Supplement Chassis & Body Rm651e-D

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RM651E-D FOREWORD Pages From Supplement

TOYOTA MOTOR CORPORATION TO MODEL INDEX
This supplement has been prepared to provide information covering general service repairs for the
Chassis and body of the TOYOTA HILUX which underwent changes in May, 1998.
Applicable models: RZN142, 144, 147, 148, 149, 154, 168, 169, 173, 174, 193 series
LN141, 145, 146, 147, 150, 152, 165, 166, 167, 170, 171, 172, 191 series
For the service specifications and repair procedures of the above model other than those listed in this supple-
ment, refer to the following manuals.
Manual Name Pub.No.
S HILUX Chassis and Body Repair Manual RM585E
S 1RZ, 2RZ, 2RZ--E Engine Repair Manual RM167E
S 1RZ--E Engine Repair Manual RM467E
S 3RZ--F, 3RZ--FE Engine Repair Manual RM521E
S 2RZ, 2RZ--E Engine Repair Manual Supplement RM558E
S 1RZ, 1RZ--E, 2RZ--FE, 3RZ--F, 3RZ--FE Engine Repair Manual Supplement RM584E
S 2L, 3L Engine Repair Manual RM520E
S 2L, 2L--T, 3L, 5L Engine Repair Manual Supplement RM582E
S 2L, 2L--T, 5L Engine Repair Manual Supplement RM647E
S A340E, A340F, A340H Automatic Transmission Repair Manual RM391U
S HILUX Electrical Wiring Diagram EWD307F
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice. 1998 TOYOTA MOTOR CORPORATION
All rights reserved. This CD may not be repro-
CAUTION duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jul. 21, 1998 01--980721--00
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 uncertified technicians 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.
S Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
S 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.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S 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 improper service 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.
BACK TO MAIN FOREWORD & Chassis & Body Index RM651E-D Pages From Supplement
TO MODEL INDEX
MAIN INDEX: HILUX.
SUPPLEMENT: CHASSIS & BODY:
May 1998
INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
SUSPENSION AND AXLE
STEERING
BODY ELECTRICAL
BODY
ALPHABETICAL INDEX
BACK TO MAIN INDEX CHAS. & BODY: RM651E-D Pages From Supplement
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INTRODUCTION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . IN--1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . IN--1
IDENTIFICATION INFORMATION . . . . . . . . . . IN--3
VEHICLE IDENTIFICATION AND ENGINE
SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . IN--3
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . IN--4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . IN--4
VEHICLE LIFT AND SUPPORT LOCATIONS . . IN--8
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . IN--9
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN--9
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN--15
ABBREVIATIONS USED IN THIS MANUAL . . . . IN--15
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IN--1
INTRODUCTION -- HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

IN00U--23
GENERAL INFORMATION
1. 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.
2. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con-
tained in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
Filler Cap
Float Clevis Pin

z Gasket Clip
Reservoir Tank
Boot
z Grommet
Slotted Spring Pin 12 (120, 9)

Clevis
15 (155, 11)
Snap Ring
Washer Lock Nut
Push Rod
Piston
Cylinder
N∙m (kgf∙cm, ft∙lbf) : Specified torque CONTINUED

z Non--reusable part N17080
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IN--2
INTRODUCTION -- HOW TO USE THIS MANUAL
The procedures are presented in a step--by--step format:

S The illustration shows what to do and where to do it.
S The task heading tells what to do.
S The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
Task heading : what to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
SST 09350--30020 (09350--06120)
Illustration:
what to do and where Set part No. Component part No.
Detailed text : how to do task
(b) Measure the stroke applying and releasing the compressed
air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57 — 114 psi) as shown
in the illustration.
Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.)
Specification
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 informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. 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 in Service Specifications section, for quick
reference.
8. CAUTIONS, NOTICES, HINTS:
S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
S NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
S HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. 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)
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IN--3
INTRODUCTION -- IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
A IN02T--02
VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the outer sur-
face of the front right side frame. This number is also stamped
on the manufacturer’s plate and certification regulation plate
(G.C.C. countries only), as shown in the illustration.
A: Manufacturer’s Plate
B: Vehicle Identification Number
C: Certification Regulation Plate (G.C.C. countries only)
B02106
2. ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block, as
shown in the illustration.
2RZ--FE, 3RZ--F & 3RZ--FE engines: 2L, 2L--T, 3L & 5L engines: 1RZ--E engine:
B02107
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IN--4
INTRODUCTION -- REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS IN06S--03
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
FI1066
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (--)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings, oil
seals, etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts

Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
CONTINUED
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IN--5
(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (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 in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
BE1367
Illustration Symbol Part Name Abbreviation
FUSE FUSE
MEDIUM CURRENT FUSE M--FUSE
HIGH CURRENT FUSE H--FUSE
FUSIBLE LINK FL
CIRCUIT BREAKER CB
CONTINUED V00076
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IN--6
(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN -- 8).
S Cancel the parking brake on the level place and
shift the transmission in Neutral (or N range).
S When jacking up the front wheels of the vehicle, at
first place stoppers behind the rear wheels.
S When jacking up the rear wheels of the vehicle, at
first place stopper before the front wheels.
S When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
S After the vehicle is jacked up, be sure to support it
on rigid racks. 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.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not

WRONG CORRECT the middle of the hose.
IN0253
(3) To pull apart electrical connectors, pull on the con-

WRONG CORRECT
nector itself, not the wires.
(4) 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.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission--related
components from water.
IN0252 (6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
CONTINUED
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IN--7
(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
Example (m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C (68˚F). Because the resis-
IN0002 tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
TO MODEL INDEX
IN--7
(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
Example (m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C (68˚F). Because the resis-
IN0002 tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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IN--8
IN02U--02
VEHICLE LIFT AND SUPPORT LOCATIONS
2WD:
Front
4WD and pre runner:
Front
JACK POSITION
Front Center of crossmember
Rear Center of rear axle housing
SUPPORT POSITION
Safety stand
B02108
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INTRODUCTION -- FOR ALL OF VEHICLES IN--9
FOR ALL OF VEHICLES

IN041--07
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The HILUX is equipped with an SRS (Supplemental Re-
straint System), such as the driver airbag, front passen-
ger airbag assembly and seat belt pretensioners.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly 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 replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
Negative Cable
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
BO4111
disconnecting the negative (--) terminal cable from
the battery (See Pub. No. RM585E).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (--) terminal cable is discon-
nected 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 neg-
ative (--) terminal cable from the battery, the SRS
may deploy.)
When the negative (--) terminal cable is discon-
nected 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 each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back--up power supply from anoth-
er battery.
CONTINUED
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IN--10
INTRODUCTION -- FOR ALL OF VEHICLES
(3) Even in cases of a minor collision where the SRS

does not deploy, the steering wheel pad, front pas-
senger airbag assembly and seat belt pretension-
ers should be inspected (See Pub. No. RM585E).
(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 attached to the sensor during re-
pairs.
(6) Never disassemble and repair the airbag sensor as-
sembly, steering wheel pad, front passenger airbag
assembly or seat belt pretensioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly or seat belt pre-
tensioner has been dropped, or if there are cracks,
dents or other defects in the case, bracket or con-
nector, replace them with new ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work is completed, check the SRS warning
light for the supplemental restraint system (See
Pub. No. RM585E).
(c) SPIRAL CABLE (in Combination Switch)

The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR -- 10 of this manual concerning correct steer-
ing wheel installation.
CONTINUED
Marks R11910
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IN--11
(d) STEERING WHEEL PAD (with Airbag)

(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface 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 dam-
aged. In addition do not store a steering wheel pad
on top of another one. Storing the pad with its metal-
lic surface facing upward may lead to a serious acci-
dent if the airbag inflates for same reason.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the steering wheel
pad and the pad should not be cleaned with deter-
gents of any kind.
(4) Store the steering wheel pad where the ambient
temperature remains below 93˚C (200˚F), without
high humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
steering column near the combination switch con-
nector before starting work.
(6) When disposing of a vehicle or the steering wheel
pad alone, the airbag should be deployed using an
SST before disposal (See Pub. No. RM585E).
Carry out the operation in a safe place away from
electrical noise.
Example:
Correct Wrong
B02387
Example:
CONTINUED
Z13950
TO MODEL INDEX
IN--12
(e) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always store a removed or new front passenger air-
bag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deploy-
ment direction facing down could cause a serious
accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the front passen-
ger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93˚C (200˚F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) installed on
the assembly before starting work.
(6) When disposing of a vehicle or the airbag assembly
alone, the airbag should be deployed using an SST
before disposal (See Pub. No. RM585E).
Perform the operation in a safe place away from
electrical noise.
Example: Correct Wrong
Z13952
Example:
CONTINUED
B02404
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IN--13
(f) SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pre-
tensioner. (This may cause the seat belt pretension-
er to activate, which is very dangerous.)
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner in another
vehicle.
(4) Store the seat belt pretensioner where the ambient
temperature remains below 80˚C (176˚F) and
away from electrical noise without high humidity.
(5) When using electric welding, first disconnect the
connector (yellow color and 2 pins) before starting
work.
(6) When disposing of a vehicle or the seat belt preten-
sioner alone, the seat belt pretensioner should be
activated before disposal (See Pub. No. RM585E).
Perform the operation in a safe place away from
electrical noise.
(7) The seat belt pretensioner is hot after activation, so
let it cool down sufficiently before the disposal.
However never apply water to the seat belt preten-
sioner.
(g) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired deployment of the supplemental re-
straint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (--) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(h) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors in the
system are a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it.
CONTINUED
TO MODEL INDEX
IN--14
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) 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.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING HAND--HELD TESTER

CAUTION:
Observe the following items for safety reasons:
S Before using the hand--held tester, the hand--held tester’s operator manual should be read thor-
oughly.
S Be sure to route all cables securely when driving with the hand--held tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
S Two persons are required when test driving with the hand--held tester, one person to drive the
vehicle and the other person to operate the hand--held tester.
TO MODEL INDEX
IN--15
INTRODUCTION -- TERMS
TERMS
IN0CG--01
ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
ABS Anti--Lock Brake System
A/C Air Conditioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
BACS Boost Altitude Compensation System
BAT Battery
B/L Bi--Level
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CD Compact Disc
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CRS Child Restraint System
CTR Center
DC Direct Current
DIFF. Differential
DIFF. LOCK Differential Lock
DLC Data Link Connector
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECT Electronic Control Transmission
ECU Electronic Control Unit
EDU Electronic Driving Unit
EFI Electronic Fuel Injection
E/G Engine
ELR Emergency Locking Retractor
FF Front--Engine Front--Wheel--Drive
FIPG Formed In Place Gasket
CONTINUED
TO MODEL INDEX
IN--16
FL Fusible Link
Fr Front
FR Front--Engine Rear--Wheel--Drive
FWD Front--Wheel--Drive
GND Ground
H/B Hatchback
HI High
HID High Intensity Discharge (Head Lamp)
HT Hard Top
HWS Heated Windshield System
IAC Idle Air Control
IFS Independent Front Suspension
IG Ignition
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
J/B Junction Block
J/C Junction Connector
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left--Hand
LHD Left--Hand Drive
LO Low
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Fuel Injection
MPX Multiplex Communication System
M/T Manual Transmission
N Neutral
No. Number
O2S Oxygen Sensor
O/D Overdrive
OPT Option
P & BV Proportioning And Bypass Valve
PCS Power Control System
PKB Parking Brake
PPS Progressive Power Steering
CONTINUED
TO MODEL INDEX
IN--17
PS Power Steering
PTO Power Take--Off
RAM Random Access Memory
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH Right--Hand
RHD Right--Hand Drive
RLY Relay
ROM Read Only Memory
Rr Rear
RR Rear--Engine Rear--Wheel Drive
RWD Rear--Wheel Drive
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SPEC Specification
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TDC Top Dead Center
TEMP. Temperature
TEMS TOYOTA Electronic Modulated Suspension
T/M Transmission
TMC TOYOTA Motor Corporation
TRC Traction Control System
U/D Underdrive
VENT Ventilator
VIN Vehicle Identification Number
VSC Vehicle Skid Control Vehicle Stability Control
w/ With
WGN Wagon
W/H Wire Harness
w/o Without
1st First
2nd Second
2WD Two Wheel Drive Vehicle (4x2)
4WD Four Wheel Drive Vehicle (4x4)
TO MODEL INDEX
PREPARATION
SUSPENSION AND AXLE . . . . . . . . . . . . . . . . PP--1

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP--2
BODY ELECTRICAL . . . . . . . . . . . . . . . . . . . . . PP--4
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND

BODY (Pub. No. RM585E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
TO MODEL INDEX
PP--1
PREPARATION -- SUSPENSION AND AXLE
SUSPENSION AND AXLE

PP1XT--01
EQUIPMENT
Dial indicator
Torque wrench
TO MODEL INDEX
PP--2
PREPARATION -- STEERING
STEERING
PP1US--02
SST (Special Service Tools)

09612--22011 Tilt Handle Bearing Replacer Steering column
TO MODEL INDEX
PP--3
PREPARATION -- STEERING
PP1UT--02
RECOMMENDED TOOLS
09904--00010 Expander Set .
(09904--00050) No. 4 Claw
09905--00012 Snap Ring No.1 Expander .

TO MODEL INDEX
PP--4
PREPARATION -- BODY ELECTRICAL
BODY ELECTRICAL
PP090--03
RECOMMENDED TOOLS
09082--00050 TOYOTA Electrical Tester Set.
TO MODEL INDEX
PP--5
PREPARATION -- BODY ELECTRICAL
PP091--02
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
TO MODEL INDEX
SERVICE SPECIFICATIONS
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . SS--1

SUSPENSION AND AXLE . . . . . . . . . . . . . . . . SS--4
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS--19
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS--20

TO MODEL INDEX
SS--1
SERVICE SPECIFICATIONS -- STANDARD BOLT
STANDARD BOLT
SS0ZS--01
HOW TO DETERMINE BOLT STRENGTH
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
No Mark No Mark No Mark
5 5T
6 6T
w/ Washer w/ Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431
TO MODEL INDEX
SS--2
SS0ZT--01
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N∙m kgf∙cm ft∙lbf N∙m kgf∙cm ft∙lbf
6 1 5 55 48 in.∙lbf 6 60 52 in.∙lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 -- -- --
6 1 6.5 65 56 in.∙lbf 7.5 75 65 in.∙lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 -- -- --
6 1 8 80 69 in.∙lbf 9 90 78 in.∙lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 -- -- --
6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 -- -- --
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
TO MODEL INDEX
SS--3
SS0ZU--01
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
TO MODEL INDEX
SS--4
SERVICE SPECIFICATIONS -- SUSPENSION AND AXLE
SUSPENSION AND AXLE

SS10V--01
SERVICE DATA *1: RZN142 series only

Cold tire inflation pressure (2WD)
Front 220 kPa (2.2 kgf/cm2, 32 psi)
Tire size: 185R14C--8PR
Rear 450 kPa (4.5 kgf/cm2, 65 psi)
E
Europe
Unladen with 2 occupants and 100 kg of luggage or less
A t li
Australia
Fully laden
Loaded
Tire size: Fr 6.00--14--6PRLT, Rr 6.50--14--8PRLT
Tire size: 185R14C--8PR 200 kPa (2.0 kgf/cm2, 29 psi)*1
Tire size: 195R15--6PRLT
Oth
Others
Unloaded
Tire size: Fr 6.00--14--6PRLT, Rr 6.50--14--8PRLT
Tire size: 185R14C--8PR 200 kPa (2.0 kgf/cm2, 29 psi)*1

Tire size: 195R15--6PRLT
CONTINUED
TO MODEL INDEX
SS--5
Cold tire inflation pressure (4WD and pre runner)

Europe Tire size: 205R16 Reinforced radial tire
Unladen with 2 occupants and 100 kg of luggage or less
Tire size: 205R16 Reinforced radial tire
Tire size: 255/70R15 112L LT
A
Australia
li
Fully laden
Oh
Others
Tire size: 7.00--16--8PRLT
CONTINUED
TO MODEL INDEX
SS--6
Wheel alignment (2WD)

Vehicle height
Front: A --B
Rear: C -- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
Front 34 mm (1.34 in.)
LN145L--TRMDSW
Rear 33 mm (1.30 in.)
LN145R--TRMDSW
Rear 34 mm (1.34 in.)
Europe LN145L--PRMDSW
Rear 32 mm (1.26 in.)
LN145L--PRMSSW
Rear 33 mm (1.30 in.)
LN150L--CRMDSW
Rear 45 mm (1.77 in.)
RZN147R--TRMDEQ Front 25 mm (0.98 in.)
RZN149R--TRMDKQ Rear 39 mm (1.54 in.)
RZN149R--TRPDKQ
Rear 40 mm (1.57 in.)
RZN149R--PRMDKQ
Rear 42 mm (1.65 in.)
RZN149R--PRPDKQ
Rear 43 mm (1.69 in.)
Australia RZN149R--CRMDKQ
Rear 44 mm (1.73 in.)
RZN154R--CRPDKQ
Rear 44 mm (1.73 in.)
LN147R--TRMDSQ
Rear 41 mm (1.61 in.)
LN147R--PRMDSQ
Rear 44 mm (1.73 in.)
LN152R--CRMDSQ
Rear 44 mm (1.73 in.)
RZN142L--TRMDSV
Rear 42 mm (1.65 in.)
RZN147L--TRMDSV Front 24 mm (0.94 in.)
RZN149L--TRMSUV Rear 41 mm (1.61 in.)
RZN147L--PRMDSV
G.C.C. Rear 33 mm (1.30 in.)
Countries RZN144L--TRMDUV Front 34 mm (1.34 in.)
RZN144L--TRMSUV Rear 42 mm (1.65 in.)
RZN149L--PRMDUV
Rear 33 mm (1.30 in.)
LN141L--TRMDSV
Rear 42 mm (1.65 in.)
CONTINUED
TO MODEL INDEX
SS--7

LN146L--PRMDSV
G.C.C. Rear 34 mm (1.34 in.)
Countries Front 30 mm (1.18 in.)
RZN149L--PRMSUV
Rear 33 mm (1.30 in.)
RZN142L--TRMDS
Rear 39 mm (1.54 in.)
RZN147R--TRMDS Front 23 mm (0.91 in.)
RZN147L--TRMDS Rear 39 mm (1.54 in.)
RZN147R--PRMDS Front 28 mm (1.10 in.)
RZN147L--PRMDS Rear 41 mm (1.61 in.)
RZN148L--TRMDK
Rear 41 mm (1.61 in.)
RZN148L--PRMDK
Rear 43 mm (1.69 in.)
Others RZN149L--TRMDU
Rear 39 mm (1.54 in.)
RZN149L--PRMDU
Rear 42 mm (1.65 in.)
RZN149L--PRMSU
Rear 44 mm (1.73 in.)
RZN154L--CRMDU
Rear 44 mm (1.73 in.)
LN145R--TRMDS Front 30 mm (1.18 in.)
LN145L--TRMDS Rear 44 mm (1.73 in.)
LN145R--PRMDS Front 35 mm (1.38 in.)
LN145L--PRMDS Rear 46 mm (1.81 in.)
CONTINUED
TO MODEL INDEX
SS--8
Camber Right--left error: 30’ (0.5˚) or less

LN145L--TRMDSW --0˚03’ ± 45’ (--0.06˚ ± 0.75˚)
LN145R--TRMDSW
Europe LN145L--PRMDSW --0˚01’ ± 45’ (--0.02˚ ± 0.75˚)
LN145L--PRMSSW
LN150L--CRMDSW --0˚02’ ± 45’ (--0.04˚ ± 0.75˚)
RZN147R--TRMDEQ
RZN149R--TRMDKQ --0˚08’ ± 45’ (--0.13˚ ± 0.75˚)
RZN149R--TRPDKQ
RZN149R--PRMDKQ
--0˚03’ ± 45’ (--0.05˚ ± 0.75˚)
RZN149R--PRPDKQ
--0˚03’ ± 45’ (--0.06˚ ± 0.75˚)
LN152R--CRMDSQ
RZN154R--CRPDKQ --0˚02’ ± 45’ (--0.04˚ ± 0.75˚)
LN147R--TRMDSQ --0˚04’ ± 45’ (--0.07˚ ± 0.75˚)
LN147R--PRMDSQ --0˚01’ ± 45’ (--0.02˚ ± 0.75˚)
RZN142L--TRMDSV
RZN144L--TRMDUV --0˚03’ ± 45’ (--0.06˚ ± 0.75˚)
RZN144L--TRMSUV
RZN147L--TRMDSV
--0˚08’ ± 45’ (--0.14˚ ± 0.75˚)
G.C.C. RZN149L--TRMSUV
Countries RZN147L--PRMDSV
RZN149L--PRMDUV
--0˚05’ ± 45’ (--0.09˚ ± 0.75˚)
RZN149L--PRMSUV
LN141L--TRMDSV
LN146L--PRMDSV --0˚02’ ± 45’ (--0.04˚ ± 0.75˚)
RZN142L--TRMDS
RZN154L--CRMDU
--0˚03’ ± 45’ (--0.06˚ ± 0.75˚)
LN145R--PRMDS
LN145L--PRMDS
RZN147R--TRMDS
RZN147L--TRMDS
--0˚10’ ± 45’ (--0.17˚ ± 0.75˚)
RZN148L--TRMDK
RZN149L--TRMDU
Others
RZN147R--PRMDS
RZN147L--PRMDS
--0˚06’ ± 45’ (--0.10˚ ± 0.75˚)
RZN148L--PRMDK
RZN149L--PRMDU
RZN149L--PRMSU --0˚02’ ± 45’ (--0.03˚ ± 0.75˚)
LN145R--TRMDS
--0˚05’ ± 45’ (--0.09˚ ± 0.75˚)
LN145L--TRMDS
Caster Right--left error: 30’ (0.5˚) or less

Tire size: 195R14C 0˚59’ ± 45’ (0.99˚ ± 0.75˚)
LN145R--TRMDSW Tire size: 185R14C 0˚51’ ± 45’ (0.85˚ ± 0.75˚)
Tire size: 195R14C 0˚53’ ± 45’ (0.89˚ ± 0.75˚)
LN145L--PRMDSW Tire size: 185R14C 0˚49’ ± 45’ (0.82˚ ± 0.75˚)
Europe Tire size: 195R14C 0˚51’ ± 45’ (0.86˚ ± 0.75˚)

LN145L--PRMSSW Tire size: 185R14C 0˚50’ ± 45’ (0.83˚ ± 0.75˚)
Tire size: 195R14C 0˚53’ ± 45’ (0.88˚ ± 0.75˚)
LN150L--CRMDSW Tire size: 185R14C 1˚19’ ± 45’ (1.32˚ ± 0.75˚)
Tire size: 195R14C 1˚17’ ± 45’ (1.28˚ ± 0.75˚) CONTINUED
TO MODEL INDEX
SS--9
RZN147R--TRMDEQ
1˚18’ ± 45’ (1.30˚ ± 0.75˚)
RZN149R--TRPDKQ
RZN149R--TRMDKQ 1˚17’ ± 45’ (1.29˚ ± 0.75˚)
RZN149R--PRMDKQ 1˚14’ ± 45’ (1.23˚ ± 0.75˚)
RZN149R--PRPDKQ 1˚15’ ± 45’ (1.25˚ ± 0.75˚)
A t li
Australia
RZN154R--CRMDKQ 1˚23’ ± 45’ (1.38˚ ± 0.75˚)
RZN154R--CRPDKQ
1˚21’ ± 45’ (1.35˚ ± 0.75˚)
LN152R--CRMDSQ
LN147R--TRMDSQ 1˚12’ ± 45’ (1.20˚ ± 0.75˚)
LN147R--PRMDSQ 1˚09’ ± 45’ (1.16˚ ± 0.75˚)
RZN142L--TRMDSV
1˚05’ ± 45’ (1.08˚ ± 0.75˚)
LN141L--TRMDSV
RZN144L--TRMDUV 1˚03’ ± 45’ (1.06˚ ± 0.75˚)
RZN144L--TRMSUV 1˚04’ ± 45’ (1.07˚ ± 0.75˚)
G.C.C. RZN147L--TRMDSV 1˚20’ ± 45’ (1.34˚ ± 0.75˚)
Countries RZN147L--PRMDSV 1˚02’ ± 45’ (1.04˚ ± 0.75˚)

RZN149L--TRMSUV 1˚19’ ± 45’ (1.32˚ ± 0.75˚)
RZN149L--PRMDUV 1˚02’ ± 45’ (1.03˚ ± 0.75˚)
RZN149L--PRMSUV 1˚01’ ± 45’ (1.02˚ ± 0.75˚)
LN146L--PRMDSV 0˚56’ ± 45’ (0.93˚ ± 0.75˚)
RZN142L--TRMDS 1˚02’ ± 45’ (1.03˚ ± 0.75˚)
RZN147R--TRMDS
RZN147L--TRMDS
1˚18’ ± 45’ (1.30˚ ± 0.75˚)
RZN148L--TRMDK
RZN148L--PRMDK
RZN147R--PRMDS
1˚17’ ± 45’ (1.29˚ ± 0.75˚)
RZN147L--PRMDS
RZN149L--TRMDU Tire size: 185R14C 1˚17’ ± 45’ (1.29˚ ± 0.75˚)
Tire size: 195R14C 1˚19’ ± 45’ (1.32˚ ± 0.75˚)
Tire size: 195R15 1˚17’ ± 45’ (1.28˚ ± 0.75˚)
Others RZN149L--PRMDU Tire size: 185R14C, 195R15 1˚17’ ± 45’ (1.28˚ ± 0.75˚)
Tire size: 195R14C 1˚19’ ± 45’ (1.32˚ ± 0.75˚)
RZN149L--PRMSU Tire size: 185R14C 1˚11’ ± 45’ (1.19˚ ± 0.75˚)
Tire size: 195R14C 1˚13’ ± 45’ (1.22˚ ± 0.75˚)
RZN154L--CRMDU 1˚23’ ± 45’ (1.38˚ ± 0.75˚)
LN145R--TRMDS
0˚54’ ± 45’ (0.90˚ ± 0.75˚)
LN145L--TRMDS Tire size: Fr 6.00--14, Rr 6.50--14
Tire size: 185R14C 1˚12’ ± 45’ (1.20˚ ± 0.75˚)
LN145R--PRMDS
0˚54’ ± 45’ (0.91˚ ± 0.75˚)
LN145L--PRMDS Tire size: Fr 6.00--14, Rr 6.50--14
Tire size: 185R14C 1˚12’ ± 45’ (1.20˚ ± 0.75˚)
CONTINUED
TO MODEL INDEX
SS--10
Steering axis inclination Right--left error: 30’ (0.5˚) or less

LN145L--TRMDSW 10˚33’ ± 45’ (10.56˚ ± 0.75˚)
LN145R--TRMDSW
Europe LN145L--PRMDSW 10˚31’ ± 45’ (10.52˚ ± 0.75˚)
LN145L--PRMSSW
LN150L--CRMDSW 10˚32’ ± 45’ (10.54˚ ± 0.75˚)
RZN147R--TRMDEQ
RZN149R--TRMDKQ 10˚38’ ± 45’ (10.63˚ ± 0.75˚)
RZN149R--TRPDKQ
RZN149R--PRMDKQ
10˚33’ ± 45’ (10.55˚ ± 0.75˚)
RZN149R--PRPDKQ
10˚33’ ± 45’ (10.56˚ ± 0.75˚)
LN152R--CRMDSQ
RZN154R--CRPDKQ 10˚32’ ± 45’ (10.54˚ ± 0.75˚)
LN147R--TRMDSQ 10˚34’ ± 45’ (10.57˚ ± 0.75˚)
LN147R--PRMDSQ 10˚31’ ± 45’ (10.52˚ ± 0.75˚)
RZN142L--TRMDSV
RZN144L--TRMDUV 10˚33’ ± 45’ (10.56˚ ± 0.75˚)
RZN144L--TRMSUV
RZN147L--TRMDSV
10˚38’ ± 45’ (10.64˚ ± 0.75˚)
RZN149L--PRMDUV
10˚35’ ± 45’ (10.59˚ ± 0.75˚)
RZN149L--PRMSUV
LN141L--TRMDSV
LN146L--PRMDSV 10˚32’ ± 45’ (10.54˚ ± 0.75˚)
RZN142L--TRMDS
RZN154L--CRMDU 10˚33’ ± 45’ (10.56˚ ± 0.75˚)
LN145R--PRMDS
RZN147R--TRMDS
RZN147L--TRMDS
10˚40’ ± 45’ (10.67˚ ± 0.75˚)
RZN148L--TRMDK
RZN149L--TRMDU
Others
RZN147R--PRMDS
RZN147L--PRMDS
10˚36’ ± 45’ (10.60˚ ± 0.75˚)
RZN148L--PRMDK
RZN149L--PRMDU
RZN149L--PRMSU 10˚32’ ± 45’ (10.53˚ ± 0.75˚)
LN145R--TRMDS
10˚35’ ± 45’ (10.59˚ ± 0.75˚)
LN145L--TRMDS CONTINUED
TO MODEL INDEX
SS--11
Toe--in (total)
LN145L--TRMDSW Tire size: 185R14C 0˚21’ ± 10’ (0.35˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
Tire size: 195R14C 0˚20’ ± 10’ (0.34˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
LN145R--TRMDSW 0˚10’ ± 10’ (0.17˚ ± 0.17˚, 2 ± 2 mm, 0.08 ± 0.08 in.)
Europe
LN145L--PRMDSW
LN145L--PRMSSW 0˚15’ ± 10’ (0.26˚ ± 0.17˚, 3 ± 2 mm, 0.12 ± 0.08 in.)
LN150L--CRMDSW
RZN147R--TRMDEQ
RZN149R--TRMDKQ 0˚31’ ± 10’ (0.52˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
RZN149R--TRPDKQ
RZN149R--PRMDKQ
RZN149R--PRPDKQ
Australia
RZN154R--CRMDKQ 0˚21’ ± 10’ (0.35˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
LN147R--TRMDSQ
LN152R--CRMDSQ
RZN154R--CRPDKQ
0˚15’ ± 10’ (0.26˚ ± 0.17˚, 3 ± 2 mm, 0.12 ± 0.08 in.)
LN147R--PRMDSQ
RZN142L--TRMDSV
RZN144L--TRMDUV 0˚19’ ± 10’ (0.33˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
RZN144L--TRMSUV
RZN147L--TRMDSV
0˚29’ ± 10’ (0.49˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
RZN149L--PRMDUV
0˚24’ ± 10’ (0.41˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
RZN149L--PRMSUV
LN141L--TRMDSV
LN146L--PRMDSV 0˚15’ ± 10’ (0.25˚ ± 0.17˚, 3 ± 2 mm, 0.12 ± 0.08 in.)
RZN142L--TRMDS
0˚21’ ± 10’ (0.35˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
RZN154L--CRMDU
RZN147R--TRMDS
0˚31’ ± 10’ (0.52˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
RZN147L--TRMDS
RZN147R--PRMDS
0˚26’ ± 10’ (0.44˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
RZN147L--PRMDS
RZN148L--TRMDK 0˚29’ ± 10’ (0.49˚ ± 0.16˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
RZN148L--PRMDK 0˚24’ ± 10’ (0.41˚ ± 0.16˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
RZN149L--TRMDU Tire size: 185R14C 0˚31’ ± 10’ (0.52˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
Tire size: 195R14C 0˚30’ ± 10’ (0.51˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
Others Tire size: 195R15 0˚29’ ± 10’ (0.49˚ ± 0.17˚, 6 ± 2 mm, 0.24 ± 0.08 in.)
RZN149L--PRMDU Tire size: 185R14C 0˚26’ ± 10’ (0.44˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
Tire size: 195R14C 0˚25’ ± 10’ (0.43˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
Tire size: 195R15 0˚24’ ± 10’ (0.41˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
RZN149L--PRMSU 0˚15’ ± 10’ (0.26˚ ± 0.17˚, 3 ± 2 mm, 0.12 ± 0.08 in.)
LN145R--TRMDS
0˚28’ ± 11’ (0.47˚ ± 0.19˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
LN145L--TRMDS Tire size: Fr 6.00--14, Rr 6.50--14
Tire size: 185R14C 0˚26’ ± 10’ (0.44˚ ± 0.17˚, 5 ± 2 mm, 0.20 ± 0.08 in.)
LN145R--PRMDS
0˚23’ ± 11’ (0.38˚ ± 0.19˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
LN145L--PRMDS Tire size: Fr 6.00--14, Rr 6.50--14
Tire size: 185R14C 0˚21’ ± 10’ (0.35˚ ± 0.17˚, 4 ± 2 mm, 0.16 ± 0.08 in.)
Tie rod end length difference 3.0 mm (0.118 in.) or less
CONTINUED
TO MODEL INDEX
SS--12
Wheel angle
Inside wheel 36˚ (34˚ -- 37˚)
Manual steering
Outside wheel: Reference 32˚
Inside wheel 38˚ (36˚ -- 39˚)
Power steering
Wheel alignment (4WD and pre runner)

Vehicle height
Front: A --B
Rear: C -- D
Measuring points:
B: Ground clearance of lower suspension arm front bolt center.
RZN168L--TRMDKW(3)
Rear --107 mm (--4.21 in.)
RZN168L--PRMDKW
Rear --99 mm (--3.90 in.)
RZN173L--CRMDKW
Rear --96 mm (--3.78 in.)
LN165L--TRMDXW Front 65 mm (2.56 in.)
Europe
LN165R--TRMDXW(3) Rear --106mm (--4.17 in.)
LN165L--PRMDXW Front 66 mm (2.60 in.)
LN165R--PRMDXW Rear --99 mm (--3.90 in.)
LN165L--PRMSXW
Rear --98 mm (--3.86 in.)
LN170L--CRMDXW
Rear --95 mm (--3.74 in.)
RZN169R--TRMDKQ(3)
Rear --121 mm (--4.76 in.)
RZN169R--PRMDKQ
Rear --111 mm (--4.37 in.)
RZN174R--CRMDKQ
Rear --106 mm (--4.17 in.)
A t li
Australia
LN167R--TRMDSQ(3)
Rear --119 mm (--4.69 in.)
LN167R--PRMDSQ
Rear --111 mm (--4.37 in.)
LN172R--CRMDSQ(3)
Rear --105 mm (--4.13 in.)
RZN169L--TRMDUV
G.C.C. Rear --110 mm (--4.33 in.)
Countries RZN169L--PRMDUV Front 60 mm (2.36 in.)
LN166L--PRMDSV Rear --101 mm (--3.98 in.)
CONTINUED
TO MODEL INDEX
SS--13

RZN168L--TRMDK
Rear --111 mm (--4.37 in.)
RZN168L--PRMDK
Rear --104 mm (--4.09 in.)
RZN169R--TRMDU
Rear --119 mm (--4.69 in.)
RZN169L--TRMDU
Rear --110 mm (--4.33 in.)
RZN169R--PRMDU Tire size: 205R16C
Rear --112 mm (--4.41 in.)
Tire size: 255/70R15
Rear --104 mm (--4.09 in.)
Others RZN169L--PRMDU
Rear --103 mm (--4.06 in.)
RZN193L--PRMDK
Rear --106 mm (--4.17 in.)
LN166R--TRMDS Front 44 mm (1.73 in.)
LN166L--TRMDS Rear --119 mm (--4.69 in.)
LN166R--PRMDS Tire size: 7.00--16 Front 45 mm (1.77 in.)
LN166L--PRMDS Tire size: 205R16C Rear --112 mm (--4.41 in.)
Tire size: 255/70R15
Rear --103 mm (--4.06 in.)
LN171L--CRMDS
Rear --105 mm (--4.13 in.)
LN191L--PRMDS
Rear --114 mm (--4.49 in.)
CONTINUED
TO MODEL INDEX
SS--14
Camber Right--left error: 30’ (0.5˚) or less

RZN168L--TRMDKW(3)
RZN168L--PRMDKW
0˚17’ ± 45’ (0.28˚ ± 0.75˚)
LN165L--TRMDXW
LN165R--TRMDXW(3)
Europe RZN173L--CRMDKW
LN165L--PRMDXW
LN165R--PRMDXW 0˚16’ ± 45’ (0.27˚ ± 0.75˚)
LN165L--PRMSXW
LN170L--CRMDXW
RZN169R--TRMDKQ(3)
RZN169R--PRMDKQ
0˚18’ ± 45’ (0.30˚ ± 0.75˚)
LN167R--TRMDSQ(3)
Australia LN167R--PRMDSQ
RZN174R--CRMDKQ
0˚16’ ± 45’ (0.27˚ ± 0.75˚)
LN172R--CRMDSQ(3)
RZN169L--TRMDUV
G.C.C.
RZN169L--PRMDUV 0˚17’ ± 45’ (0.28˚ ± 0.75˚)
Countries
LN166L--PRMDSV
RZN169R--TRMDU
LN166R--TRMDS
0˚18’ ± 45’ (0.30˚ ± 0.75˚)
LN166L--TRMDS
LN191L--PRMDS
RZN168L--TRMDK
RZN168L--PRMDK
RZN169L--TRMDU 0˚17’ ± 45’ (0.28˚ ± 0.75˚)
RZN169L--PRMDU
Others
RZN193L--PRMDK
RZN169R--PRMDU Tire size: 205R16C 0˚18’ ± 45’ (0.30˚ ± 0.75˚)
Tire size: 255/70R15 0˚17’ ± 45’ (0.28˚ ± 0.75˚)
LN166R--PRMDS
0˚18’ ± 45’ (0.30˚ ± 0.75˚)
LN166L--PRMDS Tire size: 7.00--16, 205R16C
Tire size: 255/70R15 0˚17’ ± 45’ (0.28˚ ± 0.75˚)

LN171L--CRMDS 0˚16’ ± 45’ (0.27˚ ± 0.75˚)
CONTINUED
TO MODEL INDEX
SS--15
Caster Right--left error: 30’ (0.5˚) or less

RZN168L--TRMDKW(3) 1˚03’ ± 45’ (1.05˚ ± 0.75˚)
RZN168L--PRMDKW 1˚16’ ± 45’ (1.27˚ ± 0.75˚)
RZN173L--CRMDKW 1˚27’ ± 45’ (1.45˚ ± 0.75˚)
LN165L--TRMDXW
1˚02’ ± 45’ (1.03˚ ± 0.75˚)
Europe LN165R--TRMDXW(3)
LN165L--PRMDXW
1˚13’ ± 45’ (1.22˚ ± 0.75˚)
LN165R--PRMDXW
LN165L--PRMSXW 1˚14’ ± 45’ (1.23˚ ± 0.75˚)
LN170L--CRMDXW 1˚25’ ± 45’ (1.42˚ ± 0.75˚)
RZN169R--TRMDKQ(3) Tire size: 205R16C 0˚52’ ± 45’ (0.87˚ ± 0.75˚)
Tire size: 205R16 R/F 0˚42’ ± 45’ (0.70˚ ± 0.75˚)
RZN169R--PRMDKQ Tire size: 205R16C, 255/70R15 1˚04’ ± 45’ (1.07˚ ± 0.75˚)
Tire size: 205R16 R/F 1˚01’ ± 45’ (1.02˚ ± 0.75˚)
RZN174R--CRMDKQ Tire size: 205R16C 1˚17’ ± 45’ (1.28˚ ± 0.75˚)
Tire size: 205R16 R/F 1˚15’ ± 45’ (1.25˚ ± 0.75˚)
A t li
Australia
LN167R--TRMDSQ(3) Tire size: 205R16C 0˚51’ ± 45’ (0.85˚ ± 0.75˚)
Tire size: 205R16 R/F 0˚48’ ± 45’ (0.80˚ ± 0.75˚)
LN167R--PRMDSQ Tire size: 205R16C, 255/70R15 1˚03’ ± 45’ (1.05˚ ± 0.75˚)
Tire size: 205R16 R/F 1˚00’ ± 45’ (1.00˚ ± 0.75˚)
LN172R--CRMDSQ(3) Tire size: 205R16C 1˚17’ ± 45’ (1.28˚ ± 0.75˚)
Tire size: 205R16 R/F 1˚14’ ± 45’ (1.23˚ ± 0.75˚)
RZN169L--TRMDUV 0˚57’ ± 45’ (0.95˚ ± 0.75˚)
G.C.C.
RZN169L--PRMDUV 1˚09’ ± 45’ (1.15˚ ± 0.75˚)
Countries
LN166L--PRMDSV 1˚07’ ± 45’ (1.12˚ ± 0.75˚)
RZN168L--TRMDK Tire size: 205R16 R/F 1˚00’ ± 45’ (1.00˚ ± 0.75˚)
Tire size: 205R16C 0˚55’ ± 45’ (0.92˚ ± 0.75˚)
RZN168L--PRMDK Tire size: 205R16 R/F 1˚11’ ± 45’ (1.18˚ ± 0.75˚)
Tire size: 205R16C 1˚07’ ± 45’ (1.12˚ ± 0.75˚)
RZN169R--TRMDU 0˚44’ ± 45’ (0.73˚ ± 0.75˚)
RZN169L--TRMDU 0˚56’ ± 45’ (0.93˚ ± 0.75˚)
RZN169R--PRMDU Tire size: 205R16C 0˚56’ ± 45’ (0.93˚ ± 0.75˚)
Tire size: 255/70R15 1˚15’ ± 45’ (1.25˚ ± 0.75˚)
RZN169L--PRMDU Tire size: 205R16C 1˚07’ ± 45’ (1.12˚ ± 0.75˚)
Tire size: 255/70R15 1˚15’ ± 45’ (1.25˚ ± 0.75˚)
Others RZN193L--PRMDK 1˚11’ ± 45’ (1.18˚ ± 0.75˚)
LN166R--TRMDS
0˚49’ ± 45’ (0.82˚ ± 0.75˚)
LN166L--TRMDS Tire size: 7.00--16
Tire size: 205R16C 0˚43’ ± 45’ (0.72˚ ± 0.75˚)
LN166R--PRMDS
1˚01’ ± 45’ (1.02˚ ± 0.75˚)
LN166L--PRMDS Tire size: 7.00--16
Tire size: 205R16C 0˚55’ ± 45’ (0.92˚ ± 0.75˚)
Tire size: 255/70R15 1˚14’ ± 45’ (1.23˚ ± 0.75˚)
LN171L--CRMDS 1˚08’ ± 45’ (1.13˚ ± 0.75˚)
LN191L--PRMDS Tire size: 7.00--16 1˚00’ ± 45’ (1.00˚ ± 0.75˚)
Tire size: 205R16C 0˚54’ ± 45’ (0.90˚ ± 0.75˚)
CONTINUED
TO MODEL INDEX
SS--16
Steering axis inclination Right--left error: 30’ (0.5˚) or less

RZN168L--TRMDKW(3)
RZN168L--PRMDKW
RZN173L--CRMDKW
LN165L--TRMDXW
12˚16’ ± 45’ (12.27˚ ± 0.75˚)
Europe LN165R--TRMDXW(3)
LN165L--PRMDXW
LN165R--PRDMXW
LN165L--PRMSXW
LN170L--CRMDXW 12˚17’ ± 45’ (12.28˚ ± 0.75˚)
RZN169R--TRMDKQ(3)
12˚14’ ± 45’ (12.23˚ ± 0.75˚)
LN167R--TRMDSQ(3)
RZN169R--PRMDKQ
Australia 12˚15’ ± 45’ (12.25˚ ± 0.75˚)
LN167R--PRMDSQ
RZN174R--CRMDKQ
12˚16’ ± 45’ (12.27˚ ± 0.75˚)
LN172R--CRMDSQ(3)
RZN169L--TRMDUV
G.C.C. 12˚15’ ± 45’ (12.25˚ ± 0.75˚)
RZN169L--PRMDUV
C
Countries
ti
LN166L--PRMDSV 12˚16’ ± 45’ (12.27˚ ± 0.75˚)
RZN169R--TRMDU
LN166R--TRMDS 12˚14’ ± 45’ (12.23˚ ± 0.75˚)
LN166L--TRMDS
RZN168L--TRMDK
RZN168L--PRMDK
RZN169L--TRMDU
Others RZN169R--PRMDU
RZN169L--PRMDU 12˚15’ ± 45’ (12.25˚ ± 0.75˚)
RZN193L--PRMDK
LN166R--PRMDS
LN166L--PRMDS
LN191L--PRMDS
LN171L--CRMDS 12˚16’ ± 45’ (12.27˚ ± 0.75˚)
CONTINUED
TO MODEL INDEX
SS--17
Toe--in (total)
RZN168L--TRMDKW(3) 0˚21’ ± 18’ (0.35˚ ± 0.31˚, 2.3 ± 2 mm, 0.091 ± 0.080 in.)
RZN168L--PRMDKW 0˚19’ ± 18’ (0.32˚ ± 0.31˚, 2.1 ± 2 mm, 0.083 ± 0.080 in.)
RZN173L--CRMDKW 0˚17’ ± 18’ (0.29˚ ± 0.31˚, 1.9 ± 2 mm, 0.075 ± 0.080 in.)
LN165L--TRMDXW
0˚20’ ± 18’ (0.34˚ ± 0.31˚, 2.2 ± 2 mm, 0.087 ± 0.080 in.)
Europe
p LN165R--TRMDXW(3)
LN165L--PRMDXW
LN165R--PRMDXW 0˚18’ ± 18’ (0.31˚ ± 0.31˚, 2.0 ± 2 mm, 0.080 ± 0.080 in.)
LN165L--PRMSXW
LN170L--CRMDXW 0˚16’ ± 18’ (0.28˚ ± 0.31˚, 1.8 ± 2 mm, 0.071 ± 0.080 in.)
RZN169R--TRMDKQ(3) 0˚27’ ± 18’ (0.46˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
RZN169R--PRMDKQ
0˚19’ ± 18’ (0.32˚ ± 0.31˚, 2.1 ± 2 mm, 0.083 ± 0.080 in.)
LN167R--PRMDSQ Tire size: 205R16C, 205R16 R/F
Australia Tire size: 255/70R15 0˚19’ ± 18’ (0.33˚ ± 0.31˚, 2.1 ± 2 mm, 0.083 ± 0.080 in.)
RZN174R--CRMDKQ 0˚18’ ± 18’ (0.31˚ ± 0.31˚, 2.0 ± 2 mm, 0.080 ± 0.080 in.)
LN167R--TRMDSQ(3) 0˚27’ ± 18’ (0.45˚ ± 0.31˚, 2.9 ± 2 mm, 0.114 ± 0.080 in.)
LN172R--CRMDSQ(3) 0˚17’ ± 18’ (0.29˚ ± 0.31˚, 1.9 ± 2 mm, 0.075 ± 0.080 in.)
RZN169L--TRMDUV 0˚27’ ± 18’ (0.46˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
G.C.C.
RZN169L--PRMDUV 0˚26’ ± 18’ (0.43˚ ± 0.31˚, 2.8 ± 2 mm, 0.110 ± 0.080 in.)
Countries
LN166L--PRMDSV 0˚25’ ± 18’ (0.42˚ ± 0.31˚, 2.7 ± 2 mm, 0.106 ± 0.080 in.)
RZN168L--TRMDK
0˚29’ ± 18’ (0.49˚ ± 0.31˚, 3.2 ± 2 mm, 0.126 ± 0.080 in.)
RZN169L--TRMDU
RZN168L--PRMDK
RZN169R--TRMDU 0˚27’ ± 18’ (0.46˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
RZN193L--PRMDK
RZN169R--PRMDU Tire size: 205R16C 0˚26’ ± 18’ (0.43˚ ± 0.31˚, 2.8 ± 2 mm, 0.110 ± 0.080 in.)
Tire size: 255/70R15 0˚28’ ± 18’ (0.47˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
RZN169L--PRMDU Tire size: 205R16C 0˚27’ ± 18’ (0.46˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
Tire size: 255/70R15 0˚28’ ± 18’ (0.47˚ ± 0.31˚, 3.0 ± 2 mm, 0.120 ± 0.080 in.)
Others LN166R--TRMDS
0˚28’ ± 19’ (0.48˚ ± 0.31˚, 2.9 ± 2 mm, 0.114 ± 0.080 in.)
LN166L--TRMDS Tire size: 7.00--16
Tire size: 205R16C 0˚27’ ± 18’ (0.45˚ ± 0.31˚, 2.9 ± 2 mm, 0.114 ± 0.080 in.)
LN166R--PRMDS
0˚26’ ± 19’ (0.44˚ ± 0.33˚, 2.7 ± 2 mm, 0.106 ± 0.080 in.)
LN166L--PRMDS Tire size: 7.00--16
Tire size: 205R16C 0˚25’ ± 18’ (0.42˚ ± 0.31˚, 2.7 ± 2 mm, 0.106 ± 0.080 in.)
Tire size: 255/70R15 0˚26’ ± 18’ (0.43˚ ± 0.31˚, 2.8 ± 2 mm, 0.110 ± 0.080 in.)
LN171L--CRMDS 0˚18’ ± 18’ (0.31˚ ± 0.31˚, 2.0 ± 2 mm, 0.080 ± 0.080 in.)
LN191L--PRMDS Tire size: 7.00--16 0˚26’ ± 19’ (0.44˚ ± 0.33˚, 2.7 ± 2 mm, 0.106 ± 0.080 in.)
Tire size: 205R16C 0˚25’ ± 18’ (0.42˚ ± 0.31˚, 2.7 ± 2 mm, 0.106 ± 0.080 in.)
Tie rod end length difference 3.0 mm (0.118 in.) or less
Wheel angle Inside wheel 33˚ (31˚-- 34˚)
TO MODEL INDEX
SS--18
SS10W--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
2WD front
Upper suspension arm x Frame 96 980 71
Tie rod clamp lock nut 25 260 19
Knuckle stopper bolt lock nut 34 350 25
4WD and pre runner front
Lower suspension arm x Frame 195 2,000 145
Tie rod clamp lock nut 22 225 16
Knuckle stopper bolt lock nut 72 730 53
Pitman arm stopper bolt lock nut 72 730 53
Idler arm stopper bolt lock nut 72 730 53
TO MODEL INDEX
SS--19
SERVICE SPECIFICATIONS -- STEERING
STEERING
SS0AV--03
STEERING COLUMN
Non--tilt steering column:
Column tube support x Column tube 20 204 15
Sliding yoke x Main shaft assembly 35 360 26
Tilt steering column:
Tilt lever assembly lock nut 12 125 9
Tilt support No.1 reinforce set bolt 5.4 55 48 in.∙lbf
Steering support x Column tube 9.5 97 84 in.∙lbf
Sliding yoke x Main shaft assembly 35 360 26
TO MODEL INDEX
SS--20
SERVICE SPECIFICATIONS -- BODY
BODY
SS10U--01
FRONT SEAT (Sports type) -- -- --
Inner adjuster x Body 37 375 27
Outer adjuster x Body 37 375 27
Front seat cushion shield x Adjuster 18 185 13
REAR SEAT (Sports type ) -- -- --
Rear seat cushion frame x Body 18 185 13
Rear seatback frame x Rear seat cushion frame 18 185 13
TO MODEL INDEX
SUSPENSION AND AXLE
TIRE AND WHEEL

(2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA--1
TIRE AND WHEEL
(4WD and PRE RUNNER) . . . . . . . . . . . . . . . SA--3
FRONT WHEEL ALIGNMENT
(2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA--5
(4WD and PRE RUNNER) . . . . . . . . . . . . . . . SA--10

TO MODEL INDEX
SA--1
SUSPENSION AND AXLE -- TIRE AND WHEEL (2WD)
TIRE AND WHEEL (2WD) SA091--05
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
Europe:
Front Rear
Tire size
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)
185R14C--8PR
220 (2.2,
(2 2 32) 450 (4.5,
(4 5 65)
195R14C--8PR
Australia:
Front Rear
Tire size
Unladen or 2 passengers 100 kg of luggage or less

195R14C--8PR 220 (2.2, 32) 220 (2.2, 32)
Fully laden
195R14C--8PR 220 (2.2, 32) 450 (4.5, 65)
Others:
Front Rear
Tire size
Loaded
6.00--14--6PRLT 200 (2.0, 29) --
6.50--14--8PRLT -- 425 (4.25, 62)
220 (2.2, 32)

185R14C--8PR 450 (4.5, 65)
200 (2.0, 29)*
195R14C--8PR 220 (2.2, 32) 450 (4.5, 65)

195R15--6PRLT 180 (1.8, 26) 375 (3.75, 54)
Unloaded
6.00--14--6PRLT 180 (1.8, 26) --
6.50--14--8PRLT -- 240 (2.4, 35)
220 (2.2, 32)

185R14C--8PR 450 (4.5, 65)
200 (2.0, 29)*
195R14C--8PR 220 (2.2, 32) 450 (4.5, 65)
195R15--6PRLT 180 (1.8, 26) 375 (3.75, 54)
*: RZN142 series only
CONTINUED
(b) Check the tire runout.
Tire runout: 3.0 mm (0.118 in.) or less
R03031
TO MODEL INDEX
SA--2
SUSPENSION AND AXLE -- TIRE AND WHEEL (2WD)
2. ROTATING TIRES
(a) (b)
(a) Vehicle with front and rear tires of the different size:
Replace the right tire with the left one, vice versa.
Front (b) Vehicle with front and rear tires of the same size:
See the illustration for where to rotate each tire when you
include the spare tire in rotation.
F03265
3. INSPECT WHEEL BALANCE

(a) Check and adjust the Off--the--car balance.
(b) If necessary, check and adjust the On--the--car balance.
Imbalance after adjustment:
195R15--6PRLT: 13.0 g (0.029 lb) or less
Others: 15.0 g (0.033 lb) or less
R07928
4. CHECK WHEEL BEARING LOOSENESS

Check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check that oil leaks
F01415 S Check the mounting bushings for wear
S Bounce front and rear of the vehicle
TO MODEL INDEX
SA--3
SUSPENSION AND AXLE -- TIRE AND WHEEL (4WD and PRE RUNNER)
TIRE AND WHEEL (4WD and PRE

RUNNER) SA0LA--03
INSPECTION
HINT:
Pre runner is the model described below.
RZN193L--PRMDK, LN191L--PRMDS
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
Europe:
Front Rear
Tire size
205R16
170 (1.7, 25) 260 (2.6, 38)
Reinforced radial tire
Australia:
Front Rear
Tire size
Unladen or 2 passengers 100 kg of luggage or less

205R16
170 (1.7, 25) 170 (1.7, 25)
205R16C--6PR 170 (1.7, 25) 220 (2.2, 32)

255/70R15 112L LT 190 (1.9, 28) 190 (1.9, 28)
Fully laden
205R16
170 (1.7, 25) 240 (2.4, 35)
205R16C--6PR 170 (1.7, 25) 300 (3.0, 44)

255/70R15 112L LT 190 (1.9, 28) 240 (2.4, 34)
Others:
Front Rear
Tire size
205R16
170 (1.7, 25) 240 (2.4, 35)
205R16C--6PR 170 (1.7, 25) 300 (3.0, 44)

7.00--16--8PRLT 240 (2.4, 35) 425 (4.25, 62)
255/70R15 112L LT 190 (1.9, 28) 240 (2.4, 35)
(b) Check the tire runout.

Tire runout: 3.0 mm (0.118 in.) or less
CONTINUED
R03031
TO MODEL INDEX
SA--4
SUSPENSION AND AXLE -- TIRE AND WHEEL (4WD and PRE RUNNER)
2. ROTATING TIRES
HINT:
See the illustration for where to rotate each tire when you in-
Front clude the spare tire in rotation.
R13503
3. INSPECT WHEEL BALANCE

(a) Check and adjust the Off--the--car balance.
(b) If necessary, check and adjust the On--the--car balance.
Imbalance after adjustment:
14.0 g (0.031 lb) or less
4. CHECK FRONT SUSPENSION FOR LOOSENESS
5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
R07928 7. CHECK SHOCK ABSORBER WORKS PROPERLY
S Check that oil leaks
S Check the mounting bushings for wear
S Bounce front and rear of the vehicle
TO MODEL INDEX
SA--5
SUSPENSION AND AXLE -- FRONT WHEEL ALIGNMENT (2WD)
Front:
FRONT WHEEL ALIGNMENT (2WD) SA0LB--02
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SS -- 4)
Front: A -- B
Rear: C -- D
Measuring points:
B: Ground clearance of lower suspension arm bolt center.
B A
Rear:
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specified value.
If the vehicle height is not the specified value, try to adjust it by
pushing down on or lifting the body.
D C
F03230
2. INSTALL CAMBER--CASTER--KINGPIN GAUGE OR

POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION (See page SS -- 4)
If the steering axis inclination is not within the specified value,
after the camber and caster have been correctly adjusted, re-
Z03382 check the steering knuckle and front wheel for bearing or loose-
ness.
4. ADJUST CAMBER AND CASTER
(a) Loosen the 2 bolts.
(b) Adjust the camber and caster by adding or removing
shims on the upper suspension arm.
HINT:
Try to adjust the camber and caster to the center of the specified
values.
Shim thickness:
F03227 4.0 mm (0.157 in.) 1.6 mm (0.063 in.) 1.2 mm (0.047 in.)
If the steering axis inclination is not as specified value, after the

camber and caster have been correctly adjusted, recheck the
steering knuckle and front wheel for distortion or looseness.
NOTICE:
Adjust the shim thickness to 6.8 mm (3.8 -- 10.8 mm), and
adjust the difference between the front and rear of the up-
per suspension arm shaft to within 4 mm.
CONTINUED
TO MODEL INDEX
SA--6
(c) How to read adjustment chart.

Example: (1) Find the wheel alignment standard value applicable
F = Standard value point for the particular model.
f = Measurement point
(2) Mark the selected standard value on the adjustment
Camber chart.
Caster
Example:
Camber: --0˚06’ (--0.1˚)
Caster: 1˚00’ (1˚)
(3) Mark the alignment value measured when the ve-
hicle was non--loaded on the adjustment chart.
Example:
Camber: 0˚18’ (0.3˚)
Caster: 1˚30’ (1.5˚)
(4) As shown in the chart, read the distance from the
standard value to the measured value, and adjust
the front and/or rear adjusting shims accordingly.
Example:
Front shim: +(Increase) 2.2 mm
F05464 Rear shim: +(Increase) 1.2 mm CONTINUED
TO MODEL INDEX
SA--7
Camber
Caster
Front Shim Thickness Graduation mm

+ (Increase)
-- (Decrease)
+ (Increase)
Rear Shim Thickness
Graduation mm
CONTINUED
-- (Decrease)
F03255
TO MODEL INDEX
SA--8
(d) Tighten the 2 bolts.

B 5. INSPECT TOE -- IN (See page SS -- 4)

A
D If the toe--in is not within the specified value, adjust the tie rod
ends.
Front
C
SA3213
6. ADJUST TOE -- IN
(a) Remove the 2 clamp nuts.
F03228
(b) Adjust toe--in by turning the right and left tie rod tubes an
Front equal amount.
HINT:
Try to adjust the toe--in to the center of the specified value.
(c) Make sure that the lengths of the right and left tie rod ends
A B
are equal.
Tie rod end length difference:
A=B 3.0 mm (0.118 in.) or less
F03235 (d) Torque the clamp nuts.
7. INSPECT WHEEL ANGLE
A B B A Turn the steering wheel fully, and measure the wheel turning
angle.
Wheel turning angle:
Front
Outside wheel:
Item Inside wheel
A: Inside Reference
B: Outside Manual steering 36˚ (34˚ --- 37˚) 32˚
Power steering 38˚ (36˚ --- 39˚) 34˚
FA0018
CONTINUED
TO MODEL INDEX
SA--9
If the right and left inside wheel turning angles differ from the
specified value, adjust the wheel turning angle with the knuckle
stopper bolts.
If the wheel turning angle still cannot be adjusted within limits,
inspect and replace damaged or worn steering parts.
F03231
TO MODEL INDEX
SA--10
SUSPENSION AND AXLE -- FRONT WHEEL ALIGNMENT (4WD and PRE RUNNER)
FRONT WHEEL ALIGNMENT (4WD

and PRE RUNNER) SA1FL--01
INSPECTION
HINT:
Pre runner is the model described below.
RZN193L--PRMDK, LN191L--PRMDS
1. MEASURE VEHICLE HEIGHT (See page SS--4)

Front:
Front: A -- B
Rear: C -- D
Measuring points:
B: Ground clearance of lower suspension arm front bolt center.
NOTICE:
B A Before inspecting the wheel alignment, adjust the vehicle
height to specified value.
Rear:
If the vehicle height is not the specified value, try to adjust it by
pushing down on or lifting the body.
D
C
F03224
2. INSTALL CAMBER--CASTER--KINGPIN GAUGE OR

POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION (See page SS -- 4)
If the steering axis inclination is not within the specified value,
after the camber and caster have been correctly adjusted, re-
Z03382 check the steering knuckle and front wheel for bearing or loose-
ness.
4. ADJUST CAMBER AND CASTER
(a) Loosen the front and/or rear adjusting cam nuts.
(b) Adjust the camber and caster by front and/or rear adjust-
ing cams.
-- + HINT:
+ -- -- Try to adjust the camber and caster to the center of the specified
values.
CONTINUED
F03232
TO MODEL INDEX
SA--11
(c) How to read adjustment chart.

Example: (1) Find the wheel alignment standard value applicable
F = Standard value point for the particular model.
f = Measurement point
(2) Mark the selected standard value on the adjustment
Camber chart.
Caster Example:
Camber: 0˚00’ (0˚)
Caster: 1˚30’ (1.5˚)
(3) Mark the alignment value measured when the ve-
hicle was non--loaded on the adjustment chart.
Example:
Camber: 0˚30’ (0.5˚)
Caster: 1˚30’ (1.5˚)
(4) As shown in the chart, read the distance from the
standard value to the measured value, and adjust
the front and/or rear adjusting cams accordingly.
Example:
Front cam: +(Longer) 2.8
F05465 Rear cam: +(Longer) 2.6
Front
Front Cam Front Cam
(Longer) (Shorter) (Longer)
Rear Cam Rear Cam
(Shorter) (Longer) (Shorter)
CONTINUED R08019
TO MODEL INDEX
SA--12
Camber
Caster
Front Cam
Graduation
+ (Longer)
Rear Cam
Graduation
-- (Shorter) + (Longer)
-- (Shorter)
CONTINUED
F03237
(d) Torque the front and/or rear adjusting cam nuts.

Torque: 195 N∙m (2,000 kgf∙cm, 145 ft∙lbf)
TO MODEL INDEX
SA--13
B
5. INSPECT TOE -- IN (See page SS -- 4)
A
D If the toe--in is not within the specified value, adjust the tie rod
ends.
Front
C
SA3213
6. ADJUST TOE -- IN
(a) Remove the 2 clamp nuts.
F03234
(b) Adjust toe--in by turning the right and left tie rod tubes an
Front equal amount.
HINT:
Try to adjust the toe--in to the center of the specified value.
(c) Make sure that the lengths of the right and left tie rod ends
are equal.
A B
Tie rod end length difference:
A=B 3.0 mm (0.118 in.) or less
F03235
(d) Torque the clamp nuts.

HINT:
90˚ Face the clamp bolts toward the front of the vehicle.
Front
FA0927
7. INSPECT WHEEL ANGLE

A B B A (a) With the vehicle unladen, turn the ignition switch ON and
turn the steering wheel (steering effort: 20 N∙m (2 kgf∙m,
14 ft∙lbf)) then measure the wheel turning angle.
Front
Wheel turning angle:
A: Inside Outside wheel:
Inside wheel
B: Outside Reference
33˚ (31˚ -- 34˚) 32˚
FA0018
CONTINUED
TO MODEL INDEX
SA--14
If the right and left inside wheel turning angles differ from the
specified value, adjust the wheel turning angle with the pitman
arm and idler arm stopper bolts.
(b) Measure the clearance between the stopper bolt on the
steering knuckle side and bracket on the lower suspen-
sion arm side at the maximum wheel turning angles.
Clearance: 3.0 ± 1.0 mm (0.118 ± 0.039 in.)
If the wheel turning angle is not within the specified value, ad-
just the stopper bolt on the steering knuckle side.
Pitman Arm
Stopper Bolt Clearance:
3.0 ± 1.0 mm
(0.018 ± 0.039 in.)
Steering Knuckle
Front Stopper Bolt Arm Stopper Bolt
Idler Arm
Clearance:
3.0 ± 1.0 mm
(0.018 ± 0.039 in.)
F03238
TO MODEL INDEX
STEERING
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . SR--1

TO MODEL INDEX
STEERING:
1. Components SR-1 / 2
2. Removal SR-3
3. Disassembly SR-4 / 5
4. Inspection SR-6
5. Reassembly SR-7 / 9
6. Installation SR-10
TO MODEL INDEX
SR--1
STEERING -- STEERING COLUMN
STEERING COLUMN
SR0QS--02
COMPONENTS
Non--tilt steering column:
Transponder Key Coil
Key Cylinder
Column Upper Bracket
Transponder Key
Amplifier
z Brake Away Capsule
z Energy Absorbing Ignition Switch

Plate with Key Unlock
Warning Switch
Column Tube
z Energy Absorbing z Wave Snap Ring
Clip Column Upper Clamp
z Energy Absorbing Guide

Column Tube Support
z Energy Absorbing
Plate z Tapered--head Bolt
z Snap Ring
z Lower Bushing
20 (204, 15) z Energy Absorbing

Clip
35 (360, 26)
Lower Tube Attachment

Main Shaft Assembly
Thrust Stopper
N∙m (kgf∙cm, ft∙lbf) : Specified torque
CONTINUED
z Non--reusable part Sliding Yoke
Molybdenum disulfide lithium base grease F04882
TO MODEL INDEX
SR--2
Tilt steering column:
z Energy Absorbing Plate Transponder Key Coil
z Brake Away Capsule Key Cylinder

z Energy Absorbing Clip z Energy Absorbing Plate
z Energy Absorbing
Brake Away Bracket Guide
No. 1 Tilt Lever

Lock Bolt z Energy Absorbing Clip
z Lock Nut
9.5 (97, 84 in.∙lbf)
Column Upper
Bracket
Transponder Key
Plate Washer Ignition Switch with Key Amplifier
Unlock Warning Switch
Column Tube
Column Upper Clamp

No. 1 Support
Collar z Wave Snap Ring
Tilt Sub Lever
Tilt Steering
Support
Pawl Set Bolt

z Tapered--head Bolt
Tilt Lever Assembly
Lock Nut z Snap Ring
12 (125, 9)
Tilt Support No. 1

Reinforce
z Lower Bushing 5.4 (55, 48 in.∙lbf)
Torsion Spring
Main Shaft Assembly
35 (360, 26)
Thrust Stopper
Sliding Yoke

z Non--reusable part
Molybdenum disulfide lithium base grease
F04883
TO MODEL INDEX
SR--3
SR0QT--02
REMOVAL
(See Pub. No. RM585E on page SR--17)
TO MODEL INDEX
SR--4
SR0QU--02
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE TRANSPONDER KEY COIL
Remove the screw and transponder key coil.
2. REMOVE SLIDING YOKE

(a) Remove the bolt.
(b) Place matchmarks on the sliding yoke and main shaft as-
sembly.
(c) Remove the sliding yoke and thrust stopper.
Matchmarks
F02540
3. REMOVE COLUMN UPPER BRACKET AND COLUMN

UPPER CLAMP
Screw (a) Using a centering punch, mark the center of the 2 ta-
Extractor pered--head bolts.
(b) Using a 3--4 mm (0.12--0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts, column up-
per bracket and column upper clamp.
4. Non--tilt steering column:
F01493 REMOVE COLUMN TUBE SUPPORT
(a) Remove the bolt.
(b) Remove the column tube support with lower tube attach-
ment.
(c) Remove the lower tube attachment from the column tube
support.
5. Tilt steering column:
REMOVE TILT STEERING SUPPORT
(a) Remove the pawl set bolt, lock nut and plate washer.
(b) Remove the 2 No. 1 support collars and tilt steering sup-
port.
6. REMOVE 2 ENERGY ABSORBING PLATES

(a) Using pliers, remove the 2 energy absorbing clips.
(b) Remove the 2 energy absorbing plates, 2 energy absorb-
ing guides and 2 brake away capsules.
CONTINUED
R14934
TO MODEL INDEX
SR--5

REMOVE TILT LEVER ASSEMBLY AND BREAK AWAY
BRACKET
(a) Using a screwdriver, remove the torsion spring.
(b) Remove the tilt support No. 1 reinforce with the bolt.
HINT:
This bolt is left--handed one.
F01494
(c) To remove the lock nut, turn it clockwise.

HINT:
This nut is left--handed one.
(d) Remove the No. 1 tilt lever lock bolt, tilt lever assembly
and tilt sub lever.
(e) Remove the break away bracket.
F01495
8. REMOVE MAIN SHAFT ASSEMBLY AND LOWER

Extension Bar BUSHING
(a) Using a snap ring expander, remove the wave snap ring
from the shaft assembly.
(b) Using an extension bar and a hammer, tap out the shaft
assembly.
R15090
(c) Using a screwdriver, tap out the bushing.

(d) Using a snap ring expander, remove the snap ring from
the shaft assembly.
F01496
TO MODEL INDEX
SR--6
SR0QV--02
INSPECTION
1. INSPECT STEERING LOCK OPERATION
Check that the steering lock mechanism operates properly.
R14935
2. IF NECESSARY, REPLACE KEY CYLINDER

(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a screwdriver, and pull out
the cylinder.
(c) Install a new cylinder.
HINT:
Make sure the key is at the ACC position.
3. INSPECT IGNITION SWITCH
R14998 (See Pub. No. RM585E on page BE--13)
4. INSPECT KEY UNLOCK WARNING SWITCH
(See Pub. No. RM585E on page BE--13)
5. IF NECESSARY, REPLACE IGNITION SWITCH WITH
KEY UNLOCK WARNING SWITCH
(a) Remove the 2 screws from the column upper bracket.
(b) Remove the key cylinder.
(c) Slide out the switch.
(d) Install a new ignition switch with key unlock warning
switch with the 2 screws.
6. INSPECT TRANSPONDER KEY COIL
(See page BE--30)
7. IF NECESSARY, REPLACE TRANSPONDER KEY
COIL
8. IF NECESSARY, REPLACE TRANSPONDER KEY AM-
PLIFIER
(a) Remove the screw and transponder key amplifier.
(b) Install a new transponder key amplifier with the screw.
9. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube.
F01497
TO MODEL INDEX
SR--7
SR0QW--02
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH MOLYB-
DENUM DISULFIDE LITHIUM BASE GREASE
(See page SR--1)
2. INSTALL MAIN SHAFT ASSEMBLY AND LOWER

BUSHING
(a) Using a snap ring expander, install a new snap ring to the
SST shaft assembly.
(b) Install the shaft assembly into the column tube.
(c) Coat a new bushing with molybdenum disulfide lithium
Lower Bushing base grease.
(d) Using SST and a hammer, tap in the bushing.
R14999 SST 09612--22011
(e) Using a snap ring expander, install a new wave snap ring
to the shaft assembly.

Lower INSTALL TILT LEVER ASSEMBLY AND BREAK AWAY
Side
BRACKET
(a) Install the break away bracket.
HINT:
Install the bracket so that its bridge comes to the back of the
tube surface stopper.
F01498
(b) Install the No. 1 tilt lever lock bolt, tilt sub lever and tilt lever
assembly.
HINT:
Align the holes of the break away bracket and projections of the
tilt sub lever and No. 1 tilt lever lock bolt.
CONTINUED
F01499
TO MODEL INDEX
SR--8
(c) Torque the lock nut by turning it counterclockwise.

HINT:
S This nut is left--handed one.
S While tilting up the steering column, fix the tilt lever to the
highest position and tighten the nut.
(d) Install the tilt support No. 1 reinforce with the bolt.
Torque: 5.4 N∙m (55 kgf∙cm, 48 in.∙lbf)
F01500 HINT:
S This bolt is left--handed one.
S Align the reinforce and nut to eliminate looseness by turn-
ing the reinforce counterclockwise a little, then torque the
bolt.
(e) Install the torsion spring.
4. INSTALL 2 ENERGY ABSORBING PLATES

(a) Install the 2 new break away capsules.
(b) Install the 2 new energy absorbing guides and 2 new ab-
sorbing plates.
(c) Install the 2 new energy absorbing clips.
5. Non--tilt steering column:
INSTALL COLUMN TUBE SUPPORT
(a) Install the column tube attachment to the column tube
W03347 support.
(b) Install the column tube support with the bolt .
INSTALL TILT STEERING SUPPORT
(a) Install the 2 No. 1 support collars to the tilt steering sup-
port.
(b) Install the tilt steering support to the column tube.
(c) Install the pawl set bolt and plate washer.
(d) Install a new lock nut.
Torque: 9.5 N∙m (97 kgf∙cm, 84 in.∙lbf)
7. INSTALL COLUMN UPPER BRACKET AND COLUMN

UPPER CLAMP
(a) Install the column upper bracket and column upper clamp
with 2 new tapered--head bolts.
(b) Tighten the 2 new tapered--head bolts until the bolt heads
break off.
CONTINUED
F01501
TO MODEL INDEX
SR--9
8. INSTALL SLIDING YOKE

(a) Install the thrust stopper and sliding yoke.
(b) Align the matchmarks on the sliding yoke and main shaft
assembly.
(c) Install the bolt.
9. INSTALL TRANSPONDER KEY COIL
Install the transponder key coil with the screw.
TO MODEL INDEX
SR--10
SR0QX--02
INSTALLATION
(See Pub. No. RM585E on page SR--25)
TO MODEL INDEX
BODY ELECTRICAL
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . BE--1

ENGINE IMMOBILISER SYSTEM . . . . . . . . . . BE--23

TO MODEL INDEX
AUDIO SYSTEM:
Page 1 of 2
DESCRIPTION:
1. Radio Wave Band BE-1
2. Service area BE-1
3. Reception problems BE-1 / 2
4. Noise problems BE-2 / 3
5. Outline of AVC-LAN BE-3
TROUBLESHOOTING:
1. Always inspect the trouble with taking the following into consideration
BE-4
2. Diagnosis function BE-5 / 6
3. Diagnosis code list BE-6 / 7
4. Troubleshooting for ANTI-THEFT SYSTEM BE-8
1. Radio No power coming in BE-9
2. Radio Power coming on, but radio not operating BE-9
3. Radio Noise present, but AM-FM not operating BE-10
4. Radio Either speaker does not work BE-10
5. Radio Either AM-FM does not work, reception poor BE-11
6. Radio Sound quality poor BE12
7. Radio Cannot set station select button, present memory
disappears BE-12
8. Tape Player cassette tape cannot be inserted BE-13
9. Tape player cassette tape inserted, but no power BE13
10.Tape Player power coming in, but tape player not operating BE-14
11.Tape Player either speaker does not work BE-14
12.Tape Player sound quality poor (volume faint) BE-15
13.Tape Player tape jammed, malfunction with tape speed or
auto reverse BE15
14.Tape Player APS, SKIP, RPT, buttons not working BE-16
15.Tape Player cassette tape will not be ejected BE-16
16.CD Player CD cannot be inserted BE-17
17.CD Player CD inserted, but no power BE-17
18.CD Player power coming in, but CD player not operating BE-18
19.CD Player sound jumps BE18
CONTINUED
TO MODEL INDEX
AUDIO SYSTEM:
Page 2 of 2
20.CD Player sound quality poor (volume faint) BE-19

21,CD Player either speaker not working BE-19
22.CD Player CD will not be ejected BE-20
23.Antenna Antenna-related BE-21
24.Noise, noise produced by vibration or shock while driving BE-21
25.Noise, noise produced when engine starts BE-22
TO MODEL INDEX
BE--1
BODY ELECTRICAL -- AUDIO SYSTEM
AUDIO SYSTEM BE109--01
DESCRIPTION
1. RADIO WAVE BAND
The radio wave bands used in radio broadcasting are as follows:
Frequency 30 kHz 300 kHz 3 MHz 30 MHz 300 MHz
Designation LF MF HF VHF
Radio wave AM FM
Modulation method Amplitude modulation Frequency modulation
LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency
2. SERVICE AREA
There are great differences in the size of the service area for AM
and FM monaural. Sometimes FM stereo broadcasts cannot be
received even though AM comes in very clearly.
Not only does FM stereo have the smallest service area, but it
FM (Stereo) also picks up static and other types of interference (”noise”)
FM (Monaural) easily.
AM
BE2818
3. RECEPTION PROBLEMS
Besides the problem of static, there are also the problems
called ”fading”, ”multipath” and ”fade out”. These problems are
caused not by electrical noise but by the nature of the radio
waves themselves.
Fading Ionosphere S Fading

Besides electrical interference, AM broadcasts are
also susceptible to other types of interference, es-
pecially at night. This is because AM radio waves
bounce off the ionosphere at night. These radio
waves then interfere with the signals from the same
transmitter that reach the vehicle’s antenna directly.
This type of interference is called ”fading”.
BE2819
CONTINUED
TO MODEL INDEX
BE--2
Multipath S Multipath
One type of interference caused by bouncing of ra-
dio waves off obstructions is called ”multipath”. Mul-
tipath occurs when a signal from the broadcast
transmitter antenna bounces off buildings and
mountains and interferes with the signal that is re-
ceived directly.
BE2820
Fade Out S Fade Out

Because FM radio waves are of higher frequencies
than AM radio waves, they bounce off buildings,
mountains, and other obstructions. For this reason,
FM signals often seem to gradually disappear or
fade away as the vehicle goes behind a building or
other obstructions. This is called ”fade out”.
BE2821
4. NOISE PROBLEMS
(a) Questionnaire for noise:
It is very important for noise troubleshooting to have good un-
derstanding of the claims from the customers, so make the best
use of the following questionnaire and diagnose the problem
accurately.
Noise occurs at a specific place. Strong possibility of foreign noise.
There is a case that the same program is broadcasted

Noise occurs when listening to from each local station. This may be the case you are
AM faint broadcasting. listening to the weaker station.
Noise occurs only at night. Strong possibility of the beat from a distant broadcasting.
Noise occurs while driving and Strong possibility of multipath noise and fade out.
FM at a specific place.
HINT:
In the case that the noise occurrence condition does not meet
any of the above questionnaire, check based on the ”Trouble
Phenomenon”.
Refer to previous page for multipath and fading.
CONTINUED
TO MODEL INDEX
BE--3
(b) Matters that require attention when checking:

S Noise coming into the radio usually has no harm for
practical use as the noise protection is taken and it
is hardly thinkable for an extremely loud noise to
come in. When extremely loud noise comes into the
radio, check if the grounding is normal where the
antenna is installed.
S Check if all the regular noise prevention parts are
properly installed and if there is any installation of
non--authorized parts and non--authorized wiring.
S If you leave the radio out of tune (not tuning), it is
easy to diagnose the phenomenon as noise occurs
frequently.
5. OUTLINE OF AVC--LAN
(a) What is AVC--LAN?
AVC--LAN is the abbreviation, which stands for Audio Visual Communication--Local Area Network.
This is a unified standard co--developed by 6 audio manufactures associated with Toyota Motor Corpo-
ration.
The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication
and communication signal.
(b) Objectives
Recently the car audio system has been rapidly developed and functions have been changed drasti-
cally. The conventional system has been switched to the multi--media type such as a navigation sys-
tem. At the same time the level of customers needs to audio system has been heightened. This lies
behind this standardization.
The concrete objectives are explained below.
S When products by different manufactures were combined together, there used to be a case
that malfunction occurred such as sound did not come out. This problem has been resolved
by standardization of signals.
S Various types of after market products have been able to add or replace freely.
S Thanks to the above (2), each manufacture has become able to concentrate on developing
products in their strongest field. This has enabled many types of products provided inex-
pensively.
S Conventionally, a new product developed by a manufacture could not be used due to a lack
of compatibility with other manufactures products. Thanks to this new standard, users can
enjoy compatible products provided for them timely.
The above descriptions are the objectives to introduce AVC--LAN. By this standardization, development of
new products will no longer cause systematic errors. Thus, this is very effective standard for a product in the
future.
HINT:
S When +B short or GND short is detected in AVC--LAN circuit, communication stops. Accordingly the
audio system does not function normally.
S When audio system is not equipped with a navigation system, audio head unit is the master unit.
S The car audio system using AVC--LAN circuit has a diagnosis function.
S Each product has its own specified numbers called physical address. Numbers are also allotted to
each function in one product, which are called logical address.
TO MODEL INDEX
BE--4
BE10A--01
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (ECU part) of the audio system, be careful that no part of your
body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement
part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during sys-
tem operation and was prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
1. Always inspect the trouble with taking the following items into consideration.
(a) Open or short circuit of the wire harness
(b) Connector or terminal connection fault
(c) For audio systems with anti--theft system, troubleshooting items marked (*) indicate that ”Trouble-
shooting for ANTI--THEFT SYSTEM” should be carried out first.
Problem No.
Radio No power coming in. *1
Power coming in, but radio not operating. *2
Noise present, but AM -- FM not operating. 3
Either speaker does not work. 4
Either AM or FM does not work. 5
Reception poor (Volume faint). 5
Few preset tuning bands. 5
Sound quality poor. 6
Cannot set station select button. 6
Preset memory disappears. 7
Tape Player Cassette tape cannot be inserted. 8
Cassette tape inserted, but no power. *9
Power coming in, but tape player not operating. 10
Sound quality poor (Volume faint). 12
Tape jammed, malfunction with tape speed or auto -- reverse. 13
APS, SKIP, RPT buttons not operating. 14
Cassette tape will not be ejected. *15
CD Player CD cannot be inserted. 16
CD inserts, but no power. 17
Power coming in, but CD player not operating. 18
Sound jumps. 19
Sound quality poor (Volume faint). 20
CD will not be ejected. 22
Antenna Antenna does not fully extend or fully retract. 23
Antenna -- related. 24
Noise Noise produced by vibration or shock while driving. 25
Noise produced when engine starts. 26
CONTINUED
TO MODEL INDEX
BE--5
2. Diagnosis function
Error codes over tuner and connected equipment are displayed on the screen of tuner.
(a) Diagnosis start--up
For shifting to diagnosis mode, push ”CD” button 3 times with pressing ”1” and ”6” of TRACK TUNE
APS button at the same time while the audio power is OFF and ACC is ON.
In diagnosis mode, by pressing ”CD” button for 2 seconds or turning the ignition key OFF, the diagnosis
mode is released.
<Example>
TUNE ”UP” and ”1” button ”6” button ”CD” button

”DOWN” buttons
I08769
(b) LAN check

When starting up the diagnosis mode, the mode turns to LAN check mode, the screen displays the
code numbers (physical address) of tuner and connected equipment. Smaller codes are displayed in
order, displayed code numbers are switched by operating TUNE ”UP” or TUNE ”DOWN” button. In LAN
check mode, by pressing ”5” of TRACK TUNE APS button for more than 2 secs., diagnosis memory
of each equipment can be deleted, when deletion is completed, the mode returns to LAN check mode.
Code No. (physical address) List
Code No. Equipment name
190 Radio receiver assembly (Audio head unit)
240 CD changer (in Luggage room)
360 CD changer(in center console)
(c) System check
When pressing ”1” of TRACK TUNE APS button in LAN check mode, the mode turns to the system
check mode, the system performs self diagnosis of connected equipment and displays the results. The
smaller code numbers (physical address) are displayed in order (code No. (physical address), diagno-
sis code, support code of diagnosis code (object equipment)). When no error is detected in the system,
”00” is displayed. When an error code is detected, up to 6 codes per one system are displayed. Press-
ing TUNE ”UP” or TUNE ”DOWN” switches the display. In the system check mode, when pressing ”6”
of TRACK TUNE APS button the mode returns to LAN check mode.
CONTINUED
TO MODEL INDEX
BE--6
(d) Diagnosis memory

In LAN check mode, when pressing ”2” of TRACK TUNE APS button the mode turns to the diagnosis
memory mode. The results of self diagnosis performed over tuner and connected equipment are mem-
orized and displayed. The smaller code numbers (physical address) are displayed in order (code No.
(physical address), periodic communication number when error occurs, diagnosis code, and support
code of diagnosis code (object equipment)). When no error is detected in the system, ”00” is displayed.
When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE ”UP”
or TUNE ”DOWN” switches the display. Each diagnosis code is same as code in the system check
mode. When pressing ”6” of TRACK TUNE APS button, the mode returns to LAN check mode.
3. Diagnosis code list
Parts Countermeasure System Diagnosis

DTC Diagnosis item Diagnosis content
Name and inspected parts Check memory
41 AM tuner error There is an error in AM tuner. X f
42 FM tuner error There is an error in FM tuner.Radio receiver check. X f
50 Cassette error There is an error in cassette

deck. X f
Head An error occurs whil Radio receiver check.
Unit transmitting a signal from
D1 Transmitter error Wire harness and f f
head unit to the system.
connecter check.
AVC--LAN Radio receiver does not
D4 Periodic communica- respond to periodic X f
tion no response communication. Radio receiver check.
Result of diagnosis is not
FF Diagnosis no response f X
issued from start to finish.
Error codes other than CD changer check. X
60 CD error f
61--69 are detected.
61 EJECT error CD is not ejected. CD changer check. X f
Magazine check.
62 DISC uopside down CD is inserted inside CD check. X f
out or it has a flaw.
63 Pickup temperature High temperature in CD
detection X f
changer is detected.
CD changer check.
64 Excessive current Excessive current to
X f
detection CD changer is detected.
An error occurs in insertion
67 Tray insertion/ or discharging operation of
CD changer check. X f
CD discharging error Magazine check.
CD changer tray.
68 Elevator error An error occurs in

X f
elevator of CD changer.
An error occurs in CD
69 Clamp error X f
changer clamp.
An error occurs whil
D1 Transmitter error transmitting a signal from f f
CD changer to the system. CD changer check.
AVC--LAN CD changer does not

D4 Periodic communication respond to periodic X f
no response communication.
FF Diagnosis no response Result of diagnosis is not f X

CONTINUED
TO MODEL INDEX
BE--7
Parts Countermeasure System Diagnosis

DTC Diagnosis item Diagnosis content
Name and inspected parts Check memory
An error occurs whil

D1 Transmitter error transmitting a signal from f f
stereo component amplifier
to the system.
AMP Stereo component
AVC--LAN Stereo component amplifier check.
D4 Periodic communication amplifier does not respond X f
no response to periodic communication.
FF Diagnosis no response Result of diagnosis is not f X

CONTINUED
TO MODEL INDEX
BE--8
4. Troubleshooting for ANTI--THEFT SYSTEM
Turn Ignition key from LOCK position to ACC position.
Display A: Display E: Display B

ID Number is set. ANTI--THEFT SYSTEM
operation condition.
(ID number input error
”SEC” display disappears 10 times or more.) Radio switch ON.
after 1 second.
NO Yes Display B Display D
Take to designated
radio service station.
Refer to each Normal

malfunction item. operation.
Radio switch ON. Normal operation.

OK
NG
Cancel ID number, refer to each malfunction

item.
ANTI--THEFT SYSTEM operation condition.

(ID number input error 9 times or less.)
Input ID number to cancel ANTI--THEFT SYSTEM, and check display.
Display A → B Display B Display E Display C →A
Radio switch ON. Refer to each Take to designated ANT--THEFT SYSTEM not
malfunction item. radio service station. cancelled.
(ID number input error 9
Display D times or less.)
ANTI--THEFT SYSTEM cancelled. Normal

Check audio system again. OK operation.
Display ”E”
NG
Cancel ID number, refer to each malfunction item.
(Liquid Crystal Display (LCD) or VFD for Audio System)
Display ”A” Display ”B” Display ”C” Display ”D” Example:

Blank, Error Times Radio Display
No Illumination
I01395
TO MODEL INDEX
BE--9
1 Radio NO POWER COMING IN
Yes
Is tape player operating normally? Radio assembly faulty.
No
NG
Check CIG & RAD fuse is OK? Replace fuse.
OK
No
Is ACC applied to radio? ACC wire harness faulty.
Yes
NG
Check if GND (wire harness side) to radio is OK? GND wire harness faulty.
OK
Radio assembly faulty.
2 Radio POWER COMING ON, BUT RADIO NOT OPERATING
A Antenna w/o Motor

If radio side
A faulty
Go to No.23. Radio faulty.
Do speakers pop when the volume switch is turned
to maximum and then the power is switch ON?
No
Yes No
Is tape player operating normally? Is power for the antenna Radio assembly
being output from the radio faulty.
No or radio assembly?
Yes
Go to No.23.
No
Does continuity exist in speaker wire harness? Speaker wire harness faulty. If radio side
faulty
Yes
Radio assembly
Yes Speaker faulty. faulty.
Temporarily install another speaker
Function OK?
No
V07430
TO MODEL INDEX
BE--10
3 Radio NOISE PRESENT, BUT AM--FM NOT OPERATING
No
Is power for the antenna being output from the Radio assembly faulty.
radio or radio assembly?
Yes
Go to No.23.
If radio side faulty

Yes
No
No
Hiss noise from speaker? Power amplifier faulty. Recheck system after repair.
Yes
Radio asembly faulty. Recheck system after repair.
4 Radio EITHER SPEAKER DOES NOT WORK
Yes
No
Is hiss noise produced by non--functioning speaker? Yes Radio assembly faulty.
No
No
Does continuity exist in speaker wire harness? Speaker wire harness faulty.
Yes
Yes
Temporarily install another speaker. Speaker faulty.
Function OK?
No
CONTINUED
V07431
TO MODEL INDEX
BE--11
EITHER AM OR FM DOES NOT WORK, RECEPTION

5 Radio POOR (VOLUME FAINT), FEW PRESET TUNING BANDS
Yes
Problem with radio wave signals or location? Poor signals or poor location.
No
No
Are both AM and FM defective? Radio assembly faulty.
Yes
Is power for the antenna being output from No

the radio assembly?
Yes
Go to No.23.
If radio side faulty.
Yes
Is tape player operating normaly? Radio assembly faulty.
No
Yes
Functions OK?
No

CONTINUED
V07432
TO MODEL INDEX
BE--12
6 Radio SOUND QUALITY POOR
No Yes
Is sound quality always bad? Is sound quality bad in Poor signals or poor
certain areas only? location.
Yes
No
Yes
Is tape player operating normaly? Go to No.23.
No If radio side faulty
Is speaker properly installed? No

Install properly.
Yes
Yes
Function OK?
No
Go to No.23. If radio side faulty

CANNOT SET STATION SELECT BUTTON, PRESET

7 Radio MEMORY DISAPPEARS
Yes
Can cassette tape be inserted in tape player? Radio assembly faulty.
No
NG
Check if DOME fuse is OK? Replace fuse.
OK
No
Is +B applied to radio or radio assembly? +B wire harness faulty.
Yes
NG
Check if GND (wire harness side) to GND faulty.
radio assembly is OK?
OK
CONTINUED
V07433
TO MODEL INDEX
BE--13
8 Tape Player CASSETTE TAPE CANNOT BE INSERTED
Yes
Is there a foreign object inside tape player? Remove foreign object.
No
Yes
Is radio operating normally? Radio assembly faulty.
No
NG
OK
No
Is +B applied to radio assembly? +B wire harness faulty.
Yes
NG
Check if GND (wire harness side) to radio assembly GND faulty.
is OK?
OK
9 Tape Player CASSETTE TAPE INSERTED, BUT NO POWER
Yes
No
NG
Check if CIG & RAD fuse is OK? Replace fuse.
OK
No
Is ACC applied to radio assembly? ACC wire harness faulty.
Yes

CONTINUED
V07434
TO MODEL INDEX
BE--14
POWER COMING IN, BUT TAPE PLAYER NOT

10 Tape Player OPERATING
Yes
Functions OK if different cassette tape inserted? Cassette tape faulty.
No
Yes
No
No
Yes
Yes
Functions OK?
No
11 Tape Player EITHER SPEAKER DOES NOT WORK
Yes
No
Yes
Is hiss noise produced by non--functioning speaker? Radio assembly faulty.
No
No
Yes
OK
Functions OK?
NG
CONTINUED
V07435
TO MODEL INDEX
BE--15
12 Tape player SOUND QUALITY POOR (VOLUME FAINT)
Yes
Functions OK if different cassette tape inserted? Cassette tape faulty.
No
Yes
Operates normally after cleaning the heads? Head dirty.
No
Yes
No
No
Is speaker properly installed? Install properly.
Yes
Yes
Temporarily install another speaker. Functions OK? Speaker faulty.
No
TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR

13 Tape Player AUTO--REVERSE
Yes Cassette tape faulty.

Functions OK if different tape (less than 120 mins.) is inserted?
No
Yes
Is there a foreign object inside tape player? Remove foreign object.
No
Operates normally after cleaning the heads? Yes Head dirty.
No

CONTINUED
V04922
TO MODEL INDEX
BE--16
14 Tape Player APS, SKIP, RPT BUTTONS NOT OPERATING
No
Functions OK if different cassette tape inserted? Radio assembly faulty.
Yes
Cassette tape faulty. {Less than 3 secs. of silence between songs (APS, RPT).
Less than 15 secs. of silence (SKIP).}
15 Tape Player CASSETTE TAPE WILL NOT BE EJECTED
No
Is tape player operating normally? Cassette tape jammed.
Yes
Yes
No
NG
OK
No
Is B+ applied to radio assembly? B+ wire haness faulty.
Yes

CONTINUED
V07436
TO MODEL INDEX
BE--17
16 CD Player CD CANNOT BE INSERTED
Yes
Is CD already inserted? Eject CD.
No
Is auto search button of radio operating normally?
Yes Is +B applied to CD player? No Radio assembly
faulty.
Yes
Check if GND wire harness side
NG
to CD player is OK?
No
OK
CD player faulty.
Check if DOME fuse is OK? NG Replace fuse.

OK
No
Yes
NG
Check if GND (wire harness side) to radio assembly is OK? GND faulty.
OK
17 CD Player CD INSERTED, BUT NO POWER
Is radio operating normally? Yes Is ACC applied to CD player? No

Radio assembly
faulty.
Yes
No CD player faulty.
NG
Check if CIG fuse is OK? Replace fuse.
OK
Is ACC applied to radio assembly? No
ACC wire harness faulty.
Yes
CONTINUED
V08487
I05488
TO MODEL INDEX
BE--18
18 CD Player POWER COMING IN, BUT CD PLAYER NOT OPERATING
No
Is CD inserted with correct side up? Insert correctly.
Yes
Yes
Function OK if different CD inserted? CD faulty.
No
Is radio operating normally? Yes Yes
Is temperature inside cabin hot?
Protective circuit in
No operation.
Yes
No Has sudden temperature change Formation of condensation
occurred inside cabin? due to temp. changes.
No
CD player faulty.
No
Is there continuity in speaker wire harness? Speaker wire harness faulty.
Yes
Temporarily install another speaker. Yes
Speaker faulty.
Functions OK?
No
Radio assembly faulty.Recheck system after repair.
19 CD Player SOUND JUMPS
Yes
Does sound jump only during strong vibration? Jumping caused by vibration.
No
No
Is CD player properly installed? Install properly.
Yes
Yes
Functions OK if different CD inserted? CD faulty.
No
Yes
Has sudden temperature change occurred inside cabin? Formation of condensation due to
temp. changes.
No
CD player faulty.
CONTINUED
V08550
I05489
TO MODEL INDEX
BE--19
20 CD Player SOUND QUALITY POOR (VOLUME FAINT)
Yes
Function OK if different CD inserted? CD faulty.
No
Is radio operating normally? Yes
CD player faulty.
No
Is speaker property installed? No
Install properly.
Yes
Speaker faulty.
Functions OK?
No
Radio assembly or CD player faulty.
21 CD Player EITHER SPEAKER DOES NOT WORK
Yes
Is radio operating normally? CD player faulty.
No
Yes Radio assembly faulty.
Is hiss noise produced by non--functioning speaker?
Recheck system after repair.
No
No
Is there continuity in speaker wire harness? Speaker wire harness faulty.
Yes
Speaker faulty.
Function OK?
No
Recheck system after repair. CONTINUED
V08551
TO MODEL INDEX
BE--20
22 CD Player CD WILL NOT BE EJECTED
Is auto search button of radio Yes No Radio assembly

Is +B applied to CD player?
operating normally? faulty.
Yes
CD player faulty.
No
NG
OK
No
Yes
Radio assembly faulty. CONTINUED
I05490
TO MODEL INDEX
BE--21
23 Antenna ANTENNA--RELATED
No
Is antenna extended. Extend fully.
Yes
Yes
Temporarily install another antenna. Antenna faulty.
Functions OK?
No
Radio side faulty.
NOISE PRODUCED BY VIBRATION OR SHOCK WHILE

24 Noise DRIVING
No
Is speaker properly installed? Install properly.
Yes
No
Is each system correctly installed?
Yes
With vehicle stopped, lightly tap each system. Yes Each system faulty.
Is noise produced?
No
Noise produced by static electricity accumulating

in the vehicle body. CONTINUED
V04924
TO MODEL INDEX
BE--22
25 Noise NOISE PRODUCED WHEN ENGINE STARTS
Whistling noise which becomes high--pitched Yes

Generator noise.
when accelerator strongly depressed, disappears
shortly after engine stops.
No
Yes
Whining noise occurs when A/C is operating. A/C noise.
No
Scratching noise occurs during sudden Yes

Fuel gauge noise.
acceleration, driving on rough roads or when
ignition switch is turned on.
No
Clicking sound heard when horn button is Yes

Horn noise.
pressed, then released. Whirring/grating sound
when pushed continuously.
No
Yes
Murmuring sound stops when engine stops. Ignition noise.
No
Tick--tock noise, occurs in co--ordination with Yes

Turn signal noise.
blinking of flasher.
No
Yes
Noise occurs during window washer operation. Washer noise.
No
Scratching noise occurs while engine is running, Yes

Engine coolant temperature gauge noise.
continues a while even after engine stops.
No
Yes
Scraping noise in time with wiper beat. Wiper noise.
No
Other type of noise.
V08467
TO MODEL INDEX
ENGINE IMMOBILISER SYSTEM
TROUBLESHOOTING:
1. Cranking occurs, but engine does not start BE-23
2. Engine starts, but stops after 5 seconds BE-24
LOCATION BE-25
PRE-CHECK BE-26
1. Transponder key ECU input condition display read code BE-26
2. Transponder key ECU input condition display code list BE-27
3. Transponder key ECU input condition display malfunction list BE-28 / 29
INSPECTION BE-30
TO MODEL INDEX
BE--23
BODY ELECTRICAL -- ENGINE IMMOBILISER SYSTEM
ENGINE IMMOBILISER SYSTEM

BE0YJ--02
TROUBLESHOOTING
HINT:
If a malfunction occurs in the engine immobiliser system, either of the following symptoms occurs:
S Cranking occurs, but the engine does not start.
S The engine starts, but stops after 5 seconds.
If either or these symptoms occurs, do troubleshooting to the following flow chart.
1. CRANKING OCCURS, BUT THE ENGINE DOES NOT START
Does the engine start using another ignition key? Yes The ignition key is damaged or is not registered.
No
Check the DTC of the engine. Is code 31 output when the key is inserted in the ignition
key cylinder?
Yes No
Register the Replace the

transponder key. transponder key.
No
Is DTC code 99 output? Troubleshoot the engine.
Yes
No
Check the wire harness and connector between the engine ECU Repair or replace the wire harness or the connector.
(M/T) , engine and ECT ECU (A/T) and the transponder key ECU.
Yes
Engine immobiliser system is abnormal.
Is DTC code 32 or 33 output when the key is inserted in the ignition No

Check the wire harness and connector.
key cylinder?
Yes
CONTINUED
Troubleshoot according to the flow chart.
Code 32: See page BE-- 27
Code 33: See page BE -- 27
TO MODEL INDEX
BE--24
2. ENGINE STARTS, BUT STOPS AFTER 5 SECONDS

Does the engine still stop after 5 secs, even when the engine is No Key is damaged. Exchange key.
started using another transponder key?
Yes
NG
If EFI fuse blown? Exchange EFI fuse.
OK
NG
Is connector of transponder key ECU properly locked? Insert connector until it locks securely.
OK
Check the wire harness and connector between the engine ECU NG Repair or replace the wire harness or connector.
(M/T) , engine and ECT ECU (A/T) and the transponder key ECU.
OK
Check that voltage is applied between terminal 10 of transponder NG Exchange the engine ECU (M/T) or engine and
key ECU and body ground immediately after engine starts. ECT ECU (A/T).
(See page BE--30)
OK
Exchange the transponder key ECU.

TO MODEL INDEX
BE--25
BE0YK--02
LOCATION
Engine Room R/B

D DOME Fuse
Engine and ECT ECU

Transponder Key Coil
Driver Side J/B

D Integration Relay
D IGN Fuse
D ECU--B Fuse
Transponder Key Amplifier

Transponder Key ECU
I09475
TO MODEL INDEX
BE--26
BE0YL--02
Check Connector PRE--CHECK

E1 OP1 1. TRANSPONDER KEY ECU INPUT CONDITION DIS-
PLAY READ CODE
(a) Connect the positive (+) lead from the volt meter (Analog
Type) to OP1 of the check connector and the negative (--)
lead to E1 of the check connector.
F02201
Example (b) Insert the ignition key in the key cylinder.

0.5 1.5 sec. (c) Read the code from the movement of the tester needle.
sec. 2.5 sec. 4.5 sec. If no code is output, turn the ignition switch ON.
ON
If a code is now output, check if the DOME fuse is blown.
HINT:
S The code can be read using a luminous diode (Recom-
OFF mend activation current 10 -- 20 mA) instead of a tester.
Code 11 Code 21
S A digital tester can also be used.
I01826 Display condition:
S When there are multiple codes, they are output in order
staring from the lowest code.
S After all the codes are output, Lo is displayed for 4.5
secs., then all the code are output again starting from the
lowest code.
S If the situation changes during code output, Lo is output
for 4.5 secs. after output of the current code ceases, then
the codes are output again starting from the lowest code.
E.g. while 11 (out of 11 and 21) is being output, conditions
change and 12 is added. So after 11 is output, Lo is output
for 4.5 secs., then 11, 12 and 21 are output.
CONTINUED
TO MODEL INDEX
BE--27
2. TRANSPONDER KEY ECU INPUT CONDITION DIS-

PLAY CODE LIST
Gasoline engine:
Code Output condition
11 Key unlock warning switch ON (Ignition key inserted)
12 Any door is open. (Door courtesy switch ON)
13 Ignition switch at ON position
Master key is inserted in key cylinder and the immobiliser system
21
is OFF.
Sub key is inserted in key cylinder and immobiliser system is

22
OFF.
Key code recorded in transponder key ECU differs from code of
31
key inserted in key cylinder.
32 Transponder key code cannot be read.

Key code cannot be read because format of chip inside key is
33
wrong.
Transponder key ECU has no memory space to register key

34
code.
41 Recognition code is normal and the immobiliser system is OFF.
Diesel engine:
Code Output condition
11 Key unlock warning switch ON (Ignition key inserted)
12 Any door is open. (Door courtesy switch ON)
13 Ignition switch at ON position
Master key is inserted in key cylinder and the immobiliser system
21
is OFF.
Sub key is inserted in key cylinder and immobiliser system is
22
OFF.
Key code recorded in transponder key ECU differs from code of

31
key inserted in key cylinder.
32 Transponder key code cannot be read.

Key code cannot be read because format of chip inside key is
33
wrong.
34
code.
51 FCVC code is learned.

52 FCVC is unlocked.
53 FCVC code is error.
54 FCVC is check--sum error.
55 FCVC is factory code initialling
56 FCVC code line trouble
57 FCVC trouble
While ignition switch ON, no response from FCVC for 5 consecu-
58
tive sec,
CONTINUED
TO MODEL INDEX
BE--28
3. TRANSPONDER KEY ECU INPUT CONDITION DIS-

PLAY MALFUNCTION LIST
Symptom Cause
1. DOME Fuse
No code is output. 2. Wire harness or connector
3. Transponder key ECU
1. Key unlock warning switch
Even when key is inserted in key cylinder, Code 11 is not output. 2. Wire harness or connector
1. Door courtesy switch
Code 12 is not output when the door is open. 2. Wire harness or connector
1. IGN Fuse
Code 13 is not output when ignition switch ON. 2. Wire harness or connector
Code 31 is output when key is inserted in key cylinder. Key code is not registered.
1. Transponder key coil
Code 32 is output.
3. Transponder key amplifier
4. Wire harness or connector
Code 33 is output.
2. Transponder key amplifier

Code 34 is output.
code.
CONTINUED
TO MODEL INDEX
BE--29
S If code 32 is output, troubleshoot according to this flow chart.
NG
Check for continuity between terminals of the transponder key coil.
Exchange the transponder key coil.
OK
OK
Exchange the transponder key amplifier with a new one. Exchange the transponder key amplifier.
Check again whether the engine starts.
NG
Reinstall the original transponder key amplifier.
Check the wire harness and connector. NG Repair or replace the wire harness or the connector.
OK
Replace the transponder key ECU.
S If code 33 is output, troubleshoot according to this flow chart.
OK
Exchange the transponder key amplifier with a new one. Exchange the transponder key amplifier.
Check again whether the engine starts.
NG
Reinstall the original transponder key amplifier.
Exchange the transponder key amplifier.

TO MODEL INDEX
BE--30
BE0YM--01
2 1
INSPECTION
1. INSPECT TRANSPONDER KEY COIL CONTINUITY
Check that continuity exists between terminal 1 and 2.
If continuity is not as specified, replace the coil.
N23511
2. INSPECT TRANSPONDER KEY ECU CIRCUIT

Wire Harness Side
Disconnect the connector from the ECU and inspect the con-
nector on the wire harness side, as shown in the table below.
h--12--1 I08412
Tester connection Condition Specified condition

1 -- Ground Constant Battery voltage
2 -- Ground Ignition switch ON Battery voltage
8 -- Ground All doors closed No continuity
8 -- Ground All doors open Continuity
9 -- Ground Key unlock warning switch OFF (key removed) No continuity
9 -- Ground Key unlock warning switch ON (key inserted) Continuity
14 -- Ground Constant Continuity
If the circuit is not as specified, try replacing the ECU with a new
one.
If the circuit is not as specified, inspect the circuits connected
to other parts.
3. INSPECT TRANSPONDER KEY ECU

10
(a) With the connector connected, connect the positive (+)
lead from the analog type tester to terminal 10 and the
negative (--) lead to the body ground.
(+) (b) Check that there is battery voltage when the ignition
switch turned ON.
(c) Check that the tester needle swings strongly for approx.
(--) 1 sec. when the engine is started using the ignition key.
N15517
TO MODEL INDEX
BODY
FRONT SEAT (Sports Type) . . . . . . . . . . . . . . . BO--1

REAR SEAT (Sports Type) . . . . . . . . . . . . . . . . BO--2

TO MODEL INDEX
BO--1
BODY -- FRONT SEAT (Sports Type)
FRONT SEAT (Sports Type)

BO249--01
COMPONENTS
w/ Lumber support:
Lumber Support
Spacer
Headrest
Lumber Support
Headrest Support Lever
Front Seatback Frame
Front Seatback Pad
No.2 Front Seatback Front Seatback Edge Protector

Edge Protector
Front Seatback Cover
Front Seat
Hinge Cover
Inner Front Seat Belt
z Hog Ring
Front Seat
Cushion 43 (440, 32)
Cover
Reclining Adjuster
Inner Front Seat Inside Cover
Front Seat
Cushion Shield 43 (440, 32) Reclining
Cushion Pad
Connecting
Pipe
Front Seat
Cushion Spring
37 (375, 27)
Reclining Adjuster
Inner Adjuster Inside Cover
37 (375, 27) 43 (440, 32) Reclining
Seat Track Adjuster Handle Adjuster
Release
Passenger’s seat: Outer Adjuster 18 (185, 13) Handle
Reclining Adjuster Release Handle
Front Seat Cushion Shield
42 (440, 32)
Outer Adjuster
Front Seat
43 (440, 32) Cushion Shield
18 (185, 13) Vertical Seat
Adjuster Knob
37 (375, 27)
Inner Adjuster
18 (185, 13)
N∙m (kgf∙cm, ft∙lbf) : Specified torque Inner Front Seat Cushion Shield
z Non--reusable part H07334
TO MODEL INDEX
BO--2
BODY -- REAR SEAT (Sports Type)
REAR SEAT (Sports Type)

BO24A--01
COMPONENTS
Headrest No.1 Rear Seatback Pin
Rear Seatback Lock Rod Snap

Spring
Rear Seatback Pad
Rear Seatback Cover
Rear Seatback
Rubber Shock
Rear Seatback Frame
18 (185, 13)
zHog Ring Rear Seatback Spacer

Rear Seat Cushion Cover
Rear Seat Cushion Pad
18 (185, 13) Rear Seat Cushion Frame

z Non--reusable part
H07335
ID --1
ALPHABETICAL INDEX TO MODEL INDEX
ALPHABETICAL INDEX (A - V)
A V
Page Page
ABBREVIATIONS USED IN THIS MANUAL VEHICLE IDENTIFICATION AND ENGINE SERIAL
(TERMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN--15 NUMBER (IDENTIFICATION INFORMATION) . . . . . IN--3
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BE--1 VEHICLE LIFT AND SUPPORT LOCATIONS
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . . IN--8
B
BODY (SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . SS--20
BODY ELECTRICAL (PREPARATION) . . . . . . . . . . . . . . PP--4
E
ENGINE IMMOBILISER SYSTEM . . . . . . . . . . . . . . . . . . BE--23
F
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . IN--9
FRONT SEAT (Sports Type) . . . . . . . . . . . . . . . . . . . . . . . BO--1
FRONT WHEEL ALIGNMENT (2WD) . . . . . . . . . . . . . . . SA--5
(4WD and PRE RUNNER) . . . . . . . . . . . . . . . . . . . . . . SA--10
G
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) . . . . . . . . . . . . . . . . . IN--1
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . . IN--4
H
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . IN--1
I
IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . IN--3
P
PRECAUTION (FOR ALL OF VEHICLES) . . . . . . . . . . . IN--9
R
REAR SEAT (Sports Type) . . . . . . . . . . . . . . . . . . . . . . . . BO--2
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . IN--4
S
STANDARD BOLT (SERVICE SPECIFICATIONS) . . . . SS--1
STEERING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . PP--2
STEERING (SERVICE SPECIFICATIONS) . . . . . . . . . . SS--19
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . SR--1
SUSPENSION AND AXLE (PREPARATION) . . . . . . . . . PP--1
SUSPENSION AND AXLE
(SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . . SS--4
T
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN--15
TIRE AND WHEEL (2WD) . . . . . . . . . . . . . . . . . . . . . . . . SA--1
TIRE AND WHEEL (4WD and PRE RUNNER) . . . . . . . SA--3

Supplement Chassis & Body Rm651e-D

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Supplement Chassis & Body Rm651e-D

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Back To Chassis & Body Index THE MAIN INDEX

RM651E-D FOREWORD Pages From Supplement

S HILUX Chassis and Body Repair Manual RM585E

S 1RZ, 2RZ, 2RZ--E Engine Repair Manual RM167E

S 1RZ--E Engine Repair Manual RM467E

S 3RZ--F, 3RZ--FE Engine Repair Manual RM521E

S 2RZ, 2RZ--E Engine Repair Manual Supplement RM558E

S 2L, 3L Engine Repair Manual RM520E

S 2L, 2L--T, 3L, 5L Engine Repair Manual Supplement RM582E

S 2L, 2L--T, 5L Engine Repair Manual Supplement RM647E

S A340E, A340F, A340H Automatic Transmission Repair Manual RM391U

S HILUX Electrical Wiring Diagram EWD307F

HOW TO USE THIS MANUAL . . . . . . . . . . . . . IN--1

HOW TO USE THIS MANUAL

Float Clevis Pin

Slotted Spring Pin 12 (120, 9)

N∙m (kgf∙cm, ft∙lbf) : Specified torque CONTINUED

The procedures are presented in a step--by--step format:

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

VEHICLE IDENTIFICATION AND

2. ENGINE SERIAL NUMBER

REPAIR INSTRUCTIONS IN06S--03

(f) Precoated parts

(3) Precoated parts are indicated in the component il-

Illustration Symbol Part Name Abbreviation

MEDIUM CURRENT FUSE M--FUSE

HIGH CURRENT FUSE H--FUSE

(k) Care must be taken when jacking up and supporting the

(2) To disconnect vacuum hoses, pull off the end, not

(3) To pull apart electrical connectors, pull on the con-

(7) When checking continuity at the wire connector, in-

Example (m) Installation and removal of vacuum hose:

(7) When checking continuity at the wire connector, in-

Example (m) Installation and removal of vacuum hose:

VEHICLE LIFT AND SUPPORT LOCATIONS

4WD and pre runner:

Rear Center of rear axle housing

INTRODUCTION -- FOR ALL OF VEHICLES IN--9

FOR ALL OF VEHICLES

(3) Even in cases of a minor collision where the SRS

(c) SPIRAL CABLE (in Combination Switch)

(d) STEERING WHEEL PAD (with Airbag)

(e) FRONT PASSENGER AIRBAG ASSEMBLY

Example: Correct Wrong

(f) SEAT BELT PRETENSIONER

2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

4. FOR USING HAND--HELD TESTER

ABBREVIATIONS USED IN THIS MANUAL

SUSPENSION AND AXLE . . . . . . . . . . . . . . . . PP--1

REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND

SUSPENSION AND AXLE

SST (Special Service Tools)

(09904--00050) No. 4 Claw

09905--00012 Snap Ring No.1 Expander .

STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . SS--1

REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND

HOW TO DETERMINE BOLT STRENGTH

No Mark No Mark No Mark

SPECIFIED TORQUE FOR STANDARD BOLTS

6 1 6.5 65 56 in.∙lbf 7.5 75 65 in.∙lbf

6 1 10.5 110 8 12 120 9

8 1.25 29 300 22 33 330 24