Toyota VZN150 series User manual

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FOREWORD
This manual contains maintenance and repair procedures for
the 1996 TOYOTA TACOMA.
Applicable models:
RZN140,
150, 161, 171 series
VZN
150, 160, 170 series
The manual is divided
into 21 sections with a thumb index for
each section at the edge of the pages.
Please note that the publications below have also been
prepared
as relevant service manuals for the components and
systems in this vehicle.
Manual Name Pub. No.
•
A43D Automatic Transmission Repair
RM387U
Manual (Nov. 1993)
• A340E, A340F, A340H Automatic
RM391 U
Transmission Repair Manual (Nov.
1993)
• A340F, A343F Automatic Transmission
RM479U
Repair Manual (Sep. 1995)
• 1996 Toyota Tacoma Electrical Wiring
EWD246U
Diagram
•
1996 Model TOYOTA New Car Features NCF120U
All
information in this manual is based on the latest product in-
formation at the time of publication. However, specifications
and procedures are subject
to change without notice.
TOYOTA MOTOR CORPORATION
©2000 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First
Printing: Jul. 14, 1995 01-950714-00
Sixth Printing: Feb. 28, 2000 06-000228-01-2

CAUTION
This manual does not include all the necessary items about repair and service. this manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non-specialized or uncertifiedtechnicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer's vehicle.
In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow
the instruction shown below.
• Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of "IN" section.
•
• The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non-specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer's vehicle before starting the operation.
•
If part replacement is necessary, must replace the part with the same partnumber or equivalent
part. Do not replace it with inferior quality.
•It is important to note that this manual contains various "Cautions" and "Notices" that must be •
carefully
observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improperservice or repair may damage the vehicle or render it unsafe. It is also
important to understand that these "Cautions" and "Notices" are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
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INTRODUCTION
MAINTENANCE
2RZ-FE, 3RZ-FE ENGINE
5VZ-FE ENGINE
IGNITION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
CLUTCH
W59 MANUAL TRANSMISSION
R150, R150F
MANUAL TRANSMISSION
A43D AUTOMATIC TRANSMISSION
A340E, A340F AUTOMATIC TRANSMISSION
TRANSFER
PROPELLER SHAFT
SUSPENSION AND AXLE
BRAKE SYSTEM
STEERING
SUPPLEMENTAL RESTRAINT SYSTEM
BODY ELECTRICAL SYSTEM
BODY
AIR CONDITIONING SYSTEM

J .......... ----------.
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IN-1
INTRODUCTION
HOW TO USE THIS MANUAL IN -2
IDENTIFICATION INFORMATION IN- 4
GENERAL REPAIR INSTRUCTIONS IN- 5
PRECAUTION
IN -8
HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEM IN- 13
VEHICLE LIFT AND SUPPORT
LOCATIONS
IN- 30
ABBREVIATIONS USED IN THIS
MANUAL IN - 31
GLOSSARY OF SAE AND TOYOTA
TERMS
IN- 33
STANDARD BOLT TORQUE
SPECIFICATIONS
IN- 36

GENERAL DESCRIPTION
INOlO-01
HOW TO USE THIS MANUAL
INDEX •
INOZE-01
INTRODUCTION -HOW TO USE THIS MANUAL
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist you in finding your
way through the manual, the Section Title and major heading are
given at the
top of every page.
IN-2
At the beginning of each section, ageneral Description is given that pertains to all repair
operations contained
in that section.
Read these precautions before starting any repair task.
_-00
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause. The fundamentals
of how to proceed with troubleshooting are described on page
IN -13. Be sure to read this before performing troubleshooting.
tNOaJ-01
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and
SSM (Special Service Materials)
which should be prepared before beginning the operation and
explains the purpose
of each one.
REPAIR PROCEDURES
Most repair operations.begin with an overview illustration. It identifies the components and •
shows
how the parts fit together.
Example:
•
Nl1306
Clevis Pin
.G .....lClip
t) Cl,v',
ILock Nut
Snap Ring
Washer
Push Rod
Piston
-~
___ -"!U
~§~~----Reservoir Tank
Cylinder
®-------Filler Cap
~ Float
•Non-reusable part

INTRODUCTION -HOW TO USE THIS MANUAL
IN-3
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The procedures are presented in a step-by-step format:
•The 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:
This
format provides the experienced technician with aFAST TRACK to the information needed.
The upper case task heading can
be read at aglance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.
IN02L-01
REFERENCES
References have been kept to aminimum. However, when they are required you are given the
page
to refer to.
IN02.M-OI
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to
leave the procedure to look up your specifications. They are also found at the end of each section,
for quick reference.

SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International
System
of Unit). and alternately expressed in the metric system and in the English System.
Example:
Torque:
30 N·m (310 kgf·cm. 22 ft.lbf)
III02N-01
INOOI-OO
HIOII-01
The vehicle identification number is stamped on the •
vehicle identification number plate and certification
label.
A. Vehicle Identification Number Plate
B. Certification Label
The engine serial number is stamped on the engine
block
as shown.
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
INTRODUCTION -IDENTIFICATION INFORMATION
IWOI'-OI
CAUTIONS are presented in bold type. and indicate there is apossibility of injury to you or •
other people.
NOTICES are also presented in bold type. and indicate the possibility
of damage to the
components being repaired.
HINTS are separated from the
text but do not appear in bold. They provide additional
information
to help you perform the repair efficiently.
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2RZ-FE, 3RZ-FE Engi-ne :
CAUTIONS, NOTICES, HINTS:
IN-4
5VZ-FE
Engine:
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N14492

INTRODUCTION -GENERAL REPAIR INSTRUCTIONS
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•IN0036 Seal Lock Adhesive
FI1066
Zll554
IN-5
GENERAL REPAIR INSTRUCTIONS
IN059-01
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in the appropriate
order
to facilitate reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect
the negative
(-) terminal cable from the battery.
(b) If it is necessary to disconnect the battery for
inspection or repair, always disconnect the nega-
tive
(-) terminal cable which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal,
loosen the cable
nut and raise the cable straight
up without twisting or prying it.
(d) Clean the battery terminals and cable ends with a
clean shop rag. Do
not scrape them with afile or
other abrasive objects.
(e) Install the cable ends to the battery terminals
with the nut loose, and tighten the nut after
installation. Do not use ahammer to tap the cable
ends
onto the terminals.
(f)
Be sure the cover for the positive (+) terminal is
properly in place.
4. Check hose and wiring connectors
to make sure that
they are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and
oil seals etc.
with new ones.
(b) Non-reusable parts are indicated in the compo-
nent illustrations by the
••• symbol.
6. Precoated parts
Precoated parts are bolts and nuts, etc.
that are
coated
with aseal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated
with the specified adhesive.

IN-6 INTRODUCTION -GENERAL
REPAIR INSTRUCTIONS
(b) When reusing precoated parts, clean off the old
adhesive and
dry with compressed air. Then
apply the specified seal lock adhesive
to the bolt, •
nut or threads.
(c) Precoated parts are indicated in the component
illustrations
by the -*- symbol.
7. When necessary, use asealer on gaskets to prevent
leaks.
8. Carefully observe all specifications
for bolt tightening
torques. Always use atorque 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 specified and
follow the proper work proce-
dure. Alist
of SST and SSM can be found in the
preparation part
at the front of each section in this
manual.
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
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BE1367
10. When replacing fuses, be sure the new fuse has the
correct amperage rating.
DO NOT exceed the rating or
use one with a lower rating. •
Illustration Symbol Part Name
Abbreviation
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FUSE FUSE
0,<>;
BE5694 IN0366
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MEDIUM CURRENT FUSE M-FUSE
BE6696 IN0366
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HIGH CURRENT FUSE H-FUSE
BE6696 IN0367
/
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FUSIBLE LINK
FL
BE6697 IN0367
~
-+=4- .. .-
CIRCUIT BREAKER
CB
BE5598
VWJ76
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