2005 Toyota 4Runner Service & Repair Manual

0108G−08 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non−reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) − INTRODUCTION HOW TO USE THIS MANUAL 01−1 1 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (b) Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection (c) This manual explains the ”Diagnosis” (found in the ”Diagnostics” section) and ”Removing and Instal- ling, Replacing, Disassembling, Installing and Checking, and Adjusting”. ”Final Inspection” is omitted. (d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair situation. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non−reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Example:

Illustration: what to do and where Component part No. Detailed text: how to perform task Task heading: what to do Set part No Illustration: what to do and where Component part No. Explanation test: how to perform task Task heading: what to do Set part No Illustration: what to do and where Component part No. Task heading: what to do Set part No. D26745 01−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) (c) Torque specifications, grease application areas, and non−reusable parts are emphasized in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. (e) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (f) Illustrations of similar vehicle models are sometimes used. In those cases, specific details may be dif- ferent from the actual vehicle. (g) Procedures are presented in a step−by−step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task. It also has information such as specifications and warnings. Example: HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task headings are easy to read and the text below the task heading provides detailed information. Important specifications and warnings are always written in bold type. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in bold−faced text throughout the manual. The specifications are also found in the Service Specifications section for quick reference. 6. TERMS DEFINITION CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to the components being repaired. HINT Provides additional information to help you perform repairs.

− INTRODUCTION HOW TO USE THIS MANUAL 01−3 3 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) 7. SI UNIT (a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

01044−24 01−24 − INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 24 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION A large number of ECU controlled systems are used in the 4RUNNER. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system’s circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. Detailed information and troubleshooting procedures on major ECU controlled systems in this vehicle are outlined below: System Page 1. SFI System (1GR−FE) 05−1 2. SFI System (2UZ−FE) 05−394 3. Tire Pressure Warning System 05−858 4. Rear Air Suspension System 05−919 5. ABS with EBD & BA & TRAC & VSC System 05−994 6. Electronically Controlled Automatic Transmission [ECT] ((A750E/A750F)(1GR−FE)) 05−1199 7. Electronically Controlled Automatic Transmission [ECT] ((A750E/A750F)(2UZ−FE)) 05−1352 8. Air Conditioning System 05−1501 9. Supplemental Restraint System 05−1597 10.Lighting System 05−1926 11.Wiper & Washer System 05−1968 12.Audio System 05−1988 13.Navigation System 05−2061 14.Back Monitor System 05−2202 15.Combination Meter 05−2213 16.Power Window Control System 05−2260 17.Back Door Power Window Control System 05−2287 18.Power Door Lock Control System 05−2307 19.Back Door Closer System 05−2332 20.Wireless Door Lock Control System 05−2349 21.Key Reminder Warning System 05−2373 22.Engine Immobilizer System 05−2387 23.Theft Deterrent System 05−2414 24.Multiplex Communication System 05−2435 25.Can Communication System 05−2456 26.Cruise Control System 05−2514

− INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01−25 25 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) FOR USING OBD II SCAN TOOL OR HAND−HELD TESTER S Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly. S If the scan tool or tester cannot communicate with the ECU controlled systems when you have connected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a problem on the vehicle side or tester side. (1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Busęline) or ECU power circuit of the vehicle. (2) If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. So perform the Self Test procedures outlined in the Tester Opera- tor’s Manual.

03123−04 03−8 − SERVICE SPECIFICATIONS FUEL 139 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) TORQUE SPECIFICATION 1GR−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe sub−assy x Intake manifold 15 153 11 Intake air surge tank x Intake manifold 28 286 21 Intake air surge tank x Throttle body bracket 21 214 16 Intake air surge tank x Surge tank stay No. 1 21 214 16 Intake air surge tank x Surge tank stay No. 2 21 214 16 Fuel pressure regulator assy x Fuel delivery pipe sub−assy 9.0 92 80 in.⋅lbf Fuel tank x Body 40 408 30 Fuel tank protector sub−assy No.1 x Body 20 204 15 2UZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Delivery pipe x Intake manifold 21 214 16 Delivery pipe No.2 x Intake manifold 21 214 16 Fuel hose x Delivery pipe 39 400 29 Vacuum switching valve assy No.1 x Intake manifold 18 185 13 Fuel pipe sub−assy No.3 x Intake manifold 7.5 80 66 in.⋅lbf Fuel pipe sub−assy No.1 x Delivery pipe 39 400 29 Throttle body cover sub−assy x Intake manifold 7.5 80 66 in.⋅lbf Fuel tank x Body 40 408 30 Fuel tank protector sub−assy No.1 x Body 20 204 15

0312D−02 03−24 − SERVICE SPECIFICATIONS COOLING 155 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) TORQUE SPECIFICATION 1GR−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Cylinder block water drain cock plug x Cylinder block water drain cock 13 130 9 Water pump assy x Timing chain or belt cover sub−assy 10 mm (0.39 in.) head 12 mm (0.47 in.) head 9.0 23 92 235 80 in.⋅lbf 17 Idler pulley sub−assy No. 2 x Timing chain or belt cover sub−assy 39 398 29 Water inlet x Timing chain or belt cover sub−assy 9.0 92 80 in.⋅lbf Fan shroud x Radiator 5.0 51 44 in.⋅lbf Fan w/ fluid coupling x Water pump 21 214 15 V−bank cover x Intake air surge tank 7.5 76 66 in.⋅lbf Engine under cover sub−assy No. 1 x Frame assy 29 296 21 Water inlet w/ thermostat x Water inlet 9.0 92 80 in.⋅lbf Radiator x Radiator support 18 184 13 2UZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Drain plug x Union on cylinder block 13 130 9 Fan x Fluid coupling 5.5 55 47 in.⋅lbf Water pump x Cylinder block Bolt Stud bolt and nut 21 18 215 185 16 13 Water inlet housing x Water pump 18 185 13 Water inlet x Water inlet housing 19 195 14 Radiator x Radiator support 18 184 13 Fan shroud x Radiator 5.0 51 44 in.⋅lbf Radiator reserve tank x Fan shroud 5.0 51 44 in.⋅lbf

0312E−03 − SERVICE SPECIFICATIONS LUBRICATION 03−25 156 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) LUBRICATION SERVICE DATA 1GR−FE: Oil pressure at idle speed at 3,000 rpm 29 kPa (0.3 kgf/cm 2 , 4.2 psi) or more 294 − 588 kPa (3.0 − 6.0 kgf/cm 2 , 43 − 85 psi) Oil pump Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0.06 − 0.16 mm (0.0024 − 0.0063 in.) 0.16 mm (0.0063 in.) 0.03 − 0.09 mm (0.0012 − 0.0035 in.) 0.09 mm (0.0035 in.) 0.250 − 0.325 mm (0.0098 − 0.0128 in.) 0.325 mm (0.0128 in.) 2UZ−FE: Oil pressure at idle speed at 3,000 rpm 29 kPa (0.3 kgf/cm 2 , 4.2 psi) or more 294 − 588 kPa (3.0 − 6.0 kgf/cm 2 , 43 − 85 psi) Oil pump Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0.060 to 0.180 mm (0.0024 to 0.0071 in.) 0.18 mm (0.0071 in.) 0.030 to 0.090 mm (0.0012 to 0.0035 in.) 0.09 mm (0.0035 in.) 0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.)

0312F−04 03−26 − SERVICE SPECIFICATIONS LUBRICATION 157 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) TORQUE SPECIFICATION 1GR−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Oil pressure switch x Oil filter bracket sub−assy 15 152 11 Oil pan drain plug x Oil pan sub−assy No.2 40 408 30 Timing chain cover sub−assy x Cylinder head and block 23 235 17 Oil filter bracket sub−assy x Timing chain cover sub−assy 19 194 14 Camshaft timing oil control valve assy x Timing chain cover sub−assy 9.0 92 80 in.⋅lbf Ignition coil assy x Cylinder head cover sub−assy 10 102 7 V−bank cover x Intake air surge tank 7.5 76 66 in.⋅lbf Oil pump relief valve x Oil pump cover 49 500 36 Oil pump cover x Timing chain or belt cover sub−assy 9.0 92 80 in.⋅lbf Oil pipe x Timing chain or belt cover and oil pump cover 9.0 92 80 in.⋅lbf Oil cooler assy x Oil filter bracket sub−assy 68 693 50 2UZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf No. 2 oil pan x Drain plug 39 398 29 Oil pump x Cylinder block 14 mm head Others 31 16 311 160 23 11 Oil pump body cover x Oil pump body 10 105 7 Oil pump relief valve x Oil pump body 49 500 36 Oil cooler x Oil filter bracket 69 700 51

0312G−06 − SERVICE SPECIFICATIONS IGNITION 03−27 158 Author: Date: 2005 4RUNNER REPAIR MANUAL (RM1165U) IGNITION SERVICE DATA 1GR−FE: Spark plug Recommended spark plug DENSO made NGK made Electrode gap Maximum electrode gap K20HR−U11 LFR6C−11 1.0 to 1.1 mm (0.039 to 0.043 in.) 1.41 mm (0.056 in.) VVT sensor Voltage VVT1+ − VVT1− VVT2+ − VVT2− 3.375 to 4.950V (Hi), 0.450 to 1.375V (Lo) 3.375 to 4.950V (Hi), 0.450 to 1.375V (Lo) Crankshaft position sensor Resistance at Cold at Hot 1,630 to 2,740 Ω 2,065 to 3,225 Ω 2UZ−FE: Spark plug Recommended spark plug DENSO made NGK made Electrode gap Maximum electrode gap Correct insulation resistance SK20R11 1FR6A11 1.0 to 1.1 mm (0.039 − 0.043 in.) 1.3 mm (0.051 in.) 10 MΩ or more VVT sensor Resistance at Cold at Hot 835 to 1,400 Ω 1,060 to 1,645 Ω Crankshaft position sensor Resistance at Cold at Hot 1,630 to 2,740 Ω 2,065 to 3,225 Ω

2005 Toyota 4Runner Service & Repair Manual

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