Toyota 22R-E User manual

INTRODUCTION
–INTRODUCTION IN–1

HOW TO USE THIS MANUAL
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist you in finding your way through the manual, the Section Title and major heading are
given at the top of every page.
GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair
operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause.
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:
–INTRODUCTION HOW TO USE THIS MANUAL
IN–2

The procedures are presented in a step–by–step format:
Example:
•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.
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.
This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. 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 refer to.
–INTRODUCTION HOW TO USE THIS MANUAL IN–3

CAUTIONS, NOTICES, HINTS:
•CAUTIONS are presented in bold type, and indicate there is a possibility 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.
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the
vehicle identification number plate and certification
label.
A. Vehicle Identification Number Plate
B. Certification Label
The UNITS given in this manual are primarily expressed according to the SI UNIT(Internationai
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)
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine
block as shown.
SI UNIT
–INTRODUCTION IDENTIFICATION INFORMATION
IN–4

GENERAL REPAIR INSTRUCTIONS
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 cable from the battery terminal.
(b) If it is necessary to disconnect the battery for
inspection or repair, always disconnect the cable
from the negative (–) terminal which is grounded
to the vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable str–
aight up without twisting or prying it.
(d) Cleah the battery terminal posts and cable ter–
minals with a clean shop rag. Do not scrape them
with a file or other abrasive objects.
(e) Install the cable terminal to the battery post with
the nut loose, and tighten the nut after installa–
tion. Do not use a hammer to tap the terminal
onto the post.
(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, 0– rings and
oil seals etc. with new ones.
(b) Non–reusable parts are indicated in the com–
ponent illustrations by the“♦” symbol.
6. Precoated parts
Precoated parts are bolts and nuts, etc. that are
coated with a seal 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.
–INTRODUCTION GENERAL REPAIR INSTRUCTIONS IN–5

(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 a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. 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 specified and follow the proper work proce–
dure. A list of SST and SSM can be found in the
preparation part at the front of each section in this
manual.
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.
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
CIRCUIT BREAKER
FUSIBLE L!1VK
Abbreviation
Illustration Part Name
Symbol
M–FUSE
H–FUSE
FUSE
FUSE
–INTRODUCTION GENERAL REPAIR INSTRUCTIONS
IN–6

(b) To disconnect vacuum hoses, pull on the end, not
the middle of the hose.
(c) To pull apart electrical connectors, pull on the
connector itself, not the wires.
(d) 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.
(e) When steam cleaning an engine, protect the
distributor, air filter, and VCV from water.
(f) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(g) When checking continuity at the wire connector,
insert the tester probe carefully to prevent ter–
minals from bending.
(h) 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.
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–9).
(a) If the vehicle is to be jacked up only at the front
or rear end, be sure to block the wheels at the
opposite end in order to ensure safety.
(6) After the vehicle is jacked up, be sure to support
it on stands. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
12. Observe the following precautions to avoid damage to
the parts:
(a) Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the
IC terminals are touched, the IC may be destr–
oyed by static electricity.)
13. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(b) After completing a job, double check that the
vacuum hoses are properly connected. A label
under the hood shows the proper layout.
–INTRODUCTION GENERAL REPAIR INSTRUCTIONS IN–7

PRECAUTION
FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create
a fire hazard. To prevent 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 idle speed for more than 20 minutes.
3. Avoid spark jump test.
(a) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.
Engine compression tests must be done 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 contaminated with gasoline or oil.
IN=–01
FOR VEHICLES WITH AN AUDIO SYSTEM
WITH BUILT–IN ANTI–THEFT SYSTEM
Audio System displaying the sign ”ANTI –THEFT
SYSTEM” shown on the left has a built–in anti–theft
system which makes the audio system soundless if
stolen.
If the power source for the audio system is cut even
once, the anti–theft system operates so that even if
the power source is reconnected, the audio system
will not produce any sound unless the ID number
selected by the customer is input again. Accordingly,
when performing repairs on vehicles equipped with
this system, before disconnecting the battery termi–
nals or removing the audio system the customer
should be asked for the ID number so that the tech–
nician can input the ID number afterwards, or else a
request made to the customer to input the ID number.
For the method to input the ID number or cancel the
anti–theft system, refer to the Owner’s Manual.
–INTRODUCTION PRECAUTION
IN–8

VEHICLE LIFT AND SUPPORT LOCATIONS
–INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS IN–9

ABBREVIATIONS USED IN THIS
MANUAL
Load Sensing Proportioning and By–Pass Valve
Vehicles Sold in USA except California
Automatic Disconnecting Differential
Load Sensing Proportioning Valve
Emergency Locking Retractor
Positive Crankcase Ventilation
Automatic Transmission Fluid
Automatic Locking Retractor
Progressive Power Steering
Exhaust (Manifold, Valve)
Special Service Materials
Electronic Spark Advance
Before Top Dead Center
Intake (Manifold, Valve)
Automatic Transmission
Formed in Place Gasket
Electronic Control Unit
Special Service Tools
Manual Transmission
Over Head Camshaft
Single Rear Wheel
Double Rear Wheel
Cab and Chassis
Power Steering
Junction Block
Circuit Breaker
Multipurpose
Right–Hand
Fusible Link
Left–Hand
LSP & BV
0/D, OD Overdrive
California
Maximum
Minimum
Dash Pot
Standard
Oversize
Ignition
Except
Switch
C&C
BTDC
LSPV
Front
Calif.
ADD
DRW
SRW
A/T
OHC
o/s
FIPG
J/6
M/T
Min.
Rear
PCV
ALR
SSM
Fed.
SST
Max.
ATF
PPS
STD
ELR
ESA
ECU
Ex.
–INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL
IN–10

Toyota Computer Controlled System
Two Wheel Drive Vehicles (4 x 2)
Four Wheel Drive Vehicles (4 x 4)
Vacuum Transmitting Valve
Vacuum Switching Valve
Vacuum Control Valve
Top Dead Center
Temperature
Transmission
Undersize
Without
TEMP.
4WD
TCCS
w/o
T/M
With
2WD
TDC
U/S
VCV
VSV
VTV
–INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL IN–11

GLOSSARY OF SAE AND TOYOTA TERMS
M076–03
This glossary lists all SAE–J 1930 terms and abbreviations used in this manual in compliance
with SAE recommendations, as well as their Toyota equivalents.
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
1: Check Connector
2: Toyota Diagnosis Communication Link (TDCL)
3: OBDII Diagnostic Connector
Electrically Erasable Programmable Read Only
Memory
Flash Electrically Erasable Programmable
Read Only Memory
Data Link Connector 1
Data Link Connector 2
Data Link Connector 3
Cold Mixture Heater (CMH), Heat Control Valve (HCV)
Coolant Temperature, Water Temperature (THW)
Flash Erasable Programmable Read Only Memory
TOYOTA TERMS
( )––ABBREVIATIONS
Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
Evaporative Emission Control (EVAP)
Engine ECU (Electronic Control Unit)
Toyota Distributable Ignition (TDI)
Exhaust Gas Recirculation (EGR)
Heated Oxygen Sensor (H02S)
Engine Coolant Temperature
Direct Fuel Injection (Diesel)
SAE ABBRE–
VIATIONS
Continuous Trap Oxidizer
Continuous Fuel Injection
Engine Modification (EM)
Diagnostic Trouble Code
Exhaust Gas Recirculation
Battery Positive Voltage
Secondary Air Injection
Heated Oxygen Sensor
Engine Control Module
Early Fuel Evaporation
Closed Throttle Position
Diagnostic Test Mode
Evaporative Emission
Engine Control Level
+ B, Battery Voltage
Direct Injection (DI)
Clutch Pedal Position
Engine Modification
Barometric Pressure
Distributor ignition
Crankshaft Position
Electronic Ignition
DLC1
DLC2
DLC3
Charge Air Cooler
Air Injection (AD
Camshaft Position
Accelerator Pedal
Diagnostic Code
Air Conditioning Air Conditioner
Ground (GND)
Closed Loop
Closed Loop Crank Angle
Flexible Fuel
SAE TERMS
Cam Angle
Fan Control
Fuel Pump
Air Cleaner
Fuel Pump
Air Cleaner
Intercooler
Carburetor
Carburetor
Alternator
FEEPROM
Generator
EEPROM
FEPROM
Ground
EPROM
CTOX
BARO
CARB
EVAP
H02S
CMP
A/C
GND
CKP
DTM
DTC
ECT
EGR
GEN
ECM
ACL
CAC
ECL
CPP
CT P
AIR
EFE
D F!
–INTRODUCTION GLOSSARY OF SAE AND TOYOTA TERMS
IN–12

Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
Diesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
Electronic Fuel Injection (EFI), Sequential Injection
Single Point Injection
Central Fuel Injection (Ci)
Transmission ECU (Electronic Control Unit)
Oxidation Catalyst Converter (OC), CCo
Non–Volatile Random Access Memory
Sequential Multiport Fuel Injection
Programmable Read Only Memory
Manifold Pressure
Intake Vacuum
Oxygen Sensor, O2Sensor (02S)
Random Access Memory (RAM)
Pulsed Secondary Air Injection
Intake or Inlet Air Temperature
Manifold Surface Temperature
Electronic Fuel Injection (EFI)
Oxidation Catalytic Converter
On–Board Diagnostic (OBD)
Throttle Body Fuel Injection
Manifold Differential Pressure
Transmission Control Module
Malfunction Indicator Lamp
Read Only Memory (ROM)
Powertrain Control Module
Service Reminder Indicator
Manifold Absolute Pressure
Torque Converter Clutch
Power Steering Pressure
Random Access Memory
Ignition Control Module
Multiport Fuel Injection
System Readiness Test
Idle Speed Control (ISC)
Intake Air Temperature
Periodic Trap Oxidizer
Park/Neutral Position
On–Board Diagnostic
Indirect Fuel Injection
Manifold Vacuum Zone
Supercharger Bypass
Transmission Range
Inertia Fuel–Shutoff
Read Only Memory
Check Engine Light
Idle Speed Control
Smoke Puff Limiter
Torque Converter
Indirect injection
Air Suction (AS)
Oxygen Sensor
Throttle Position Throttle Position
Mixture Control
Idle Air Control
Air Flow Meter
Engine Speed
Throttle Body
Relay Module
Turbocharger
Mass Air Flow
Throttle Body
Supercharger
Engine Speed
Turbocharger
Supercharger
Knock Sensor Knock Sensor
Open Loop Open Loop
Scan Tool
NVRAM
PROM
PTOX
M DP
PAIR
ROM
MAP
OBD
PCM
RPM
RAM
PNP
MAF
02S
MVZ
TCM
PSP
MST
SCB
SPL
MIL
ICM
M Ft
TCC
IAC
S RT
I AT
SRI
TBI
ISC
IFS
SFI
–INTRODUCTION GLOSSARY OF SAE AND TOYOTA TERMS IN–13

Bimetal Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
Three–Way Catalyst (TWC)
CCRO
Three–Way + Oxidation Catalytic Converter
Warm Up Three–Way Catalytic Converter
Vehicle Speed Sensor (Read Switch Type)
Warm Up Oxidation Catalytic Converter
Three–Way Catalytic Converter
Vehicle Speed Sensor
Thermal Vacuum Valve
Wide Open Throttle
Voltage Regulator Voltage Regulator
Manifold Converter
Volume Air Flow Air Flow Meter
Full Throttle
Fourth Gear
CCR+ CCo
Third Gear
WU–TWC
TWC+OC
WU –OC
wot
twc
TVV
VAF
3GR
4GR
VSS
–INTRODUCTION GLOSSARY OF SAE AND TOYOTA TERMS
IN–14

STANDARD BOLT TORQUE SPECIFICATIONS
4–
5–
6–
8–
9–
10–
11–
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
HOW TO DETERMINE BOLT STRENGTH
4T
5T
fiT
7T
8T
9T
10T
11T
Two
protruding
lines
Four
protruding
lines
Three
protruding
lines
Two
protruding
lines
Hexagon
head bolt
Hexagon
head bolt
Hexagon
head bolt
Hexagon
head bolt
Welded bolt
Stud bolt
No mark
No mark
Class
Class
Mark Mark
–INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS IN–15

SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Diameter
mm Pitch
mm
Class
1 OT
11T
–INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS
IN–16

MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. (3VZ–E ENGINE)
REPLACE TIMING BELT
(a) Remove the timing belt.
(See pages EG–32)
(b) Install the timing belt.
(See pages EG–41)
2. INSPECT DRIVE BELTS
(a) Visually check the belt for excessive wear, frayed
cords etc.
HINT:
Conventional type:
Check that the belt does not touch the bottom of the
pulley groove.
If necessary, replace the drive belt.
V–Ribbed type:
Cracks on the ribbed side of the belt are considered
acceptable.
If the belt has chunks missing from the ribs, it should
be replaced.
(b) Using a belt tension gauge, check the drive belt ten–
sion.
Belt tension gauge:
Nippondenso BTG – 20 (95506–00020) or
Borroughs No. BT–33–73F
Drive belt tension:
22R–E Used belt 80 ±20 lbf
New belt 125±25 lbf
3VZ – E
Generator Used belt 100 ±20 lbf
New belt 160 ±20 lbf
PS Used belt 80 ±20 lbf
New belt 125 ±25 lbf
A/C Used belt 80 20 lbf
New belt 125 ±25 lbf
If necessary, adjust the drive belt tension.
–MAINTENANCE MAINTENANCEOPERATIONS
MA–6

HINT:
•”New belt” refers to a belt which has been used
less than 5 minutes on a running engine.
•”Used belt” refers to a belt which has been used
on a running engine for 5 minutes or more.
•After replacing the drive belt, check that it fits
properly in the ribbed grooves, especially in the
places difficult to see.
•After installing a new belt, run the engine for
approx. 5 minutes and then recheck the tension.
3. REPLACE SPARK PLUGS
(a) Disconnect the high–tension cords at the boot.
Do not pull on the cords.
(b) (2213 – E)
Remove the spark plugs.
(3VZ – E)
Using plug wrench (16 mm), remove the spark plugs.
4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
HINT: Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from back side thoroughly, then blow off
the 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
22R – E (See page EG–236)
3VZ– E (See page EG–278)
Oil grade:
API grade SG Energy – Conserving II multigrade
and recommended viscosity oil
Engine oil capacity:
Drain and refill
(c) Check the electrode gap of new spark plugs.
Correct electrode gap:
0.8 mm (0.031 in.)
Recommended spark plugs:
22R–E ND W16EXR–U
NGK BPRSEY
3VZ–E ND K76R–U
NGK BKR5EYA
–MAINTENANCE MAINTENANCEOPERATIONS MA–7

7. REPLACE ENGINE COOLANT
(a) Drain the coolant from the radiator and engine drain
cocks.
(b) Close the drain cocks.
(c) Fill system with coolant.
Coolant capacity (w/ Heater or air conditioner):
22R–E
Ex. 4WD A/T 8.4 liters (8.8 US qts, 7.4 Imp. qts)
4WD A/T 9.1 liters 0.6 US qts, 8.0 Imp. qts)
3VZ–E
2WD M/T 10.4 liters (11.O US qts, 9.2 Imp. qts)
A/T 10.2 liters (10.8 US qts, 9.5 Imp. qts)
4WD M/T 10.5 liters (11.1 US qts, 9.2 Imp. qts)
A/T 10.3 liters (10.9 US qts, 9.1 Imp. qta)
HINT:
Use a good brand of ethylene–glycol base coo–
lant, mixed according to the manufacturer’s in–
structions.
Using coolant which has more than 50% ethyl–
ene–glycol (but not more than 70%) is recom–
mended.
NOTICE:
•Do not use an alcohol type coolant.
•The coolant should be mixed with demineralized
water or distilled water.
22 R – E
w/o Oil filter change
3.8 liters (4.0 US qts, 3.3 Imp. qts)
w/ Oil filter change
4.3 liters (4.5 US qts, 3.8 Imp. qts)
3VZ–E
w/o Oil filter change
2WD 4.0 liters (4.2 US qts, 3.5 Imp. qts)
4WD 4.2 liters (4.4 US qts, 3.7 Imp. qts)
w/ Oil filter change
2WD 4.3 liters (4.5 US qts, 3.8 Imp. qts)
4WD 4.5 liters (4.8 US qts, 4.0 Imp. qts)
–MAINTENANCE MAINTENANCEOPERATIONS
MA–8

9. REPLACE GASKET IN FUEL TANK CAP
(a) Remove the old gasket (0–ring) from the tank cap.
Do not damage the cap.
(b) Install a 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
Visually inspect the fuel lines for cracks, leakage loose
connections, deformation or tank band looseness.
(c) Check for clogged filter and stuck check valve.
(1) Using low compressed air (4.71 kPa (48 gf/cm2,
0.68 psi), blow into the tank pipe and check that
air flows without resistance from the other pipes.
(2) Blow air (4.71 kPa (48 gf/cm2, 0.68 psi) into the
purge pipe and check that air does not flow from
the other pipes.
If a problem is found, replace the charcoal canister.
(d) Clean filter in canister.
(1) Clean the filter by blowing 294kPa (3 kgf/cm2,43
psi) of compressed air into the tank pipe while
holding the purge pipe closed.
NOTICE:
•Do not attempt to wash the canister.
•No activated carbon should come out.
(e) Install charcoal canister.
8. INSPECT CHARCOAL CANISTER
(a) Remove charcoal canister.
HINT:Label hoses for correct installation.
(b) Visually inspect canister case.
–MAINTENANCE MAINTENANCEOPERATIONS MA–9