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2002 Toyota Truck Tundra Access Cab SR5 2WD Timing Belt Service and Repair Manual

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Filed Under (Toyota Manuals) by admin on 09-06-2012

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2002 Toyota Truck Tundra Access Cab SR5 2WD V6-3.4L (5VZ-FE) Copyright © 2008, ALLDATA 9.50 Page 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT PS PUMP FROM ENGINE a. Disconnect the 2 PS air hoses from the air intake chamber and resonator. b. Remove the bolt holding the PS pressure tube clamp to the frame. c. Remove the drive belt. d. Remove the bolt and nut, and disconnect the PS pump from the engine. 5. w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE a. Disconnect the A/C compressor connector. b. Remove the drive belt. c. Remove the 4 bolts, and disconnect the A/C compressor from the engine. 6. LOOSEN FAN WITH FLUID COUPLING AND FAN PULLEYS 7. REMOVE DRIVE BELT FOR GENERATOR 8. REMOVE NO.2 FAN SHROUD 9. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS 10. w/ A/C: REMOVE A/C COMPRESSOR BRACKET Remove the 5 bolts and A/C compressor bracket. 11. DISCONNECT UPPER RADIATOR HOSE 12. REMOVE NO.2 TIMING BELT COVER a. Disconnect the camshaft position sensor connector from the No. 2 timing belt cover. b. Disconnect the 4 high-tension cord clamps from the No. 2 timing belt cover. c. Remove the 6 bolts and timing belt cover. 13. REMOVE FAN BRACKET a. Remove the nut and PS pump adjusting strut. b. Remove the bolt, nut and fan bracket. 14. SET NO. 1 CYLINDER AT TDC/COMPRESSION a. Turn the crankshaft pulley and align its groove with timing mark “0″ of the No. 1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°) . HINT: When re-using timing belt: Place the matchmarks on the timing belt and camshaft timing pulleys, and place matchmark on timing belt to match the end of the No. 1 timing belt cover. 15. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 16. REMOVE TIMING BELT

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1994 Toyota Camry DX TIMING BELT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 22-01-2012

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Removal 1. Disconnect negative battery cable. Raise and support vehicle. Remove lower engine cover. On Celica and Camry, remove right front wheel. On all models, lower vehicle. 2. On MR2, remove right hood side panel and cruise control actuator. Remove right rear wheel. On Celica and Camry, remove alternator from engine and secure out of way. On Camry, remove coolant reservoir tank if it interferes with timing belt removal. Remove engine control (torque) rod from front of engine. 3. On all models, remove accessory drive belts. Using floor jack, slightly raise engine to remove weight from right (timing belt side) engine mount at timing belt cover. 4. Remove right (timing belt side) engine mount and bracket from front of engine. Remove spark plugs. Remove No. 2 timing belt cover and gaskets. See Fig. 1 . 5. Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. 6. Ensure timing mark on crankshaft pulley aligns with “0″ mark on No. 1 timing belt cover. Ensure hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2 . If hole in camshaft sprocket is not aligned with alignment mark, rotate crankshaft clockwise one full revolution. 7. Loosen No. 1 idler pulley bolt. See Fig. 1 . Move No. 1 idler pulley outward, away from timing belt as far as possible. Temporarily retighten No. 1 idler pulley bolt. Remove timing belt from camshaft sprocket. 8. Using Pulley Holder (SST 09213-54015) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. 9. Using gear puller, remove crankshaft pulley. Remove No. 1 timing belt cover and gasket. Note direction of timing belt guide installation. See Fig. 1 . Remove timing belt guide. 10. Loosen No. 1 idler pulley bolt. See Fig. 1 . Remove timing belt from crankshaft sprocket. Remove idler pulleys (if necessary).

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1992 Toyota Truck Pickup 2WD Cooling and Exhaust Engine Ignition Timing Adjustments Manual

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Filed Under (Toyota Manuals) by admin on 15-03-2012

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1. Connect a tachometer test probe to terminal IG of the check connector, Fig. 211 2. NOTE: Never let the tachometer lead touch ground as this could cause damage to the igniter and/or coil. Be sure to check that your tachometer is compatible with this ignition system. Consult the operating manual for your instrument. Service Check Connector 3. Fig. 223 Ignition Timing (10) Check idle speed . 4. Idle Speed : 800 rpm Using a timing light, verify that the timing mark on the timing cover is aligned with the mark on the crankshaft pulley, Fig. 223 5. Ignition Timing: 10°BTDC at idle Tighten the distributor bolt and recheck the ignition timing. 6. Remove service wire. 7. Check idle advance timing with service wire removed. 8. Ignition Timing: 8°BTDC at idle Check idle speed and adjust if necessary, COMPUTERIZED ENGINE CONTROLS. 9. Disconnect tachometer and timing light from engine. 10. Timing Belt Removal Notes Fan Shroud Removal & Installation Remove radiator fan upper and lower shrouds. 1. Installing Power Steering Pump And Belt Remove power steering pump drive belt and pump. 2. Disconnect No. 2 and No. 3 air hoses from air pipe. 3. 4. Fan Removal Remove alternator drive belt , cooling fan, belt guide and fan pulley. 5. Remove No. 2 timing belt cover. 6. Fig. 6 Aligning Timing Marks Place No. 1 cylinder at TDC of compression stroke by turning the crankshaft pulley and aligning pulley groove with the “0” mark on the No. 1 timing belt cover. Ensure alignment marks on the camshaft timing sprockets and the No. 3 timing belt cover are correctly aligned, Fig. 6. 7. If not, turn the crankshaft pulley one complete revolution. 8. Crankshaft Pulley Removal

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1996 TOYOTA T100 ENGINE MECHANICAL TIMING BELT INSTALLATION

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Filed Under (Toyota Manuals) by admin on 24-09-2011

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1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER PULLEY (a) Using a 10 mm hexagon wrench, install the No.1 idler pulley with the plate washer and bolt. Torque: 35 N·m (350 kgf·cm, 26 ft·lbf) (b) Check that the pulley bracket moves smoothly. (c) Install the No.2 idler pulley with the bolt. Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) (d) Check that the pulley moves smoothly. 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Use the crankshaft pulley bolt to turn the crankshaft and align the timing marks on the crankshaft timing pulley and on the oil pump body. (b) Remove any oil or water on the crankshaft timing pulley, idler pulley and water pump pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (c) Align the installation mark on the timing belt with the drilled mark of the crankshaft timing pulley. (d) Install the timing belt on the crankshaft timing pulley, No.1 idler and water pump pulleys. 4. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward

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Rotary Fuel Pumps Timing to engine steps

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Filed Under (Toyota Manuals) by admin on 12-04-2012

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SMALL | MEDIUM | LARGE Previous Next Fuel Injection Pump (Distributor Type) The fuel injection pumps, Bosch® VE, Lucas CAV DPA, Stanadyne DB4, Lucas CAV DPS, and Delphi DP210, are rotary distributor pumps. These pumps perform the four basic functions of: 1. Producing the high fuel pressure required for injection 2. Metering the exact amount of fuel for each injection cycle 3. Distributing the high-pressure, metered fuel to each cylinder at the precise time 4. Varying the timing relative to engine speed. SMALL | MEDIUM | LARGE Previous Next Distributor-Type Pump Governor Balance between the governor flyweights and control lever position controls the metering of the amount of fuel to be injected. The fuel injection pump governor performance and setting can affect engine power. Special equipment and qualified personnel are required to verify governor performance. If the seals are broken on the external Bosch® VE adjustment screw, the fuel rate can, perhaps, be out of adjustment The Lucas CAV DPA/DPS fuel injection pump uses a coded spring connection to change the governor setting. Incorrect connection of the governor spring can affect performance. Adjustments and rating changes are described in the Master Repair Manual, Injector Pumps and Injectors, Manual Shutdown Levers Both fuel injection pumps are equipped with mechanical shutdown levers. These levers are spring-loaded in the run position. Not all applications will use these manual shutdown controls and there will be no cable or rod connected to the lever. NOTE: Partial actuation of the mechanical shutdown levers will affect fuel flow and engine power. SMALL | MEDIUM | LARGE Previous Next Advance Timing Mechanism Regulated pressure produced by a vane supply pump in both fuel injection pumps is used to advance the timing as the engine speed increases. A return spring is used to retard the timing as the engine speed is reduced. If a spring breaks, the timing will go to the advance position, resulting in torque loss, fuel knock, and possible engine overheating. Retarded (late) timing will result in torque loss, high fuel consumption, and white to black smoke. SMALL | MEDIUM | LARGE Previous Next The Lucas CAV DPA/DPS advance timing mechanism uses a check ball in the circuit which, if omitted during assembly, will result in no timing advance. If the fuel injection pump has been replaced or the mechanism has been removed to fix a leak, the problem can be that the check ball is missing

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Toyota LandCruiser 4.2TD Timing belt replacement intervals

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Filed Under (Toyota Manuals) by admin on 02-03-2012

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Timing belt replacement intervals The information relating to timing belt replacement intervals is additional to the main purpose of this CD, but is included to provide guidance to garages and for customer advice. Where possible the recommended intervals have been compiled from vehicle manufacturers’ information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt. Apart from the visible condition of the belt, which is explained fully later in this section, there are several other factors which must be considered when checking a timing belt: Is the belt an original or a replacement. 1. When was the belt last replaced and was it at the correct mileage. 2. Is the service history of the vehicle known. 3. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval. 4. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected. 5. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due. 6. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable expensive damage may well be the result. 7. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences. 8. If in doubt about the condition of the belt – RENEW it. 9. Removal Removal Remove timing belt cover [1]. 1. Turn crankshaft clockwise until timing marks aligned [2]. 2. Ensure timing marks aligned: 1KZ-T/TE: [3]. 3. 4. Remove: Automatic tensioner unit [6]. Tensioner pulley bolt [7]. Tensioner pulley [8]. Timing belt. 5. Installation Installation Check tensioner pulley for smooth operation [8]. Replace if necessary. 1. Remove dust cover. Check tensioner body for leakage or damage [6]. Check pushrod protrusion is 9,0-9,8 mm [9]. 2. Check pushrod does not move when pushed against a firm surface. If pushrod moves: Replace automatic tensioner unit. 3. Slowly compress pushrod into tensioner body until holes aligned. Use press. 4. Retain pushrod with 1,5 mm Allen key through hole in tensioner body [10]. Fit dust cover. 5. Ensure timing marks aligned [2]. 6. Ensure timing marks aligned: 1KZ-T/TE: [3]. 1HD-FT/1HD-FTE: [4]. 7. Fit timing belt in anti-clockwise direction, starting at lower sprocket. Ensure belt is taut between sprockets. 8. Fit tensioner pulley [8]. Tighten bolt to 34 Nm [7]. 9. Push tensioner pulley against belt. Install automatic tensioner unit [6]. Tighten bolts evenly to 13 Nm [5]. 10. Remove Allen key from tensioner body to release pushrod. 11. Turn crankshaft two turns clockwise. Ensure timing marks aligned [2] & [3] or [4]. 12. If not: Repeat installation and tensioning procedures. 13. Install components in reverse order of removal. 14. Reset timing belt replacement warning lamp as follows: 15. -Runner/Landcruiser: Remove grommet in speedometer housing. Depress switch using a thin screwdriver [11]. 16. Colorado: Remove speedometer housing. Remove screw indicated and insert in alternative location [12]. 17. Amazon: Lamp illuminates at 90,000 miles. Return vehicle to dealer.

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2000-2002 Toyota Corolla, Celica, MR2 Spyder, and ECHO DTC P1349 – VVTi ACTUATOR Repair Manual

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Filed Under (Toyota Manuals) by admin on 27-04-2012

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TC P1349 – VVTi ACTUATOR – EG009-03 May 19, 2003 Page 3 of 4 1. Inspect the condition of the valve cover oil baffle as per TSB EG007-02. If camshaft or camshaft position sensor damage resulting from a bent baffle is identified, repair the damage as necessary. 2. Make sure the vehicle is in “PARK” with the engine idling. 3. Referring to the screen flow below, connect the Toyota Diagnostic Tester to the vehicle and select the VVT Control Bank One Active Test (VVT CTRL B1) from the Active Test Menu. 1: DATA LIST 2: DTC INFO 3: 4: SNAPSHOT 5: SYSTEM CHECK 6: RESET MEMORY 7: MONITOR INFO 8: CHECK MODE SELECT DATA B DIAGNOSTIC MENU ENGINE A C INJ VOL A/F CONTROL CAN CTRL VSV TANK BYPASS VSV EVAP VSV (ALONE) A/C MAG CLUTCH FUEL PUMP/SPD LINE PRESS UP VVT CTRL B1 Confirm that the Vehicle is Stopped And Engine Idling 3: ACTIVE TEST PRESS [ENTER] INJECTOR 3.5ms IGN ADVANCE 11.0deg CALC LOAD 22% MAF 3.68gm/s ENGINE SPD 684rpm COOLANT TEMP186.8F INTAKE AIR 129.2F THROTTLE POS 14% CTP SW ON VEHICLE SPEED0MPH O2S B1S2 0.82V AFS B1 S1 3.25V SHORT FT #1 1.5% LONG FT #1 5.4% TOTAL FT #1 1.08 E D VVT CTRL B1 OFF INJECTOR 8.3ms IGN ADVANCE 5.0deg CALC LOAD 0% MAF 0.00gm/s ENGINE SPD 0rpm COOLANT TEMP186.8F INTAKE AIR 129.2F THROTTLE POS 14% CTP SW ON VEHICLE SPEED0MPH O2S B1S2 0.33V AFS B1 S1 3.29V SHORT FT #1 -0.1% LONG FT #1 5.4% TOTAL FT #1 1.08 VVT CTRL B1 ON 4. Using the right arrow key, toggle the VVTi actuator “ON.” 5. If at this point the vehicle does not run rough and/or stalls when the active test is performed, proceed with Repair Manual P1349 VVTi Fault Isolation Procedure (FIP). If the vehicle does stall and/or runs rough, this indicates the the VVTi control system is operating. Proceed to replace the VVTi actuator following the repair procedures listed on the Technical Information System (TIS): Engine Mechanical Section, Camshaft, Replacement The camshaft timing gear should come in the unlocked position from the factory. If it is difficult to install the camshaft timing gear, the lock pin may be engaged. To disengage the lock pin, apply and hold approximately 20 psi of air pressure at the oil feed hole located 90 degrees clockwise of the oval slot. (See Figure 1.) Once the pin has released, turn the interior assembly counterclockwise. (See black arrow in Figure 1.) B. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove. C. Turn the camshaft timing gear assembly (as shown in Figure 2) while pushing it lightly against the camshaft. Push further at the position where the pin fits into the groove. NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (in the clockwise direction). D. Check that there is no clearance between the end of the camshaft and the camshaft timing gear. E. Tighten the camshaft bolt with the camshaft timing gear fixed. Torque: 54 Nm (551 kgfcm, 40 ftlbf) F. Check that the camshaft timing gear assembly can move to either side and is not locked

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Toyota Starlet Timing belt replacement intervals

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Filed Under (Toyota Manuals) by admin on 15-01-2012

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Removal Removal Raise and support front of vehicle. 1. Support engine. 2. Remove: RH front wheel. Inner wing panel. Engine mounting and bracket. Auxiliary drive belt(s). Cylinder head cover. Timing belt upper cover [1] . 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft pulley timing mark aligned [2] . 4. Check hole in camshaft sprocket aligned with mark on camshaft bearing cap [3] . 5. If not: Turn crankshaft one turn clockwise. 6. Remove: Crankshaft pulley bolt [4] . Use tool Nos.09213-14010 & 09330-00021. Crankshaft pulley [5] . Use tool No.09213-31021. Timing belt lower cover [6] . 7. Temporarily fit crankshaft pulley bolt [4] . 8. Ensure timing marks aligned [3] & [7] . 9. Slacken tensioner bolt [8] . Move tensioner away from belt and lightly tighten bolt. 10. Remove: Timing belt. Tensioner pulley and spring [9] & [10] . 11. Installation Installation Check tensioner pulley for smooth operation [9] . 1. Check free length of tensioner spring is 38,4 mm [10] . 2. Fit tensioner and spring. Ensure spring is connected correctly. 3. Push tensioner to left and lightly tighten bolt [8] . 4. Ensure timing marks aligned [3] & [7] . 5. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. 6. Slacken tensioner bolt [8] . 7. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [3] & [7] . 8. If not: Repeat installation and tensioning procedures. 9. Tighten tensioner bolt [8] . Tightening torque: 19 Nm. 10. Remove crankshaft pulley bolt [4] . 11. Install: Timing belt lower cover [6] . Crankshaft pulley [5] . 12. Install components in reverse order of removal. 13. Tighten crankshaft pulley bolt [4] . Tightening torque: 152 Nm. Use tool Nos.09213-14010 & 09330-00021. 14.

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1987-1988 Toyota Supra EMS P/N 30-1110 Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-03-2012

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1) Removing the Stock Engine Control Unit a) Access the stock Engine Control Unit (ECU). The location of the ECU on the Toyota Supra is behind the Glove box. b) Remove the Phillips head screw on the bottom of the glove box hinge. Remove the glove box by tilting the box at an angle from side to side and slide it toward you. c) Carefully disconnect the wiring harness from the ECU. Avoid excessive stress or pulling on the wires, as this may damage the wiring harness. Some factory ECU’s use a bolt to retain the factory connectors, and it must be removed before the harness can be disconnected. There may be more than one connector, and they must all be removed without damage to work properly with the AEM ECU. Do not cut any of the wires in the factory wiring harness to remove them. d) Remove the fasteners securing the ECU to the car body, and set it aside. Do not destroy or discard the factory ECU, as it can be reinstalled easily for street use and troubleshooting. 2) Install the AEM Engine Management System. a) Plug the factory wiring harness into the AEM ECU, and position it so that the wires are not pulled tight or stressed. Secure it with the provided Velcro fasteners. NOTE: The fourth 6 position factory connector is not used with the AEM EMS. b) Plug the comms cable into the EMS and into your PC. c) Turn your ignition on but do not attempt to start the engine. d) Upload the base calibration file (.cal) that most closely matches your vehicle’s configuration. (These files can be found in the AEMPro/Startup Calibrations/Toyota folder on your computer’s hard drive) e) Set the throttle range: Select the Configure drop down menu, then ECU Setup | Set Throttle Range and then follow the direction given on the screen. f) Verify the ignition timing by selecting the Configure drop down menu, then ECU Setup | Set Ignition. Use a timing light and compare the physical timing numbers to the Parameter Ignition Timing displayed. Use the Advance/Retard buttons to make the timing number match

1993-1998 Toyota Supra TT EMS P/N 30-1100 Installation Manual

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Filed Under (Toyota Manuals) by admin on 20-03-2012

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Read and understand these instructions BEFORE attempting to install this product. 1) Removing the Stock Engine Control Unit a) Access the stock Engine Control Unit (ECU). The location of the ECU on the Toyota Supra is under the passenger firewall carpet and has a black cover that is removed by 4 10 mm nuts. b) Carefully disconnect the wiring harness from the ECU. Avoid excessive stress or pulling on the wires, as this may damage the wiring harness. Some factory ECU’s use a bolt to retain the factory connectors, and it must be removed before the harness can be disconnected. There may be more than one connector, and they must all be removed without damage to work properly with the AEM ECU. Do not cut any of the wires in the factory wiring harness to remove them. c) Remove the fasteners securing the ECU to the car body, and set it aside. Do not destroy or discard the factory ECU, as it can be reinstalled easily for street use and troubleshooting. d) Make sure any aftermarket electronics are COMPLETELY and properly removed before starting the vehicle. 2) Install the AEM Engine Management System. a) Plug the factory wiring harness into the AEM ECU, and position it so that the wires are not pulled tight or stressed. Secure it with the provided Velcro fasteners. b) Plug the comms cable into the EMS and into your PC. c) Turn your ignition on but do not attempt to start the engine. d) Upload the base calibration file (.cal) that most closely matches your vehicle’s configuration. (These files can be found in the AEMPro/Calibrations/Toyota folder on your computer’s hard drive) e) Set the throttle range: Select the Configure drop down menu, then ECU Setup | Set Throttle Range and then follow the direction given on the screen f) Verify the ignition timing by selecting the Configure drop down menu, then ECU Setup | Set Ignition . Use a timing light and compare the physical timing numbers to the Parameter Ignition Timing displayed. Use the Advance/Retard buttons to make the timing number match. 3) You are now ready to begin tuning your vehicle. a) Note: This calibration needs to be properly tuned and is not recommended for street use. NEVER TUNE YOUR VEHICLE WHILE DRIVING.

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