Toyota 2.4L (2RZ-FE) & 2.7L (3RZ-FE) Engine Service & Repair Manual

• • • 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, a general 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..... l Clip t) Cl,v', I Lock Nut Snap Ring Washer Push Rod Piston ___ -"!U Tank Cylinder ®-------Filler Cap Float • Non-reusable part

INTRODUCTION - HOW TO USE THIS MANUAL IN-3 • • 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 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. IN02L-01 REFERENCES References have been kept to a minimum. 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 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. • • • 2RZ-FE, 3RZ-FE Engi-ne : CAUTIONS, NOTICES, HINTS: IN-4 5VZ-FE Engine: • N14492

INTRODUCTION - GENERAL REPAIR INSTRUCTIONS • • • 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 negative (-) 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 a file 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 a hammer 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 component 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.

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 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 procedure. A list 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 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 FUSE FUSE 0,<>; BE5694 IN0366 MEDIUM CURRENT FUSE M-FUSE BE6696 IN0366 HIGH CURRENT FUSE H-FUSE BE6696 IN0367 / FUSIBLE LINK FL BE6697 IN0367 -+=4- .. .- CIRCUIT BREAKER CB BE5598 VWJ76 •

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 - 30). (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. (b) 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 following 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.) • INTRODUCTION - GENERAL REPAIR INSTRUCTIONS IN-7 • • WRONG CORRECT IN0253 WRONG CORRECT IN0252 Example INOOO2 (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 dis- tributor. 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 terminals 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. 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. 14. Unless otherwise stated. all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running. measurements should be made when the engine has cooled down.

IN-8 INTRODUCTION - PRECAUTION PRECAUTION INOIA.-01 FOR VEHICLES EQUIPPED WITH AIRBAG The 1996 TOYOTA TACOMA is equipped with an SRS (Supplemental Restraint System), such as the driver airbag. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, pos- sibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replace- ment), be sure to read the following items carefully, then follow the correct procedure described in this manual. • 804111 1. 2. Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page RS - 2). Work must be started after 90 seconds from the time the ignition switch is turned to the -LOCK- position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back- up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery. the SRS may deploy.) When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. This vehicle has power tilt and power telescopic steering, power seat, power outside rear view mirror and power shoulder belt anchorage, which are all equipped with memory function, it is not possible to make a record of the memory contents. •

So when the work is finished, therefore it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory of each memory system. never use a back- up power supply from outside the vehicle. 3. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad should be in- spected (See page RS - 8). 4. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. 5. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. 6. Never disassemble and repair the airbag sensor assembly, steering wheel pad in order to reuse it. 7. If the airbag sensor assembly, steering wheel pad have been dropped, or if there are cracks. dents or other defects in the case, bracket or connector, replace them with new ones. 8. Do not expose the airbag sensor assembly, steering wheel pad directly to hot air or flames. 9. Use a volt/ohmmeter with high impedance (10 kQ/V minimum) for troubleshooting of the electrical circuit. 10. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. 11. After work on the supplemental restraint system is completed, check the SRS warning light (See page RS -26). • • INTRODUCTION - PRECAUTION IN-9 • Red Mark Spiral Cable (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other tro- ubles may result. Refer to SR-16 of this manual concerning correct steering wheel installation. Rl1910

IN·10 INTRODUCTION - PRECAUTION Steering Wheel Pad (with Airbag) Example: N01560 1. 2. 3. 4. 5. 6. When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top sUJ:face facing up. In this case, the twin -lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. In addition do not store a steering wheel pad on top of another one. Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with deter- gents of any kind. Store the steering wheel pad where the ambient temperature remains below 93° C (200° F), without high humidity and away from electrical noise. When using electric welding. first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. When disposing of a vehicle or the steering wheel pad alone, the airbag be deployed using an SST before disposal (See page RS-11). Carry out the operation in a safe place away from electrical noise. Wrong X Zl3<J53 ZI3950

Toyota 2.4L (2RZ-FE) & 2.7L (3RZ-FE) Engine Service & Repair Manual

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