriate article:

WARNING: DO NOT apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy.

1997 Lexus LX 450

WIPER/WASHER SYSTEM 1997 ACCESSORIES & EQUIPMENT Toyota - Wiper/Washer Systems

1997 Lexus LX 450


Microsoft


Microsoft


Fig. 1: Identifying Front Wiper Motor Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT WIPER SWITCH TEST

With wiper switch in specified position, ensure continuity exists between specified terminals. See WIPER SWITCH CONTINUITY TEST table. See Fig. 2 . Replace wiper switch assembly if continuity is not as specified.

WIPER SWITCH CONTINUITY TEST

Switch Position (1) TerminalsOff B4 & B7Intermittent B4 & B7Low B7 & B18High B13 & B18(1) See Fig. 2 .

1997 Lexus LX 450


Microsoft


Fig. 2: Identifying Combination Switch Connectors For Wipers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT WASHER SWITCH TEST

With washer switch in specified position, ensure continuity exists between specified terminals. See WASHER SWITCH CONTINUITY TEST table. See Fig. 2 . Replace complete wiper switch assembly if continuity is not as specified.

WASHER SWITCH CONTINUITY TEST

REAR WIPER MOTOR TEST

1. Disconnect wiring connector from wiper motor. Using 12-volt battery, connect jumper wire from positive battery terminal to wiper motor terminal No. 3. See Fig. 3 . Using another jumper wire, connect wiper motor terminal No. 2 to negative battery terminal. Motor should operate.

2. To check automatic PARK operation, with motor running, stop motor operation anywhere except PARK position by removing power from terminal No. 3. Install another jumper wire between terminals No. 3 and 4. Connect jumper wire from positive battery terminal to wiper motor terminal No. 1. Ensure motor operates and stops at PARK position. Replace motor if operation is not as described.

Switch Position (1) Terminals ContinuityOff B8 & B16 NoOn B8 & B16 Yes(1) See Fig. 2 .

1997 Lexus LX 450


Microsoft


Fig. 3: Identifying Rear Wiper Motor Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR WIPER RELAY TEST

Using an ohmmeter, check continuity between relay terminals No. 1 and 3. See Fig. 4 . No continuity should exist. Connect ohmmeter leads to relay terminals No. 2 and 3. Continuity should exist. If continuity is not as described, replace relay.

REAR WIPER RELAY LOCATION

NOTE: For relay locations, see REAR WIPER RELAY LOCATION table.

Model LocationLand Cruiser Inside Back Door, To Left Of Motor

1997 Lexus LX 450


Microsoft


Fig. 4: Identifying Rear Wiper Relay Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR WIPER SWITCH TEST

With wiper switch in specified position, ensure continuity exists between specified terminals. See REAR WIPER/WASHER SWITCH CONTINUITY TEST table. See Fig. 2 . Replace complete wiper switch if continuity is not as specified.

REAR WIPER/WASHER SWITCH CONTINUITY TEST


For Land Cruiser, see AIR BAG RESTRAINT SYSTEM .

Switch Position (1) Terminals ContinuityOff B1, B2, B10 & B16 NoIntermittent B10 & B16 YesOn B1 & B16 YesWash

W/Wiper On B2 & B16 YesW/Intermittent On B1, B2 & B16 Yes

(1) See Fig. 2 .

WARNING: Deactivate air bag system before performing any service operation. See appropriate article:

1997 Lexus LX 450


Microsoft


For Lexus LX450, see AIR BAG RESTRAINT SYSTEM .

FRONT WIPER SWITCH

Removal

1. Disconnect negative battery cable. To access combination switch connector, remove instrument panel lower finish panel under steering column. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION in INSTRUMENT PANEL article. Remove steering column upper and lower covers. Remove steering wheel. See STEERING WHEEL .

2. Locate wiper/washer switch wire terminal positions installed into combination switch harness connector. See Fig. 2 . Lift tab locks on combination switch connector. See Fig. 5 .

3. Using miniature screwdriver, release wire terminal securing tab inside connector. See Fig. 5 . Pull wire(s) from connector and through harness jacket tubing. Remove wiper switch retaining screws from rear of combination switch body and remove switch. See Fig. 6 .

Installation

To install, reverse removal procedure. When installing wiper switch wire terminals to harness connector, push inward on wire terminal until terminal clicks into place.

WARNING: DO NOT apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy.

NOTE: Wiper switch is component of combination switch, mounted to steering column. For further information on combination switch removal procedure, see STEERING COLUMN SWITCHES article.

1997 Lexus LX 450


Microsoft


Fig. 5: Releasing Wire Terminal Inside Combination ConnectorCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Identifying Combination Switch Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR WIPER SWITCH


Switch is integral part of wiper switch mounted to combination switch on steering column. See FRONT WIPER SWITCH .

STEERING WHEEL

Removal

1. Ensure front wheels are in straight-ahead position. Place ignition switch in LOCK position and remove key. Disconnect negative battery cable. Remove 2 screw covers from outer sides of steering wheel. Using Torx Wrench (T30), loosen air bag pad retaining Torx screws until screw heads are snug against screw case. See Fig. 7 .

1997 Lexus LX 450


Microsoft


2. Carefully pull air bag pad away from steering wheel enough to unlock and disconnect air bag electrical connector. DO NOT pull on electrical connector or wiring. Store air bag pad aside with pad facing upward.

3. Remove steering wheel lock nut and washer from steering shaft. Make alignment mark on steering shaft and steering wheel for installation reference. Using appropriate steering wheel puller, pull steering wheel from shaft while guiding spiral cable wire through steering wheel opening.

Installation

1. Ensure front wheels are in straight-ahead position. Connect and install spiral cable to combination switch. Turn spiral cable counterclockwise by hand until it is hard to turn. Turn spiral cable clockwise about 2 1/2-3 turns and align Red mark at bottom with opening.

2. Guide spiral cable through steering wheel opening while installing steering wheel to shaft. Align reference marks on steering shaft and steering wheel. Install steering wheel lock nut and washer. Tighten steering wheel lock nut to 25 ft. lbs. (34 N.m).

3. Connect air bag electrical connector and snap down connector lock. Before installing air bag pad, ensure Torx screws are retracted and snug against screw case. See Fig. 7 .

4. Install air bag pad to steering wheel ensuring all wiring is NOT pinched and DOES NOT interfere with moving parts. Tighten 4 Torx screws to 78 INCH lbs. (8.8 N.m). Install screw covers. Connect negative battery cable.

Fig. 7: Removing Air Bag From Steering Wheel (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1997 Lexus LX 450


Microsoft


WIRING DIAGRAMS

1997 Lexus LX 450


Microsoft


1997 Lexus LX 450


Microsoft


Fig. 8: Front Wiper/Washer System Wiring Diagram

1997 Lexus LX 450


Microsoft


1997 Lexus LX 450


Microsoft


Fig. 9: Rear Wiper/Washer System Wiring Diagram

1997 Lexus LX 450


Microsoft


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