Introduction
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HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
- (a) This manual is written in accordance with SAE J2008.
- (1) Diagnosis
- (2) Removing/Installing, Replacing, Disassembling/ Reassembling, Checking and Adjusting
- (3) Final Inspection
- (b) The following procedures are omitted from this manual. However, these procedures must be performed.
- (1) Use a jack or lift to perform operations
- (2) Clean all removed parts
- (3) Perform a visual check
2. INDEX
- (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired.
3. PREPARATION
- (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of this manual.
4. REPAIR PROCEDURES
- (a) A component illustration is placed under the title where necessary.
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- (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Following illustration is example
- (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures.
HINT:
There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration.
- (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices.
- (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle.
- (f) Procedures are presented in a step-by-step format.
| Illustration | What to do and where to do |
|---|---|
| Task heading | What work will be performed |
| Explanation text | How to perform the task Also has information such as specifications and warnings, which are written in boldface text |
Table Caption: This table outlines the essential components of a structured task description, including what the task is, where it will be performed, a clear heading for the work, and detailed instructions with important specifications and warnings presented in bold.
5. SERVICE SPECIFICATIONS
- (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference.
6. TERMS DEFINITION
| CAUTION | Possibility of injury to you or other people. |
|---|---|
| NOTICE | Possibility of damage to components being repaired. |
| HINT | Provides additional information to help you perform repairs. |
Table Caption: This table categorizes important information for performing repairs, with "CAUTION" warning of personal injury, "NOTICE" highlighting potential equipment damage, and "HINT" offering helpful supplementary details.
7. INTERNATIONAL SYSTEM OF UNITS
- (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English system are also provided.
Example is as follow.
Torque: 30 Nm (310 kgfcm, 22 ft.*lbf)
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IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
- (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustration.
- A:
Vehicle Identification Number
B:
Certification Label
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER
- (a) The engine serial number is stamped on the cylinder block of the engine and the transaxle serial number is stamped on the housing as shown in the illustration.
- A:
- 1NZ-FE
- B:
- U340E
- C:
- C50
REPAIR INSTRUCTION
PRECAUTION
- BASIC REPAIR HINT
- (a) HINTS ON OPERATIONS
| 1 | Attire | • Always wear a clean uniform. • Hat and safety shoes must be worn. |
|---|---|---|
| 2 | Vehicle protection | Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. |
| 3 | Safe operation | • When working with 2 or more persons, be sure to check safety for one another. • When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. • If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. • When jacking up the vehicle, be sure to support the specified location with a safety stand. • When lifting up the vehicle, use appropriate safety equipment. |
| 4 | Preparation of tools and measuring gauge | Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. |
| 5 | Removal and installation, disassembly and assembly operations | • Diagnose with a thorough understanding of proper procedures and of the reported problem. • Before removing the parts, check the general condition of the assembly and for deformation and damage. • When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. • Clean and wash the removed parts if necessary and assemble them after a thorough check. |
| 6 | Removed parts | • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. • Retain the removed parts for customer inspection, if requested. |
Table Caption: This table outlines essential safety and procedural guidelines for vehicle maintenance and repair operations, covering attire, vehicle protection, safe working practices, tool preparation, and handling of removed parts.
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