Toyota 4-Runner 1985 Operating instructions

1985 TOYOTA TRUCK &
4-RUNNER Gasoline
REPAIR MANUAL
INTRODUCTION ImI
MAINTENANCE
ENGINE MECHANICAL
EMISSION CONTROL SYSTEM
EFI SYSTEM
FUEL SYSTEM
COOLING SYSTEM ==
LUBRICATION SYSTEM
IGNITION SYSTEM·
STARTING
SYSTEM m
CHARGING SYSTEM D=I
CLUTCH 01
MANUAL TRANSMISSION I~~II
AUTOMATIC TRANSMISSION lilI.
TRANSFER mil
PROPELLER SHAFT IAI
FRONT AXLE AND SUSPENSION 1m
REAR AXLE AND SUSPENSION Im1
BRAKE SYSTEM I:JI
STEERING '-1a
BODY ELECTRICAL SYSTEM I:JI
BODY l:l.J
WINCH awl
AIR CONDITIONING SYSTEM 1.:.tI
© 1984 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
reproduced or copied, in whole or in part, without
the written permission of Toyota Motor
Corporation.
SERVICE SPECIFICATIONS ..
STANDARD BOLT TIGHTENING TORQUE _
SSTANDSSM _
AUTOM~V5RTf&L~~~\~~181~ ..
ELECTRICAL WIRING DIAGRAMS ..

IN-1
INTRODUCTION
Page
HOW TO USE THIS MANUAL ....................................... IN-2
IDENTIFICATION INFORMATION ................................... IN-4
GENERAL REPAIR INSTRUCTIONS ............................... IN-4 ~
PRECAUTIONS FOR VEHICLES EQUIPPED WITH ~
A CATALYTIC CONVERTER ...................................... IN-7
VEHICLE LIFT
AND SUPPORT LOCATIONS ................. IN-8
ABBREVIATIONS USED IN THIS MANUAL................... IN-9

IN-2 INTRODUCTION -
How to Use This Manual
260 (19, 25)
750 (54, 74)
Propeller Shaft
I
I
I
L..---
HOW TO USE THIS MANUAL
To assist in finding your way through the manual, the Secti
Title and major heading are given at the top of every page.
An INDEX is provided on the first page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given that
pertain to all repair operations contained in that section. Read
these precautions before starting any repair task.
TROUBLESHOOTING tables are fncluded for each system to help
you diagnose the system problem and find the cause. The repair
for each possible cause is referenced in the remedy column to
quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit together.
Example:
-- ..,
I
_--1
I
I
I
):)@
~9&~
L..--- I
l))~~-:
Bearing Cap I
Lock
I Front Bearing
Oil Slinger
+Oil Seal
Companion Flange
• Nut and Washer
Ikg-cm (ft-Ib, N·m) I :Tightening torque
+ :Non-reusable part
RAOl88

INTRODUCTION - How to Use This Manual
IN-3
Photograph or illustration:
what to do and where
The procedures are presented in a step-by-step format:
• The photo or illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives other
information such as specifications and warnings.
Example:
/ Task heading: what to do
INSTALL DRIVE SHAFT ON CENTER SUPPORT
BEARING FLANGE
(a) Align the marks on the flanges and connect the flanges with
four bolts and nuts.~
(b) Torque the bolts and nuts. ________
Torque: 750 kg-em (54 ft-Ib, 74 N.m) Detail text:
~howtOdOit
Specification
This format enables the experienced technician to have a FAST
TRACK. He can read the task headings and only refer to the
detailed text when he needs it. Important specifications and
warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text
in the applicable step. You never have to leave the procedure
to look up your specs. All specifications are also found in Ap-
pendix A, specifications for quick reference.
WARNINGS, CAUTIONS, NOTES:
• WARNINGS are presented in bold type, and indicate there is
a
possibility of injury to you or other pepole.
• CAUTIONS are also presented in bold type, and indicate the
possibility of damage to the components being repaired.
• NOTES are separated from the text but do not appear in bold.
They provide additional information to help you efficiently per-
form the repair.

IN-4 INTRODUCTION - Identification Information, General Repair Instructions
INOOOB
IN0007
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on top of the in-
strument panel.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS
1. Use fender seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate re-
assembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
such.
(e) Install
the cable terminal to the battery post with the
nut loose, and tighten the nut after installation.
Do not use a hammer or such to tap the terminal on-
to the post.
(f) Be sure the cover for the positive (+) terminal is pro-
perly in place.
4. Check hose and wiring connectors to make sure that thr
are secure and correct.

INTRODUCTION - General Repair Instructions
IN-5
5. Non-reusable Parts
(a) Always replace cotter pins, gaskets, a-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the symbol ".".
6. Precoated Parts
Precoated parts are the bolts, nuts, etc. which are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is tightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.
Seal Lock Adhesive (b) Recoating of Precoated Parts
84460
(1) Clean off the old adhesive from the bolt, nut or
installation part threads.
(2) Dry with compressed air.
(3)
Apply the specified seal lock adhesive to the bolt
or nut threads.
(c) Precoated parts are indicated in the component illus-
trations by the symbol "*".
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench.
9. Use of special service tools (SST) and special service
materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse is the correct
amperage rating. DO NOT exceed the fuse amp rating or
use one of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the proper
locations. (See page IN-8)
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to en-
sure safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on the vehicle raised on jack alone, even for a small
job that can be finished quickly.

IN-6 INTRODUCTION -General Repair
Instructions
I N0002
12. Observe the following precautions to avoid damage to the
parts:
(a) To disconnect vacuum hoses, pull on the end, not ~
middle of the hose.
(b) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(c) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
(d)
When steam cleaning an engine, protect the distribu-
tor, coil, air filter, carburetor intake, air pump and VCV
from water.
(e) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(f) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(g) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched,
it may leak.
13. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
(b) After completing a job, double check that the vac
um hoses are properly connected. A label under the
hood shows the proper layout.

INTRODUCTION - Precautions for Vehicles Equipped with A Catalytic Converter IN-7
PRECAUTIONS FOR VEHICLES EQUIPPED
WITH A CATALYTIC CONVERTER
WARNING: If large amounts of unburned gasoline flow into
the converter, it may overheat and create a fire hazard. To pre-
vent this, observe the following precautions and explain them
to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than
10 minutes and at idle speed for more than 20 minutes.
3. Avoid spark jump test.
(a) Spark jump test only when absolutely necessary. Per-
form this test as rapidly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.
Engine compression tests must be made as rapidly as
possible.
5. Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra
load on the converter.
6. Avoid coasting with ignition turned off and prolonged
braking.
7. Do not dispose of used catalyst along with parts con-
taminated with gasoline or oil.

IN-8
[4WD]
[2WD]
INTRODUCTION - Vehicle Lift and Support Locations
VEHICLE LIFT AND SUPPORT LOCATIONS
JACK POSITION ........................ @
Front .... . . .. [2WD] Center of crossmember
[4WD] Center of front axle housing
Rear ........ Center of rear axle housing
SUPPORT POSITION
Safety stand ....................... ~
INOOll
INOO12

INTRODUCTION - Abbreviations Used in This Manual
IN-9
ABBREVIATIONS USED IN THIS MANUAL
AAP
A/C
AI
APPROX.
AS
AIT, ATM
ATF
BTDC
BVSV
CALIF.
CB
C&C
CMH
DP
EACV
ECU
EFI
EGR
ESA
EVAP
EX
Ex.
FED.
HAC
HAl
IN
IG
LH
MAS
MC
MP
MIT, MTM
OC
00
OPT
OIS
PCV
PS
RH
SC
SSM
SST
STD
S/W
TCCS
TDC
TWC
UIS
VCS
VCV
VSV
VTV
2WD
4WD
Short
Long
wi
wlo
Auxiliary Acceleration Pump
Air Conditioner
Air Injection
Approximate
Air Suction
Automatic Transmission
Automatic Transmission Fluid
Before Top Dead Center
Bi-metal Vacuum Switching Valve
Vehicles Sold in California
Choke Breaker
Cab and Chassis
Cold Mixture Heater
Dash Pot
Electronic Air Control Valve
Electronic Control Unit
Electronic Fuel Injection
Exhaust Gas Recirculaion
Electronic Spark Advance
Evaporative (Emission Control)
Exhaust (manifold, valve)
Except
Vehicles Sold in USA except California
High Altitude Compensation
Hot Air Intake
Intake (manifold, valve), Inch
Ignition
Left-hand
Mixture Adjusting Screw
Mixture Control
Multipurpose
Manual Transmission
Oxidation Catalyst
Overdrive
Option
Oversized
Positive Crankcase Ventilation
Power Steering
Right-hand
Spark Control
Special Service Materials
Special Service Tools
Standard
Switch
Toyota Computer Control System
Top Dead Center
Three Way Catalyst
Undersized
Vacuum Control Switch
Vacuum Control Valve
Vacuum Switching Valve
Vacuum Transmitting Valve
Two Wheel Drive Vehicles (4x2)
Four Wheel Drive Vehicles (4x4)
Short wheel base
Long wheel base
With
Without

MA-1
MAINTENANCE
Page
MAINTENANCE SCHEDULE.................................. MA-2
MAINTENANCE OPERATIONS .............................. MA-4
GENERAL MAINTENANCE.................................... MA-18
GENERAL NOTES:
• Every service item in the periodic maintenance list must be
performed.
• Failure to do even one item can cause the engine to run
poorly and increase exhaust emissions.

MA-2
MAINTENANCE - Maintenance Schedule
MAINTENANCE SCHEDULE
Maintenance operations: A = Check and/or adjust if necessary;
R = Replace, change or lubricate;
= Inspect and correct or replace if necessary
NORMAL CONDITION SCHEDULE
I~ervice interval
Maintenance services beyond 60,000 miles
(Odometer reading or months,
(96,000 km) should be performed at the same
System
whichever comes first)
intervals shown in each maintenance schedule. See page
Miles x 1,000
10 15
20
30 40 45 50 60
(item No.)
Maintenance items
\
Km x 1,000
16 24 32
48 64
72
80
96
Months
12 18 24
36 48
54
60
72
ENGINE
Valve clearance * A A
MA-7 (item 13)
Drive belts (1)
I I MA-4 (item 1)
Engine oil and oil filter*
R R R R R R
MA-5 (item 6)
Engine
coolant (2)
R
MA-5 (item 7)
Exhaust pipes and mountings
I I
MA-7 (item
11 )
FUEL Idle speed 22R-E
engine (3)
A A A MA-8 (item 14
Idle speed and fast idle speed
22R engine (4)
A
MA-8 (item 14)
MA-9 (item 15)
Air filter*
R R
MA-5 (item 5)
Fuel lines
and connections
I I
MA-7 (item 10)
Fuel filler cap gasket
R MA-7 (item 9)
IGNITION
Spark plugs* * R R
MA-4 (item 2)
EVAP
Charcoal canister
\ Calif. only
I MA-6 (item 8)
EXHAUST
Oxygen sensor* (5)
IFed. 22R-E engine only
R MA-7 (item 17'
BRAKES
Brake linings and drums
I I I I
MA-11 (item 1.,
Brake pads and discs
I I I I
MA-11 (item 18)
Brake line pipes and hoses
I I I I
MA-11 (item 16)
CHASSIS
Steering linkage
I I I I
MA-11 (item 19)
Ball joints and dust covers (RN 2WD)
I I I I
MA-12 (item 21)
Automatic transmission (6), manual transmission,
MA-12 (item 20)
transfer (RN 4WD). differential and steering
I I I I
MA-12 (item 22)
gear box (6) oil
MA-13 (item 23)
Front wheel bearing grease
R R
MA-14 (item 26)
Steering knuckle and chassis grease (RN 4WD)
R R R R
MA-14 (item 27)
Propeller shaft grease (RN 4WD) (7)
R R R R
MA-14 (item 27)
Bolts and nuts on chassis and body
I I I I
MA-16 (item 28)
Maintenance services indicated by a star (*) or asterisk (*) are required under the terms of the Emission Control Sys-
tems Warranty. See Owner's Guide for complete warranty information.
* For vehicles sold in California
* For vehicles sold outside California
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(3) After 30,000 miles (48,000 km) or 36 months, adjust every 30,000 miles (48,000 km) or 36 months.
(4) Adjustment at 30,000 miles (48,000 km) or 36 months only
(5) Replace at 60,000 miles (96,000 km) or 72 months only.
(6) Inspect the automatic transmission and steering gear box for oil leakage only.
(7) If the propeller shaft has been immersed in water, it should be re-greased within 24 hours.

MAINTENANCE - Maintenance Schedule
MA-3
Follow the severe condition schedule if vehicle is operated mainly under one or more of the following severe conditions:
• Pulling a trailer
• Repeated short trips
• Driving on rough and/or muddy roads
• D riving on dusty roads
• Driving in extremely cold weather and/or on salted roads
SEVERE CONDITION SCHEDULE
Service interval
Maintenance services beyond 60,000 miles (96,000 km) should be
(Odometer reading or months,
performed at the same intervals shown in each maintenance schedule.
System
whichever comes first I
Miles x 1,000
5
7.5 10
15 20
22.5 25 30
35 37.5 40 45
50
52.5
55 60 See page
\
Kmx1,OOO
8
12
16 24
32 36 40 48
56
60
64
72 80
84 88
96
(item No.)
Maintenance items
Months
6 9 12 18
24
27
30
36
42
45
48
54 60 63 66 72
ENGINE Valve clearance * A A
MA-7 (item 13)
Drive belts III
I I
MA-4 (item 1)
Engine oil
and oil filter * R R R R R R R R R R R R
MA-5 (item 6)
Engine coolant 121
R
MA-5 (item 7)
Exhaust pipes and mountings
I I I I
MA-7 (item 11)
FUEL Idle
speed
22R-E engine 131
A A A
MA-8 (item 14)
Idle speed and
22R engine (4)
A
MA-8 (item 14)
fast idle speed
MA-S (item 15)
Air filter * 191
I I I I I R I I I I I R
MA-5 (item 4, 5)
Fuel lines and connections
I I
MA- 7 (item 10)
Fuel filler cap gasket
R
MA-7 (item 9)
IGNITION Spark plugs * ..
R R
MA-4 (item 2)
Ignition wiring and distributor cap * .. (5)
MA-5 (item 3)
EVAP
Charcoal canister
I Calif. only
I
MA-6 (item 8)
EXHAUST Oxygen sensor*161 IFed. 22R-E engine only
R
MA-7 (item 12)
\KES Brake linings and drums
I I I I I I I I MA-l1 (item 17)
Brake pads and discs I I I I I I I I
MA-l1 (item 18)
Brake line pipes and hoses
I I I I MA-11 (item 1 6)
CHASSIS
Steering linkage 1101
I I I I I I I I MA-l1 (item 19)
Ball joints and dust covers (RN 2WD)
I I I I I I I I MA-12 (item 21)
Automatic transmisslon17l, manual transmission,
MA-12 (item 20)
transfer (RN 4WD), differential and steering R R R R
MA-13 (item 24)
gear box 171 oil
MA-14 (item 25)
Front wheel bearing grease
R R MA-14 (item 26)
Steering knuckle and chassis grease (RN 4WD)
R R R R R R R R
MA-14 (item 27)
Propeller shaft grease (RN 4WD)(SI R R R R R R R R
MA-14 (item 27)
Bolts and nuts on chassis and body (101
I I I I I I I I MA-16 (item 28)
Maintenance services indicated by a star (*) or asterisk (* ) are required under the terms of the Emission Control Sys-
tems Warranty. See Owner's Guide for complete warranty information.
* For vehicles sold in California
*
NOTE:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
))
For vehicles sold outside California
After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
After 30,000 miles (48,000 km) or 36 months, adjust every 30,000 miles (48,000 km) or 36 months.
Adjustment at 30,000 miles (48,000 km) or 36 months only.
In areas where road salt is used, inspect and clean each year just after the snow season.
Replace at 60,000 miles (96,000 km) or 72 months only
Inspect the automatic transmission and steering gear box for oil leakage only.
If the propeller shaft has been immersed in water, it should be re-greased within 24 hours.
Applicable when operating mainly on dusty roads. If not, follow the normal condition schedule.
Applicable when operating mainly on rough and/or muddy roads. If not, follow the normal condition schedule.

MA-4
CORRECT
n ?Nippondenso
Lfi
MAINTENANCE - Maintenance Operations
WRONG
MA0035
Borroughs
EC0003 EC0004 ECOOOl
MA0038
IG0004
MAINTENANCE OPERATIONS
ENGINE
Cold Engine
Operations
1. INSPECT DRIVE BELTS
(a) Visually check the drive belt for cracks, oiliness or
wear. Check that the belt does not touch the bottom
of the pulley groove.
If necessary, replace the drive belt.
(b) Using a belt tension gauge, check the drive belt
tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020) or
Borroughs No.BT -33-73F
Drive belt tension: Used belt 80 ± 20 Ib
New belt 1 25 ± 25 Ib
If necessary, adjust the drive belt tension.
2. REPLACE SPARK PLUGS
(a) Disconnect the spark plug wires at the boot.
DO NOT pull on the wires.
(b) Remove the spark plugs.
(c) Set the gap on the new plugs.
Gap: 0.8 mm (0.031 in.)
Recommended spark plugs:
NO W16EXR-U
NGK BPR5EY

- ~------- --------
MAINTENANCE - Maintenance Operations
MA-5
22R Engine 22R-E Engine
Front Back
MA0060 MA0061
Drain Cock
MA0039
3. INSPECT IGNITION WIRING AND DISTRIBUTOR CAP
(a) Remove the distributor cap with the wire.
(b) Clean the distributor cap and wires with a clean cloth.
(c) Visually inspect the wiring for cracks or damage.
(d) Visually inspect the cap for cracks, carbon tracks or
wear.
NOTE: In areas where road salt is used, inspection and
cleaning
should be performed each year just after the snow
season.
4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not ex-
cessively dirty, damaged or oily.
NOTE: Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from inside (or back side) thoroughly, then blow
off the outside (or front side) of the element.
5. REPLACE AIR FILTER
Replace the used air cleaner element with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
(See page LU-3)
Oil grade: API grade SF or SF/CC multigrade, fuel-efficient
and recommended viscosity oil.
Engine oil capacity (Drain and refill with oil filter
change): 4.6 liters (4.9 US qts, 4.0 Imp. qts)
7. REPLACE ENGINE COOLANT
(a) Drain the coolant from the radiator and engine drain
cocks. (Engine drain is at left rear of engine block.)
(b) Close the drain cocks.
(c) Fill system with coolant.
Coolant capacity (w/heater or air conditioner):
8.4 liters (8.9 US qts, 7.4 Imp. qts)
Use a good brand of ethylene-glycol base coolant, mixed
according to the manufacturers instruction.

MA-6 MAINTENANCE
Maintenance Operations
8. CALIFORNIA VEHICLES ONLY:
For Fuel Tank B
...
lC
Air should flow through freely and no
charcoal should come out. MA0042
For Fuel Tank
C.J
Air should flow through freely and no
charcoal should come out.
For Carburetor
lC
Air should flow through freely and no
charcoal should come out.
ECl121
MA0043
INSPECT CHARCOAL CANISTER
A. 22R-E ENGINE
(a) Disconnect the hoses to the charcoal canister.
Label hoses for correct installation.
(b) Plug pipe A with your finger and blow compressed air
(3 kg/cm2, 43 psi or 294 kPa) through pipe B (fuel
tank side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary, replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(c) Connect the hoses to the charcoal canister.
B. 22R ENGINE
(a) Inspect the fuel tank and carburetor charcoal
canisters.
For Fuel Tank
(b)
(c)
Disconnect the hoses to the fuel tank charcoal
canister. Label hoses for correct installation.
Plug pipe A with your finger and blow compressed air
(3 kg/cm2, 43 psi or 294 kPa) through pipe 8 (fuel
tank side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary, replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(d) Connect the hoses to the charcoal canister.
For Carburetor
(e)
Disconnect the hoses to the carburetor charcoal
canister located below the battery. Label hoses for
correct installation.
(f) Plug pipe A with your finger and blow compressed air
(3 kg/cm2, 43 psi or 294 kPa) through pipe B (Outer
vent control valve side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary I replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(g) Connect the hoses to the charcoal canister.

-r-
MAINTENANCE - Maintenance Operations
MA-7
MA0298
MA0309
MA0306
9. REPLACE GASKET IN FUEL FILLER CAP
(a) Remove the old gasket (O-ring) from the fuel filler cap.
Do not damage the cap.
(b) Install the new gasket by hand.
(c) Inspect the cap for damage or cracks.
(d) Install the cap and check the torque limiter.
10. INSPECT FUEL LINES AND CONNECTIONS
(22R Engine: See page FU-30)
(22R-E Engine: See page FI-53)
Visually inspect the fuel lines for cracks, leakage or loose
connections.
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually inspect the pipes, hangers and connections for
severe corrosion, leaks or damage.
12. FEDERAL 22R-E ENGINE ONLY:
REPLACE OXYGEN SENSOR
(a) Disconnect the oxygen sensor wiring connector.
(b) Remove the oxygen sensor and gasket from the ex-
haust manifold.
(c) Install the new gasket and oxygen sensor to the ex-
haust manifold.
Torque: 200 kg-cm (14 ft-Ib, 20 N·m)
(d) Inspect oxygen sensor operation.
Inspect feed back control.
(See page FI-69)
Hot Engine Operations
13. ADJUST VALVE CLEARANCE
(a) Warm up the engine to normal operating temperature.
(b) Stop the engine and remove the valve cover.
(c) Set No. 1 cylinder to TOe/compression.
• Turn the crankshaft with a wrench to align the tim-
ing marks at TOC. Set the groove on the pulley to
the 0 position.
• Check that the rocker arms on No. 1 cylinder are
loose and rockers on No. 4 are tight.
If not, turn the crankshaft one complete revolution and align
marks as above.

MA-8
First
Tachometer
MAINTENANCE - Maintenance Operations
MA0046
MA0047
MA0046
MA0307
(d) Adjust the clearance of half of the valves.
• Adjust only those valves indicated by arrows.
Valve clearance: Intake 0.20 mm (0.008 in.)
Exhaust 0.30 mm (O.012 in.)
• Use a feeler gauge to measure between the valve
stem and rocker arm. Loosen the lock nut and turn
the adjusting screw to set the proper clearance.
Hold the adjusting screw in position, and tighten
the lock nut.
• Recheck the clearance. The feeler gauge should
move with a very slight drag.
(e) Turn the crankshaft one complete revolution (360°)
and align timing marks in the manner mentioned
above. Adjust only the valves indicated by arrows.
(f) Reinstall the valve cover.
(g) Reinstall the air cleaner (22R engine).
14. ADJUST IDLE SPEED
A. 22R-E ENGINE
(a) Preparation
• Air cleaner installed
• All pipes and hoses of air intake system connected
• All vacuum lines connected (i. e., SC, EGR systems,
etc.)
• EFI system wiring connectors fully plugged
• Engine at normal operating temperature
• Accessories switched off
• Transmission in N range
(b)
Connect a tachometer to the engine.
Connect the tachometer positive (+ ) terminal to the
ignition coil negative (-) terminal.
CAUTION:
1. NEVER allow the tachometer terminal to touch ground
as it could result in damage to the igniter and/or ig'
tion coil.
2. As some tachometers are not compatible with this ig-
nition system, it is recommended that you consult
with the manufacturer.

Rubber Cap
For HAl System
MAINTENANCE - Maintenance Operations
MA-9
~MA0010
Ignition Coil
MA0308
MA0310
(c) Race the engine at 2,500 rpm for about 2 minutes.
(d) Set the idle speed by turning the IDLE SPEED ADJUST-
ING SCREW.
Idle speed: 750 rpm
(e) Remove the tachometer.
B. 22R ENGINE
(a) Preparation
• Air cleaner installed
• Choke valve fully open
• Accessories switched off
• All vacuum lines connected (i.e., AS, EGR systems,
etc.)
• Transmission in N range
• Engine idling at normal operating temperature
(b) Connect a tachometer to the engine.
Remove the rubber cap and connect the tachometer
positive (+) terminal to the service connector at the
igniter.
CAUTION:
1. NEVER allow the tachometer terminal to touch ground
as it could result in damage to the igniter and/or igni-
tion coil.
2. As some tachometers are not compatible with this ig-
nition system, it is recommended that you consult
with the manufacturer.
(c) Set the idle speed by turning the IDLE SPEED ADJUST-
ING SCREW.
Idle speed: 700 rpm M/T
750 rpm AfT
NOTE: Leave the tachometer connected for further ad-
justment.
15. 22R ENGINE ONLY:
ADJUST FAST IDLE SPEED
(a)
Stop the engine and remove the air cleaner.
(b) Plug
the hose connections for HAl system and MC
system (w/M/T only) to prevent rough idling.

MA-10
MAINTENANCE - Maintenance Operations
Choke Opener Diaphragm
~ ,
Disconnect ~ i
~0
22R (ex. Calif.)
22R (Calif.)
MA0311 MA0312
(c) Disconnect the hose from the choke opener diaphragm
and plug the hose end.
This will shut off the choke opener system.
(d) Disconnect the hose from the EGR valve.
This will shut off the EGR system.
(e) Set the fast idle cam.
While holding the throttle valve slightly open, push
the choke valve closed, and hold it closed as you
release the throttle valve.
(f) Start the engine, but do NOT touch the accelerat,-_
pedal.
(g) Set the fast idle speed by turning the fast idle adjust-
ing screw.
Fast idle speed: 2,600 rpm
(h) Reconnect the vacuum hoses to the proper locations.
(i) Reinstall the air cleaner.
(j) Stop the engine and remove the tachometer.