EM089±03
P03265
SST
P03266
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±41
1213 Author: Date:
DISASSEMBLY
1. REMOVE CAMSHAFT POSITION SENSOR AS-
SEMBLY
Remove the bolt and sensor assembly.
2. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in the correct order.
3. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring, valve and
spring seat.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.
(c) Using needle±nose pliers, remove the oil seal.
EM2534
Overall Length
EM0255
P03272
45° Carbide
Cutter
Z00055
Width
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±45
1217 Author: Date:
(d) Check the valve overall length.
Standard overall length:
Intake97.40 ± 97.80 mm (3.8346 ± 3.8504 in.)
Exhaust98.25 ± 98.65 mm (3.8681 ± 3.8839 in.)
Minimum overall length:
Intake97.1 mm (3.823 in.)
Exhaust98.0 mm (3.858 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum length.
8. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
EM04T±03
P12683
P12476
SST
P12686
P12720
Magnetic Finger EM±42
± ENGINE MECHANICAL (1MZ±FE)CYLINDER HEAD
1328 Author: Date:
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in the correct order.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
(c) Using needle±nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.
EM2534
Overall Length
EM0255
P12704
P12729
Width
Z03988
45°
1.0 ± 1.4 mm30° EM±46
± ENGINE MECHANICAL (1MZ±FE)CYLINDER HEAD
1332 Author: Date:
(d) Check the valve overall length.
Standard overall length:
Intake95.45 mm (3.5779 in.)
Exhaust95.40 mm (3.7559 in.)
Minimum overall length:
Intake94.95 mm (3.7382 in.)
Exhaust94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
Q01614
Q08124
Q08125
Q08126
Z00182
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±17
1818 Author: Date:
25. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
26. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N´m (240 kgf´cm, 17 ft´lbf)
27. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, and remove the No.1 shift fork
shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.
28. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
29. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
30. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
31. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
SA3213
Front A
DB
C
F02245
F02246
SA0028
Front AB
A B
A: Inside
B: Outside
± SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA±3
510 Author: Date:
5. INSPECT TOE±IN
Toe±in:
Toe±in
(total)A + B: 0° ± 12' (0° ± 0.2°)
C ± D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe±in is not within the specified value, adjust it at the rack
ends.
6. ADJUST TOE±IN
(a) Using pliers, remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe±in.
HINT:
Try to adjust the toe±in to the center of the specified value.
(d) Make sure that the lengths of the right and left rack ends
are the same.
Rack end length difference: 1.5 mm (0.059 in.) or less
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (750 kgf´cm, 54 ft´lbf)
(f) Place the boots on the seats and using pliers, install the
clips.
HINT:
Make sure that the boots are not twisted.
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Wheel turning angle:
Inside wheel35°50' ± 2° (35.84° ± 2°)
Outside wheel: Reference31°28' (31.47°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
SEAT BELT EXTENDER: '98 ± '00 ± BO002±00 January 21, 2000
Page 6 of 7
Failure to follow the recommendations indicated below could result in less effectiveness
of the seat belt restraint system in case of vehicle collision, causing personal injury.
The Seat Belt Extender must not be used:
A. By anyone other than for whom it was provided (name recorded on seat belt
extender).
B. In any vehicle and/or seat position other than the one for which it was provided.
C. When the Seat Belt Extender is provided for rear seat positions (with automatic
locking retractor), make sure the retractor is locked when in use.
If your seat belt cannot be fastened securely because it is not long enough, a
personalized seat belt extender is available from your Toyota dealer free of charge.
Please contact your local Toyota dealer so that the dealer can order the proper required
length for the extender. Bring the heaviest coat you expect to wear for proper
measurement and selection of length. Additional ordering information is available at your
Toyota dealer.
CAUTION:
When using the seat belt extender, observe the following. Failure to follow these
instructions could result in less effectiveness of the seat belt restraint system in case
of vehicle accident, increasing the chance of personal injury.
Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt
without it.
The Seat Belt Extender must never be used with any child safety seats.
Remember that the extender provided for you may not be safe when used on a
different vehicle, or for another person or at a different seating position than the
one originally intended for.
To connect the extender to the seat
belt, insert the tab into the seat belt
buckle so that the ªPRESSº signs on
the buckle±release buttons of the
extender and the seat belt are both
facing outward as shown.
You will hear a click when the tab locks
into the buckle.
When releasing the seat belt, press on
the buckle±release button on the
extender, not
on the seat belt. This helps
prevent damage to the vehicle interior
and extender itself.
When not in use, remove the extender and store in the vehicle for future use.
Owner
Instructions
Seat Belt Extender
Seat Belt Release
SEAT BELT EXTENDER: '99±'01 MODEL YEAR ± BO002-01 January 26, 2001
Page 6 of 7
Failure to follow the recommendations indicated below could result in reduced
effectiveness of the seat belt restraint system in case of vehicle collision, causing
personal injury.
The Seat Belt Extender must not be used:
a. By anyone other than for whom it was provided (name recorded on seat belt
extender).
b. In any vehicle and/or seat position other than the one for which it was provided.
c. When the Seat Belt Extender is provided for rear seat positions (with automatic
locking retractor), make sure the retractor is locked when in use.
If your seat belt cannot be fastened securely because it is not long enough, a
personalized Seat Belt Extender is available from your Toyota dealer free of charge.
Please contact your local Toyota dealer so that the dealer can order the proper required
length for the extender. Bring the heaviest coat you expect to wear for proper
measurement and selection of length. Additional ordering information is available at your
Toyota dealer.
CAUTION:
When using the Seat Belt Extender, observe the following. Failure to follow these
instructions could result in reduced effectiveness of the seat belt restraint system in
case of vehicle accident, increasing the chance of personal injury.
Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt
without it.
The Seat Belt Extender must never be used with any child safety seats.
Remember that the extender provided for you may not be safe when used on a
different vehicle, or for another person or at a different seating position than the
one originally intended for.
To connect the extender to the seat
belt, insert the tab into the seat belt
buckle so that the ªPRESSº signs on
the buckle-release buttons of the
extender and the seat belt are both
facing outward as shown.
You will hear a click when the tab locks
into the buckle.
When releasing the seat belt, press on
the buckle-release button on the
extender, not
on the seat belt. This helps
prevent damage to the vehicle interior
and extender itself.
When not in use, remove the extender
and store in the vehicle for future use.
Owner
Instructions
Seat Belt ExtenderSeat Belt Release