Toyota 4-Runner 1985 Operating instructions

1985

TOYOTA

TRUCK &

4-RUNNER Gasoline

REPAIR

MANUAL

INTRODUCTION

ImI

MAINTENANCE

ENGINE

MECHANICAL

EMISSION CONTROL

SYSTEM

EFI

SYSTEM

FUEL

SYSTEM

COOLING

SYSTEM

LUBRICATION

SYSTEM

IGNITION SYSTEM·

STARTING

SYSTEM

CHARGING

SYSTEM

D=I

CLUTCH

MANUAL

TRANSMISSION

I~~II

AUTOMATIC

TRANSMISSION

lilI.

TRANSFER

mil

PROPELLER

SHAFT

IAI

FRONT AXLE

AND

SUSPENSION

REAR AXLE

AND

SUSPENSION

Im1

BRAKE

SYSTEM

I:JI

STEERING

'-1a

BODY ELECTRICAL

SYSTEM

I:JI

BODY l:l.J

WINCH

awl

AIR

CONDITIONING

SYSTEM

1.:.tI

1984

TOYOTA

MOTOR

CORPORATION

All

rights

reserved.

This

book

may

not

reproduced

copied,

whole

part,

without

the

written

permission

Toyota

Motor

Corporation.

SERVICE SPECIFICATIONS

STANDARD

BOLT TIGHTENING TORQUE _

SSTANDSSM

AUTOM~V5RTf&L~~~\~~181~

ELECTRICAL

WIRING

DIAGRAMS

IN-1

INTRODUCTION

Page

HOW

TO USE

THIS

MANUAL

.......................................

IN-2

IDENTIFICATION

INFORMATION

...................................

IN-4

GENERAL REPAIR INSTRUCTIONS ...............................

IN-4

PRECAUTIONS FOR VEHICLES EQUIPPED

WITH

CATALYTIC

CONVERTER ...................................... IN-7

VEHICLE LIFT

AND

SUPPORT LOCATIONS .................

IN-8

ABBREVIATIONS USED IN THIS

MANUAL...................

IN-9

IN-2 INTRODUCTION -

How

Use

This

Manual

260

(19,

25)

750 (54,

74)

Propeller Shaft

L..---

HOW

TO USE THIS

MANUAL

assist

finding

your

way

through

the

manual,

the

Secti

Title

and

major

heading

are

given

the

top

every

page.

INDEX is

provided

the

first

page

each

section

guide

you

the

item

be repaired.

the

beginning

each

section,

PRECAUTIONS are

given

that

pertain

all

repair

operations

contained

that

section.

Read

these

precautions

before

starting

any

repair

task.

TROUBLESHOOTING tables are fncluded

for

each

system

help

you

diagnose

the

system

problem

and

find

the

cause.

The

repair

for

each

possible

cause

referenced

the

remedy

column

quickly

lead

you

the

solution.

REPAIR PROCEDURES

Most

repair

operations

begin

with

overview

illustration.

identifies

the

components

and

shows

how

the

parts

fit

together.

Example:

..,

_--1

):)@

~9&~

L..---

l))~~-:

Bearing

Cap

Lock

Front

Bearing

Oil

Slinger

+Oil

Seal

Companion Flange

•

Nut

and Washer

Ikg-cm (ft-Ib,

N·m)

I :Tightening

torque

+ :Non-reusable part

RAOl88

INTRODUCTION -

How

Use

This

Manual

IN-3

Photograph

illustration:

what

and

where

The

procedures

are

presented

step-by-step

format:

•

The

photo

illustration

shows

what

and

where

it.

•

The

task

heading

tells

what

do.

•

The

detailed

text

tells

how

perform

the

task

and

gives

other

information

such

specifications

and

warnings.

Example:

/ Task

heading:

what

INSTALL

DRIVE

SHAFT

ON CENTER SUPPORT

BEARING FLANGE

(a)

Align

the

marks

the

flanges

and

connect

the

flanges

with

four

bolts

and

nuts.~

(b)

Torque

the

bolts

and

nuts.

________

Torque:

750

kg-em

(54

ft-Ib,

N.m)

Detail

text:

~howtOdOit

Specification

This

format

enables

the

experienced

technician

have

FAST

TRACK.

can

read

the

task

headings

and

only

refer

the

detailed

text

when

needs

it.

Important

specifications

and

warnings

always

stand

out

bold

type.

REFERENCES

References

have

been

kept

minimum.

However,

when

they

are

required

you

are

given

the

page

to.

SPECIFICATIONS

Specifications

are

presented

bold

type

throughout

the

text

the

applicable

step.

You

never

have

leave

the

procedure

look

your

specs.

All

specifications

are also

found

Ap-

pendix

specifications

for

quick

reference.

WARNINGS,

CAUTIONS,

NOTES:

•

WARNINGS

are

presented

bold

type,

and

indicate

there

possibility

injury

you

other

pepole.

•

CAUTIONS

are

also

presented

bold

type,

and

indicate

the

possibility

damage

the

components

being

repaired.

• NOTES are

separated

from

the

text

but

not

appear

bold.

They

provide

additional

information

help

you

efficiently

per-

form

the

repair.

IN-4

INTRODUCTION -

Identification

Information,

General Repair

Instructions

INOOOB

IN0007

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The

vehicle

identification

number

stamped

top

the

in-

strument

panel.

ENGINE SERIAL NUMBER

The

engine

serial

number

stamped

the

left

side

the

cylinder

block.

GENERAL REPAIR INSTRUCTIONS

Use

fender

seat

and

floor

covers

keep

the

vehicle

clean

and

prevent

damage.

During

disassembly,

keep

parts

order

facilitate

re-

assembly.

Observe

the

following:

(a)

Before

performing

electrical

work,

disconnect

the

cable

from

the

battery

terminal.

(b)

is necessary

disconnect

the

battery

for

inspec-

tion

repair,

always

disconnect

the

cable

from

the

negative

(-)

terminal

which

grounded

the

vehi-

cle

body.

(c)

prevent

damage

the

battery

terminal

post,

loosen

the

terminal

nut

and raise

the

cable

straight

without

twisting

prying

it.

(d) Clean

the

battery

terminal

posts

and

cable

terminals

with

shop

rag.

not

scrape

them

with

file

such.

(e) Install

the

cable

terminal

the

battery

post

with

the

nut

loose,

and

tighten

the

nut

after

installation.

not

use a

hammer

such

tap

the

terminal

on-

the

post.

(f)

sure

the

cover

for

the

positive

(+)

terminal

pro-

perly in place.

Check

hose and

wiring

connectors

make

sure

that

thr

are secure and

correct.

INTRODUCTION -

General

Repair

Instructions

IN-5

Non-reusable

Parts

(a)

Always

replace

cotter

pins,

gaskets,

a-rings

and

oil

seals

etc.

with

new

ones.

(b)

Non-reusable

parts

are

indicated

the

component

illustrations

the

symbol

".".

Precoated

Parts

Precoated

parts

are

the

bolts,

nuts,

etc.

which

are

coated

with

a seal

lock

adhesive

the

factory.

(a)

precoated

part

tightened,

loosened

caused

move

any

way,

must

recoated

with

the

specified

adhesive.

Seal Lock Adhesive (b)

Recoating

Precoated

Parts

84460

(1)

Clean

off

the

old

adhesive

from

the

bolt,

nut

installation

part

threads.

(2)

Dry

with

compressed

air.

(3)

Apply

the

specified

seal

lock

adhesive

the

bolt

nut

threads.

(c)

Precoated

parts

are

indicated

the

component

illus-

trations

the

symbol

"*".

When

necessary,

use

a sealer on

gaskets

prevent

leaks.

Carefully

observe

all

specifications

for

bolt

tightening

tor-

ques.

Always

use

torque

wrench.

Use

special

service

tools

(SST) and

special

service

materials

(SSM)

may

required,

depending

the

nature

the

repair.

sure

use

SST

and

SSM

where

speci-

fied

and

the

proper

work

procedure.

list

SST

and

SSM

can

found

the

back

this

manual.

10.

When

replacing

fuses,

sure

the

new

fuse

the

correct

amperage

rating.

NOT

exceed

the

fuse

amp

rating

use

one

lower

rating.

11.

Care

must

taken

when

jacking

and

supporting

the

vehicle.

Be sure

lift

and

support

the

vehicle

the

proper

locations.

(See

page

IN-8)

(a)

the

vehicle

jacked

only

the

front

rear

end,

be sure

block

the

wheels

order

en-

sure

safety.

(b)

After

the

vehicle

jacked

up,

be sure

support

stands.

extremely

dangerous

any

work

the

vehicle

raised

jack

alone,

even

for

small

job

that

can

finished

quickly.

IN-6 INTRODUCTION -General Repair

Instructions

N0002

12.

Observe

the

following

precautions

avoid

damage

the

parts:

(a)

disconnect

vacuum

hoses, pull on

the

end,

not

middle

the

hose.

(b)

pull

apart

electrical

connectors,

pull

the

con-

nector

itself,

not

the

wires.

careful

not

drop

electrical

components,

such

sensors

relays.

they

are

dropped

on a

hard

floor,

they

should

be replaced and

not

reused.

(d)

When

steam

cleaning

an engine,

protect

the

distribu-

tor,

coil, air filter, carburetor

intake,

air

pump

and

VCV

from

water.

(e)

Never

use an

impact

wrench

remove

install

ther-

switches

thermo

sensors.

(f)

When

checking

continuity

the

wire

connector,

in-

sert

the

tester

probe

carefully

prevent

terminals

from

bending.

(g)

When

using

vacuum

gauge,

never

force

the

hose

onto

connector

that

too

large. Use a

step-down

adapter

instead.

Once

the

hose

has been

stretched,

may

leak.

13.

Tag

hoses

before

disconnecting

them:

(a)

When

disconnecting

vacuum

hoses, use

tags

iden-

tify

how

they

should

reconnected.

(b)

After

completing

job,

double

check

that

the

vac

hoses

are

properly

connected.

A label

under

the

hood

shows

the

proper

layout.

INTRODUCTION

Precautions

for

Vehicles

Equipped

with

Catalytic

Converter

IN-7

PRECAUTIONS

FOR

VEHICLES EQUIPPED

WITH A CATALYTIC CONVERTER

WARNING:

large

amounts

unburned

gasoline

flow

into

the

converter,

may

overheat

and

create

fire

hazard.

pre-

vent

this,

observe

the

following

precautions

and

explain

them

your

customer.

Use

only

unleaded

gasoline.

Avoid

prolonged

idling.

Avoid

running

the

engine

fast

idle

speed

for

than

minutes

and

idle speed

for

than

minutes.

Avoid

spark

jump

test.

(a)

Spark

jump

test

only

when

absolutely

necessary. Per-

form

this

test

rapidly

possible.

(b)

While

testing,

never

race

the

engine.

Avoid

prolonged

engine

compression

measurement.

Engine

compression

tests

must

made

as rapidly as

possible.

not

run

engine

when

fuel

tank

nearly

empty.

This

may

cause

the

engine

misfire

and

create

extra

load

the

converter.

Avoid

coasting

with

ignition

turned

off

and

prolonged

braking.

not

dispose

used

catalyst

along

with

parts

con-

taminated

with

gasoline

oil.

IN-8

[4WD]

[2WD]

INTRODUCTION -

Vehicle

Lift

and

Support

Locations

VEHICLE LIFT

AND

SUPPORT LOCATIONS

JACK

POSITION

........................

Front

....

. .

[2WD]

Center

crossmember

[4WD]

Center

front

axle housing

Rear

........

Center

rear axle housing

SUPPORT POSITION

Safety

stand

.......................

INOOll

INOO12

INTRODUCTION -

Abbreviations

Used

This

Manual

IN-9

ABBREVIATIONS USED

THIS MANUAL

AAP

A/C

APPROX.

AIT,

ATM

ATF

BTDC

BVSV

CALIF.

C&C

CMH

EACV

ECU

EFI

EGR

ESA

EVAP

Ex.

FED.

HAC

HAl

MAS

MIT,

MTM

OPT

OIS

PCV

SSM

SST

STD

S/W

TCCS

TDC

TWC

UIS

VCS

VCV

VSV

VTV

2WD

4WD

Short

Long

wlo

Auxiliary

Acceleration

Pump

Air

Conditioner

Air

Injection

Approximate

Air

Suction

Automatic

Transmission

Automatic

Transmission

Fluid

Before

Top

Dead

Center

Bi-metal

Vacuum

Switching

Valve

Vehicles

Sold

California

Choke

Breaker

Cab

and

Chassis

Cold

Mixture

Heater

Dash

Pot

Electronic

Air

Control

Valve

Electronic

Control

Unit

Electronic

Fuel

Injection

Exhaust

Gas

Recirculaion

Electronic

Spark

Advance

Evaporative

(Emission

Control)

Exhaust

(manifold,

valve)

Except

Vehicles

Sold

USA

except

California

High

Altitude

Compensation

Hot

Air

Intake

(manifold,

valve),

Inch

Ignition

Left-hand

Mixture

Adjusting

Screw

Mixture

Control

Multipurpose

Manual

Transmission

Oxidation

Catalyst

Overdrive

Option

Oversized

Positive

Crankcase

Ventilation

Power

Steering

Right-hand

Spark

Control

Special

Service

Materials

Special

Service

Tools

Standard

Switch

Toyota

Computer

Control

System

Top

Dead

Center

Three

Way

Catalyst

Undersized

Vacuum

Control

Switch

Vacuum

Control

Valve

Vacuum

Switching

Valve

Vacuum

Transmitting

Valve

Two

Wheel

Drive

Vehicles

(4x2)

Four

Wheel

Drive

Vehicles

(4x4)

Short

wheel

base

Long

wheel

base

With

Without

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