Nippondenso Toyota Alternators 1965-73

For Toyota Models (1965-73)

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION & OTHER ELECTRICAL SYSTEM

REPAIR CAUTIONS-Reversed polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage.

Battery Installation - Negative battery terminal must be connected to ground (negative ground systems) and positive terminal must be connected to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from battery. DO NOT use a Quick Charger to provide starting voltage.

NIPPONDENSO ALTERNATOR (TYPICAL)

Circuit Interruption - Battery must NEVER be disconnected while alternator is running.

Alternator Removal - Always disconnect battery ground before replacement of alternator.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to positive battery terminal. DO NOT reverse battery leads.

DESCRIPTION

Nippondenso alternators are conventional, three-phase, self rectifying type alternators. Six diodes (three positive and three negative) are used to rectify current

                                APPLICATION

Model                                                      Toyota Part No.

KC (1969-70)

   Corolla 1100 Before 2/69 .......................... 22010

   Corolla 1100 After 2/69.............................. 22011 

3K-C (1970-73)
   Corolla 1200 (1970-72)............................ *22011
   All Models W/ 3K-C Eng. (1973)............... 24031
2T-C (1971-72)
   Corolla (1971-72)...................................... 25010
   Carina (1972)........................................................
   All Models W/2T-C Eng. (1973)................ 25010
BR-C (1969-71)
   Corona Mk II.............................. 33010 & 33030
   Hi-Lux.............................. 22011, 31031 &31032                   
   Corona & Celica......................................... 33011
3R-B (1965-67)
   1900 Sedan................................................. 21011
   Corona & Crown
      Before Eng. 3R 479894............................ 21010
     After Eng. 3R 479894................................ 21011
   Stout Pickup
      Before Eng. 3R 590915............................ 40010
      After Eng. 3R 590915.............................. 40011
3R-C (1968-70)
   Corona & Hilux
      Before 6/68.............................................. 21011
      After 6/68................................................ 40060
18R-C (172-73)
   Corona & Celica (1972).............................. 33011
   Corona Mk II (1972).................................. 33030
   Hi-Lux (1972)............................................. 31032
   All 1973 BR-C Eng. ................................... 33030
M (1965-68)
   Crown Before 11/68.................................... 41011
2M (1968-71)
   Crown
      After 11/68............................................... 41011
      After 9/69................................................. 41012
4M (1971-73)
   Crown (1971-72).................................... **41032
   Corona (1971-72)................................. ***41032
   All 4M Eng. (1973)..................................... 45020
F (1965-73)
   From Eng. F224280.................................... 60021
   From Eng. F243298............................**** 60031
   From Eng. F270964.................................... 60040
   From 1/71.........................................***** 60033
   All F Eng. (1973)........................................ 60040
* - All part numbers start with 27020 prefix
** - Part number 22012 is optional.
*** - Part number 45010 is optional.
**** - Part numbers 60012, 60040 & 60022 are iotuibak,
***** - Part number 60040 is optional.

SPECIFICATIONS

                               Rated Output @ 3500 RPM
Application*               Amps.          **Volts
21010...........................40.....................14
21011...........................40.....................14
22010...........................25.....................14
22011.....................***25.....................14
22012...........................30.....................14
24031...........................35.....................14
25010...........................40.....................14
31031...........................30.....................14
31032...........................30.....................14
33010...........................40..........13.5-14.8
33011...........................40.....................14
33030...................****45.....................14
40010...........................40.........13.5-14.8
40011...........................40.........13.5-14.8
40060...........................40.........13.5-14.8
41010...........................40.........13.5-14.8
40011...........................40.........13.5-14.8
40012...........................40.........13.5-14.8
41032...........................45.........13.5-14.8
45010...........................55....................14
45020...........................55....................14
60012...........................35....................14
60021...........................50....................14
60022...........................50....................14
60031...........................40....................14
60032...........................40....................14
60033...........................40....................14
60040...........................55....................14
* - All part numbers start with 27020 prefix.
** - Nominal voltage, 12.
*** - Optional for part number 27020 22011 is 30 amps.
**** - Amps for part number 27020 33030 ub 1973 us 50.
                        Coil Resistance (Ohms)
Application            Rotor                Stator
21010......................3.6...............................
21011......................3.6...............................
22010......................4.2...............................
22012......................4.2...............................
24031......................4.2...............................
25010......................4.2........................0.24
31031......................4.2...............................
31032......................4.2...............................
33010......................4.2........................0.37
33011......................4.2........................0.37
33030......................4.8........................0.24
40010......................3.6...............................
40011......................3.6...............................
40060......................3.6...............................
41010..........................................................
41011......................4.2........................0.24
41012......................4.2........................0.24
41032......................4.2........................0.37
45010......................4.2........................0.37
45020......................4.2........................0.37
60012.........................................................
60021.........................................................
60022.........................................................
60031......................4.2..............................
60032.........................................................
60033......................4.2..............................
60040......................4.8..............................
* - All part numbers start with 27020 prefix.
                              Minimum Brush Length
Application*                            In. (mm)
21010, 21011, 22010................. .354 (9)
22011, 22012, 24031................. .354 (9)
40010, 40011, 40060................. .354 (9)
25010, 31031, 31032.............. .334 (8.5)
33010, 33011, 33030.............. .334 (8.5)
41010, 41011, 41012.............. .334 (8.5)
41032, 45010, 45020.............. .334 (8.5)
60012, 60021, 60022.............. .217 (5.5)
60031, 60032, 60033.............. .217 (5.5)
60040...................................... .217 (5.5)
* - All part numbers start with 27020 prefix.

TESTING

ON CAR TEST

TEST CIRCUIT FOR LOAD TEST

Preliminary Inspection - Check alternator mounting and belt tension. Inspect turn signal fuse and gauge fuse. Check alternator and regulator wire connections for tightness
No-Load Test - 1) Connect test meters as shown in illustration. Start engine and increase speed to 2300 RPM (gradually). Read the "B" terminal voltage. It should be 13.8-14.8 volts with current draw of not more than 10 Amps. If current is over 10 Amps the battery is discharged or internally shorted.
2) If voltage reading is not steady, it indicates regulator points are dirty, or defective connection exists at "F" terminal.
3) If voltage reading is too high, it indicates the following problems: Regulator low speed gap is too wide. High speed point gap is too wide. High speed point resistance is too high. Open circuit regulator coil or

CHECKING VOLTAGE BETWEEN "F" &
"E" TERMINALS

voltage relay coil. Open circuited regulator coil or voltage relay coil. Open circuited regulator "N" terminal or "B" terminal. Low speed point contact tension too heavy. Loose regulator ground connection.
"F" Terminal Voltage Test - Stop Engine, disconnect alternator wiring connector, turn ignition switch to "ON" and measure voltage between "F" and "E" terminals of connector. Voltage should be 12 volts. If voltage is zero or very low, note the following possible causes: blown fuse, regulator "IG" terminal open, or regulator high speed points are burned.
Regulator Circuit Resistance - Disconnect regulator connector plug and check resistance between regulator "IG" and "F" terminals with an ohmmeter. If there is any resistance, the low speed contact in regulator is defective.
Load Test - Connect test meter as shown in illustration. Start engine, load system by turning all lights and accessories on. Run engine at 1100 RPM. Read amperage and voltage, it should be as specified. If battery is fully charged and reading is low, discharge battery by cranking engine (without spark) for about 15 seconds. Now if amperage is low, the rectifiers are open, shorted, or stator coil is open or shorted.

OVERHAUL

DISASSEMBLY

TESTING DIODES

1) Remove three retaining screws and insert screwdrivers into notches in drive end frame, pry with screwdrivers to separate drive end frame from stator. If necessary, tap lightly o drive end frame with a mallet.
2) Secure rotor core in padded vise, remove pulley attaching nut, and withdraw pulley, fan, and spacer. Remove rotor from drive end frame, utilizing a press. Remove bearing retainer from drive end frame, then remove bearing, felt cover and felt ring.
3) Remove four rectifier holder securing nuts and two brush holder securing screws; separate stator with rectifier holders and brush holders from rectifier end frame. Remove brush lead terminal and stator coil "N" terminal from brush holder, utilizing a small screwdriver. CAUTION - When removing brush holder assembly, do not remove it by cutting "N" terminal lead or melting the solder.
TESTING
Rotor - Check rotor for open field windings by connecting an ohmmeter across the slip rings. Coil resistance should be approximately as specified. Next check bearing and replace if necessary. Check slip rings for rough condition.

ALTERNATOR GENERATING CIRCUIT
(WITH VOLTAGE RELAY)

Stator - Use ohmmeter to check stator coil for ground. To check stator for open circuit, stator leads must be disconnected from diode leads. To disconnect leads from diodes, unsolder as quickly as possible and with a low-watt iron. Check four leads of stator coil for conduction, stator coil is open and must be replaced. Resistance should be zero.
Diode Test - With diode assembly on bench, make test connections as illustrated, using an ohmmeter. Contact diode plate with one probe and contact each of the three diode leads with other probe. Not ohmmeter reading, then reverse probes and repeat test. Check both positive and negative diodes in this manner. All diodes should show a low reading in one direction and no reading in opposite direction. If any one rectifier is defective, always replace positive or negative holder assembly.
PARTS REPLACEMENT

ALTERNATOR GENERATING CIRCUIT
(WITHOUT VOLTAGE RELAY)

Brushes - Check for cracks and wear. If brushes are worn beyond specifications, replace. Brushes should slide smoothly. Install new brush spring when replacing brush. Solder brush lead wire keeping protruded length to .51" (13 mm).
REASSEMBLY
Reassemble alternator by reversing disassembly procedure, noting the following points:
1) Press brushes, against spring tension, into brush holder. Insert a wire through access hole in rectifier and frame, and into hole in brush holder. This will prevent brushes from falling. Remove wire after assembly to end frame is completed.
2) Pack multipurpose grease into rear beraing and press bearing onto rotor shaft.
3) Install felt ring and felt cover so that convex surface of cover will face toward pulley side onto drive end frame. Next pack multipurpose grease into bearing and install bearing.

Toyota GT 86 Repair Manual

Manufacturer: Toyota
Model: GT-86

• Introduction
• Preparation
• Service Specifications
• Engine Control System
• Fuel
• Emission Control
• Engine Mechanical
• Exhaust
• Cooling
• Lubrication
• Ignition
• Starting and Charging
• Front Suspension
• Rear Suspension
• Wheel and Tire
• Drive Shafts
• Braking
• Parking Brake
• Automatic Transmission
• Manual Transmission
• Clutch
• Steering Column
• Power Steering
• HVAC
• SRS
• Seat Belts
• Lighting
• Wiper and Washer
• Audio and Visual System
• Power Sources
• Communication System
• Windows and Mirrors
• Instrument Panel
• Seats
• Anti-Theft Door Locks
• Sliding Roof
• Engine Hood and Doors
• Exterior and Interior Trim
• Vehicle Control System
• Cruise Control
• Maintenance
• Diagnostics

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Toyota All Models 1975-77 Drive Axles Repair Guide

DESCRIPTION

The axle assembly is hypoid gear type with a separate carrier housing. It comes in slightly different models for use in all Toyota vehicles. Two-pinion differential cases are one-piece design while four-pinion cases are two-piece design. The differential side bearing preload is set with adjusting nuts on all models. The pinion bearing preload can be set with a solid spacer and adjusting shim or with a collapsible spacer.

AXLE RATIO & IDENTIFICATION

Toyota uses only one basic type of axle assembly. Any differences in Removal & Installation or Overhaul procedures will be noted where they occur. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.

Fig. 1 Exploded View of Toyota Two Pinion Differential Assembly
(Four Pinion Differential Assembly Shown in Inset)

Fig. 2 Rear Axle Assembly for All Models Except Pickup

REMOVAL & INSTALLATION

AXLE SHAFT & BEARINGS

Axle Shaft Removal, Exc. Pickup - Working through hole in axle flange, remove bolts holding bearing retainer to axle housing flange. Using slide hammer, remove shaft from housing using care not to damage axle seal. If both axles are to be removed, be sure to index mark for reinstallation in original position. If axle housing seal is being replaced, coat sealing lip with grease before installing.

Axle Shaft Removal, Pickup - Raise and support vehicle. Remove brake drum after first removing the mounting bolts. Disassemble brake components and plug open end of brake lines. Disconnect the parking brake linkage and place it out-of-way. Remove nuts retaining brake backing plate to axle housing, then carefully remove axle shaft from vehicle ensuring not to damage oil seal in housing.

Fig. 3 Rear Axle Assembly for Toyota Pickup

Bearing Removal & Installation, Exc. Pickup - To remove bearing, grind part way through bearing retainer ring using caution net to nick axle shaft. Cut remaining portion of retaining ring using a cold chisel. Remove split retaining ring and press bearing off shaft. Remove spacer from shaft. To install,  place spacer and bearing onto shaft and press into place. Heat new retaining ring to about 300°F (150°C) and press into place. NOTE - The retaining ring will show a faint yellow color when heated to proper temperature. Measure thickness of brake backing plate. Choose proper  thickness selective fit gasket, according to thickness of backing plate, then install between backing plate and axle housing flange. NOTE - Carina, Celica, and Corona do not use selective fit gaskets. Place other gasket into position so when shaft is installed it will be between bearing retainer and backing plate. Install axle shaft, check alignment of gaskets, then tighten bolts. Except for selective fit gaskets there is no bearing adjustment.

Bearing Removal & Installation, Pickup - Remove snap ring securing bearing retainer. Install suitable puller onto rear axle bearing case and press axle shaft out of case. Remove bearing from case and press axle shaft out of case. Remove backing plate, drive seated bolts out and separate assemblies. To reassemble proceed as follows: Drive axle shaft oil seal into housing. Fit backing plate on bearing case with index marks aligned. Press serrated bolts into position and install oil seal into bearing case. Fit axle shaft bearing into case. Slide on retainer and fit snap ring. Position new "O" ring on axle housing, then refit axle shaft assembly with backing plate and tighten nuts. Install remaining components in reverse order of removal.

Fig. 4 Removing Drive Pinion Gear Front Bearing

PINION SEAL REPLACEMENT

Corona - 1) Disconnect and remove propeller shaft, then set parking brake. Measure and record total pinion preload with pull scale attached to pinion flange at one of the propeller shaft bolt holes. Measurement is made within the small movement caused by the ring gear and axle shaft backlash. Axle shafts are locked by parking brake.

2) Remove pinion shaft nut calking, then remove nut. Using suitable flange puller tool (09557-22010), remove pinion flange. Remove oil seal using suitable puller, then take out oil slinger. Install bearing puller and remove bearing, then withdraw spacer and measure. If spacer is larger than minimum specification, it may be reused by adding an additional shim. If spacer is shorter, use new spacer. Assemble spacer and shim (if used) onto pinion shaft.

                             Minimum Spacer Length

Application                                                         Specification

Corona                                                                    In. (mm)

   6.7" Ring Gear.................................................  2.13 (54.0)

   7.1" Ring Gear.................................................  2.40 (61.0)

Fig. 5 Installing Oil Seal

3) Install bearing and oil slinger. Apply grease to seal lip and install in carrier. NOTE - Fit oil seal to a depth of .06" (1.5 mm) on Mark II Sedan, or .15" (4.00 mm) on Mark II Station Wagon. Using tool attached to pinion flange, install pinion flange. Remove tool, install new nut and tighten. Rotate pinion in both directions to seat bearing, then measure preload in same manner as before. Preload must be equal to original value plus 1.5-2.0 lbs (.7-.9 kg). If preload is insufficient, tighten nut in 7.2 ft. lbs. (.97 mkg) increments until it is to specification. If 145 ft. lbs. (20.0 mkg) is reached without preload being within specification, loosen nut and begin retightening again.

NOTE - On all other modes, carrier removal is suggested before replacing pinion seal.

DIFFERENTIAL CARRIER REMOVAL & INSTALLATION

Fig. 6 Removing Differential Carrier

Drain oil from axle housing. Loosen hub nuts, and remove wheels. Disconnect and place propeller shaft out of the way. Remove axle shafts as previously described. NOTE - Take care not to damage oil seal if it not scheduled for replacement. Loosen bolts and remove differential carrier. To install, reverse removal procedure, noting the following: Coat both sides of carrier-to-housing gasket with sealer before installation. Fill axle housing with 90W gear oil.

OVERHAUL

DISASSEMBLY

1) Mount carrier on suitable work stand. Punch aligning marks on bearing cap and carrier to prevent intermixing of left and right caps. Remove adjusting nut lock bolt. Remove side bearing bolts, caps, and adjusting nuts. Take out differential case assembly with bearing cups. Note number and thickness of any shims. Remove pinion flange bolt using suitable tool to hold the flange. On some models, drive pinion will fall out if not restrained.

Fig. 7 Removing Drive Pinion and Flange on Pickup

2) Using suitable puller (09557-22010), remove flange from pinion shaft. On pickup models, puller is not required. Using suitable puller, remove oil seal. On pickup models, seal can be pried out in lieu of special tool. Withdraw oil slinger.

3) With suitable puller, remove front pinion bearing, then press drive pinion out of rear of carrier. On pickup models, drive pinion removal does not require a press. Press out front and rear bearing cups. With drive pinion shaft installed in suitable press, remove rear bearing. Use caution to avoid deforming shim that adjusts pinion depth (height). Remove side bearings from differential case. NOTE - Cutaways are provided in case for clearance of puller hooks. Straighten out lock plates on ring gear bolts, index mark ring gear and case, then remove bolts. 

Fig. 8 Removing Rear Bearing from Drive Pinion Gear

4) Mount differential case and ring gear assembly in vise so ring gear teeth are pointed down. Tap ring gear from case using a brass hammer. Measure backlash between differential pinion and side gear for reference during reassembly. Backlash should be .002-.008: (.05-.20 mm). On two-pinion differentials, remove pinion gear shaft retaining pin from case. Drive out pinion gear shaft, remove pinion gears, side gears and thrust washers. On four-pinion differentials, separate case cover and remove pinion shaft holder, side gears and thrust washer.

REASSEMBLY & ADJUSTMENT

Fig. 9 Installing Side Bearings on Differential Case

Case Assembly - 1) Lubricate all components with hypoid gear lubricant. On two-pinion models, assemble side gears and pinion gears into differential case. Make sure oil groove, if present, on side gear thrust washer faces toward gear. On four-pinion types, install side gears, thrust washers, differential pinions, pinion shaft holder, differential shaft, and pinion shaft. Install differential case cover and tighten bolts. Note that long bolts serve to lock differential tight.

2) Check backlash between side gears and pinion gears. If backlash is not .002-.008" (.05-.20 mm) install suitable selective fit thrust washers. Install pinion shaft lock pin, if equipped, and peen over hole.

Fig. 10 Measuring Ring Gear Runout

3) Press differential side bearings onto differential case. Heat ring gear in oil or water bath to approximately 212°F (100°C), then quickly wipe off gear and install on differential case. Fit bolts and tighten evenly, then bend over lock tabs. Install differential case assembly on differential carrier and measure ring gear runout.

4) If runout is within specifications, remove differential carrier and bend up on ring gear lock plate. If runout exceeds specifications, remount ring gear 180° from original position on differential case. If this fails to bring ring gear into specifications, remove ring gear from case and examine runout. If case runout is within range specified for ring gear, then ring gear is at fault and should be replaced. Remove ring gear and case assembly from carrier.

Fig. 11 Toyota Master Gauge for Measuring
Drive Pinion Installed Height

Drive Pinion Depth - Install drive pinion cups into carrier. Adjust pinion depth using Toyota Master Gauge or equivalent. Insert drive pinion rear bearing onto suitable base rod, then install base rod head. Insert this assembly into carrier from the rear. Install front pinion bearing into carrier from front end. Install collar, preload flange pulley and nut onto front end of base rod. Using a spring scale and thin cord, measure preload of drive pinion bearings. tighten nut until preload is within specifications (see specifications). Install master gauge into differential side bearing bores, then install bearing caps and tighten. Select a shim that will just fit between master gauge and base rod head. One shim or none must be used: do not use more. After selecting the shim, remove all components of master gauge kit from carrier. Install shim onto drive pinion, if it has a chamfered edge, install that edge toward pinion gear; press rear bearing into place.

NON-COLLAPSIBLE (SOLID) SPACER

Pinion Bearing Preload - 1) Install bearing spacer onto pinion shaft and insert assembly into carrier from rear. Insert shims (if any) that were removed during disassembly onto pinion shaft.

2) Install front bearing, oil deflector, flange, washer and nut. Torque pinion flange nut to specifications. Install preload flange onto pinion flange.

3) Using torque wrench, measure pinion bearing preload. If not to specifications, shims in front of preload spacer must be changed. If preload is too great, increase shim thickness: if preload is too small, decrease shim thickness.

4) Use either two shims or non for adjustment. If thicker shim pack is needed, use thicker shims, not more shims. When preload is correct, remove flange, install oil seal and reassemble

COLLAPSIBLE SPACER

Fig. 12 Installing Pinion Flange

Pinion Bearing Preload - 1) Measure used spacer, if less than specifications, discard and use new spacer. If old spacer is longer than minimum specifications, it may be reused with a shim .012" (.03 mm) thick.

2) Fit spacer on drive pinion shaft and insert assembly into carrier from rear. If shim is to be used, install it on shaft. Insert bearing into front end of carrier. Insert oil slinger and install oil seal. On Mk II only, ensure oil seal is installed .060" (1.5 mm) from front edge of carrier bore.

Fig. 13 Measuring Side Bearing Preload

3) Apply grease to oil seal lip before installation. Using suitable pinion flange installing tool (09557-22010), fit pinion flange. Turn nut on special tool to seat pinion flange, then remove tool. Install washer and new nut and tighten to approximately 80 ft. lbs. (11.0 mkg).

4) Install preload flange and measure preload with torque wrench. If preload is less than specifications, tighten pinion flange nut more and recheck. If preload exceeds maximum specifications, disassemble and add shims (or replace collapsable spacer). Reassemble and recheck

                           Minimum Spacer Length

Fig. 14 Measuring Ring Gear Backlash

Application                                            Specification In. (mm)

Corona

   6.7" Ring Gear.......................................  2.13 (54.0)

   7.1" Ring Gear.......................................  2.40 (61.0)

Backlash & Side Bearing Play - 1) Assemble bearings in cups and install onto carrier. Install differential assembly into carrier, then fit adjusting nuts. Put bearing caps on in original position. Tighten bolts carefully, while checking that adjusting plunger touches flange side of ring gear. Tighten flange side adjusting nut until a slight backlash remains. During operation, rotate ring gear through several revolutions to seat side bearings. Tighten tooth side nut just to the point where there is no differential end play when measured with dial indicator. At this point tighten tooth side nut just tot the point where there is no differential end play when measured with dial indicator. At this point tighten tooth side nut on additional 1-1½ notches to preload side bearings. 

2) Confirm that some backlash is still present. Install preload flange onto the pinion shaft flange and measure preload. If within specifications go on to next step; if not tighten tooth side adjusting nut on more notch and recheck.

3) Install dial gauge so that plunger is perpendicular to ring gear tooth. Measure ring gear backlash. If not within specifications, turn left and right adjusting nuts to shift differential assembly in proper direction. If left side is loosened one notch, the right side must be tightened one notch to maintain side bearing preload. Continue procedure until backlash is within specifications. One notch will change backlash .002" (.06 mm). Tighten side bearing cap bolts. Check gear tooth contact pattern. See Gear Tooth Contact Pattern at beginning of this section. Install differential carrier.

Fig. 15 Exploded View of Limited Slip Differential

LIMITED SLIP DIFFERENTIAL

Disassembly - Remove case cover and take out side gear side thrust washer, lock pin, left and right cluch and differential pinion

Inspection - Visually inspect all components for excessive wear or damage, then replace those parts found defective.

Reassembly and Adjustment - 1) Fit ring gear to differential case and check runout. Dial gauge reading should be .004" (.10 mm); correct, if necessary, as previously indicated.

2) Adjust clearance between differential case, side gear and clutch using thrust washers that will provide a clearance of  .001-.004" (.03-.11 mm). Proceed as follows to select proper thrust washer:

Fig. 16 Measuring Mounting Distance

3) Install case cover and tighten bolts. Check differential case mounting distance as shown in illustration, then record value. With side gear and clutches mounted in suitable vise measure distance between outside edges of side gears; use a micrometer. The difference between  the two recorded figures indicates necessary thrust washer thickness. To complete reassembly, reverse removal procedure

Toyota xB/BB Scion Repair Manual

Manufacturer: Toyota/Scion
Model: Scion xB / BB
Year: 2004

Contains the following information and repairs for:

• Introduction
• Preparation
• Service Specifications
• Diagnostics
• Engine Control System
• Fuel
• Emission Control
• Engine Mechanical
• Exhaust
• Cooling
• Lubrication
• Ignition
• Starting and Charging
• Front and Rear Suspension
• Tire and Wheel 
• Drive Shaft
• Brake and Parking Brake
• Automatic and Manual Transmission
• Clutch
• Steering Column
• Power Steering
• Heater and Air conditioning
• Supplemental Restraint System
• Seat Belt
• Lighting
• Wiper and Washer
• Audio and Visual System
• Wiring
• Communication System
• Windshield
• Instrument Panel
• Seat
• Theft Deterrent and Door Lock
• Engine Hood and Doors
• Exterior and Interior Trims
• Vehicle Control System
• Maintenance
• Wiring Manuals
• Installation Manuals

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Toyota 1MZ-FE Engine Repair Manual

Toyota Vehicles that Uses this Engine:

• Toyota Camry
• Lexus ES300
• Windom (Japanese Domestic Market)
• Lexus RX300
• Toyota Harrier
• Toyota Sienna
• Toyota Solara
• Toyota Estima

Contains the following information and engine repairs for:

TOYOTA 1MZ-FE ENGINE

• Engine Mechanical
• Emission Control Systems
• SFI System
• Cooling System
• Lubrication System
• 1MZ-FE Engine Troubleshooting
• Engine Operating Condition
• Matrix Chart of Problem Symptoms
• Location of Connectors
• Circuit Inspection

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Toyota 1976 Models Wheel Alignment Guide

1976 TOYOTA ADJUSTMENTS AND SPECIFICATIONS

TIRE INFLATION (COLD)

Before attempting to check or adjust wheel alignment, make sure tires are properly inflated. Refer to manufacturers specifications given in owner's manual.

RIDING HEIGHT
Corona and Mk II - Place vehicle on level surface. Bounce several times and allow suspension to settle. Check riding height dimensions (See Fig 1) and if not within specifications, inspect suspension components. Replace or repair parts as required.

CASTER

Corona - NOTE - Camber and caster adjustments should always be made in one operation. If caster angle is not within specifications, adjust eccentric on front of lower control arm.

Corona Mk II and Hi-Lux - NOTE - Camber and caster adjustments should always be make in one operation. If caster angle is not within specifications, adjust by adding or removing shims between the upper control arm shaft and the front suspension crossmember. To increase caster, add shims to rear side of the upper control arm shaft mounting bolt or remove shims from the front side. To decrease caster, reverse procedure.

All Other Models - Caster angle is not adjustable. If caster angle is not within specifications, inspect front suspension for wear or damage and repair or replace components as necessary.

CAMBER

Corona - NOTE - Caster and camber adjustments should always be made in one operation. If camber angle is not within specifications, adjust eccentric on rear of lower control arm.

Corona Mk II and Hi-Lux - NOTE - Caster and camber adjustments should always be made in one operation. If camber angle is not within specifications, adjust by adding or removing shims between upper control arm shaft and the front suspension crossmember. To increase camber angle, remove shims from upper control arm shsaft bolts in equal amount. To decrease camber, reverse procedure.

All Other Models - Camber angle is not adjustable. If camber angle is not within specifications, inspect fornt suspension for wear or damage and repair or replace components as necessary.

TOE-IN

All Models - If toe-in is not within specification, loosen steering link (tie-rod) clamping bolts and rotate adjusting sleeves on equal amount until correct toe-in is obtained. Position clamp bolts at right angles to slot in tie rod and tighten bolts.

Toyota 1974 Models Wheel Alignment Guide

1974 TOYOTA SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)

Before attempting to check or adjust wheel alignment, make sure tires are properly inflated. Refer t manufacturers specifications given in owner's manual.

RIDING HEIGHT

Corona & Mark II (RX & MX Models) - Place vehicle on level surface. Bounce several times and allow suspension to settle. Check riding height dimension (see illustration) and if not within specifications, inspect suspension components. Replace or repair parts as necessary.

CASTER

Corolla, Celica & Land Cruiser - Caster angle is not adjustable. If caster angle is not set to specifications, inspect front suspension for wear or damage and repair or replace components as necessary.

All Other Models - NOTE - Camber and caste adjustments should always be made in one operation. If caster not within specifications, adjust by adding or removing shims between the upper arm shaft and the front suspension crossmember. To increase the caster, add shims to rear side of the upper arm shaft mounting bolt or remove shims from the front side of the upper arm shaft mounting bolt. To decrease caster, reverse procedure.

CAMBER

Corolla, Celica and Land Cruiser - Camber angle is not adjustable. If camber angle is not set to specifications, inspect front suspension for wear or damage and repair or replace components as necessary.
All Other Models - NOTE - Camber and caster adjustments should always be made in one oepration. If camber is not within specifications, adjust by adding or removing shims between the upper arm shaft and the front suspension crossmember. To increase camber, remove shims from upper arm shat bolt in equal amounts. To decrease camber, reverse procedure.

TOE-IN

Land Cruiser & Hi-Lux - If toe-in is not within specifications loosen steering link (tie rod) clamping bolts and rotate adjusting sleeve until correct toe-in is obtained. Position clamp bolts at right angles to slot in tie rod and tighten bolts.
All Other Models - If toe-in is not to specifications, loosen steering link (tie rod) clamping bolts and rotate each adjustable sleeve same amount to obtain correct toe-in. Tighten clamping bolts and make sure clamp slots are aligned with adjusting tube slots.

1974 Models

1975 Models

Toyota 1965-73 Wheel Alignment Guide

1965-73 TOYOTA SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)

Before attempting to check or adjust wheel alignment, make sure tires are properly inflated.

RIDING HEIGHT

Corona & Mark II (RX & MX Models) - Place vehicle on level surface. Bounce several times and allow suspension to settle. Check riding height dimension (see illustration) and if not within specifications, inspect suspension components. Replace or repair parts as necessary.

Mark II (All Other Models) - Place vehicle on level surface. Install suitable height adjuster (09730-22010) in place on front and rear suspension. Check riding height dimensions. If not within specifications, inspect suspension components. Replace or repair parts as necessary.

Crown - Place vehicle on level surface. Place suitable height adjusters in place for the front and rear (09731-30020 & 09732-30010) suspension and check riding height dimensions (see illustration). If not within specifications, adjust using suitable height adjuster. If there is considerable difference between actual height and specifications check suspension components. Replace or repair parts as necessary.

RIDING HEIGHT DIMENSIONS

CASTER

Corolla, Carina, Celica (1971-73) & Land Cruiser (All) - Caster is nonadjustable. If alignment is not within specifications inspect for damaged parts and replace as necessary.

Stout (1965-69) - Place front wheels on a turning gauge set at zero. Turn front wheels until gauge reads 20°. Wheel to be measured should be turned outward at the front of the wheel. Zero bubble in caster scale. Turn wheels until turned 20° inward at the front and read caster scale. If not within specifications install suitable caster adjusting wedge (48191-35020 or 48192-35020) to bring specifications within limits.

All Other Models - NOTE - Camber and caster adjustments should always be made in one operation. If caster not within specifications, adjsut by adding or removing shims between the upper arm shaft and the front suspension crossmember. To increase the caster, add shims to rear side of the upper arm shaft mounting bolt or remove shims from the front side of the upper arm shaft mounting bolt. To decrease caster, reverse procedure.

CAMBER

Corolla, Carina, Celica (1971-73) & Land Cruiser (All) - Camber is nonadjustable. If alignment is not within specifications, inspect for damaged parts and replace as necessary.

Stout (1965-69) - Place front wheels on a turning gauge set at zero and check camber angle with camber gauge. If not within specifications, use a front axle aligning tool and correct camber to specifications.

All Other Models - NOTE - Camber and caster adjustments should always be made in one operation. If camber not within specifications, adjust by adding or removing shims between the upper arm shaft and the front suspension crossmember. To increase camber, remove shims from upper arm shaft bolts in equal amounts. To decrease camber, reverse procedure.

TOE-IN

Land Cruiser, Hi-Lux (1970-73) & Stout (1965-69) - To adjust toe-in, loosen tie rod clamp bolts at each end of the tie rod. Rotate rod to set toe-in to specifications. Position clamp bolts at right angles to the slot in the tie rod and tighten. Clamps should not project beyond end of adjusting tube.

All Other Models - NOTE - On Mark II (Exc. RX & MX Models) and Crown models, checking and adjustment is done with height adjuster installed. To adjust toe-in, loosen tie rod lock nuts or clamps on both tie rods and ensure that the rods are equal lengths. Turn both tie rods same amount to set toe-in to specifications. Tighten lock nuts or clamps making sure clamp slots are aligned with adjusting tube slots except on Lite Stout position clamp bolts at right angle to slot in adjusting tube. Clamps should not project beyond end of adjusting tube.

NOTE: Tariffs apply only when new strut bar bushings are installed in vehicle

1 - ¼°±½°

2 - 11/12°±¼°

3 - 11/12°±½°

4 - 1°±¾°-¼°

5 - 1/6°±½°

6 - 0±½°

7 - .04±.04

8 - .08 to .16

1965 Import Vehicles Ball Joint Checking Guide

ARROW / COLT

All Models - With components removed from control arm and ball joint still installed, check following: Horizontal and vertical free play (0"), and ball joint rotation starting torque 4-6 ft. lbs. (6-8Nm). Replace ball joints if correct specifications are not obtained

AUDI

Fox - Clearance of ball joint with pressure applied by leverage should be .04-.10" (1.0-2.5 mm). if not replace ball joints

BMW

All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint.

COURIER

All Models - Check working surfaces of ball joints and studs for wear or damage. End play should not exceed .031" (.8 mm), if end play is excessive, replace ball joint.

DATSUN

All Models (Exc. 620 Pickup) - Remove lower control arm. Use appropriate spring tension gauge and and attach it to top of ball joint stud nut. Measure force (INCH Lbs.) required to move ball joint stud laterally. If measurement is not within specifications, replace ball joint

FIAT

All Models - With vehicle raised and supported under lower control arms, grasp wheel at top and bottom and try to shake wheel. If any movement is noted, control arm must be removed for further inspection.

HONDA

All Models - Raise and support front of vehicle. Attach dial indicator onto lower control arm with indicator tip on steering knuckle near ball joint. Place pry bar between lower control arm and steering knuckle. NOTE - Take care not to damage ball joint rubber boot. Push on pry bar and observe movement on dial indicator. If movement is in excess of .020" (.5 mm), ball joint must be replaced.

JAGUAR

All Models - Upper ball joint must be replaced if signs of wear or play are evident. The lower ball joint is adjustable with shims if axial play exceeds .004-.006" (.10-.15 mm). Shims must not be removed to take excessive wear in ball pin and socket. If parts are excessively worn, replacement is required.

LANCIA

All Models - if ball joint shows excessive amounts of wear (play) replace ball joints.

LUV

With vehicle raised and supported under lower control arms, grasp wheel at top and bottom. Try to move wheel and replace ball joint if movement exceeds .06" (1.52 mm).

MAZDA

All Models - Check ball joint dust seal for wear or damage and if necessary, replace seal. Ball joint end play must not exceed .039" (1 mm). If end play exceeds specifications, replace ball joint

MERCEDES-BENZ

There should be no lateral movement of ball joint. Vertical movement is adjusted by adding or removing washers.

OPEL

All Models - Raise and support front of vehicle. Inspect ball joint rubber boots for damage and replace as necessary. If lower ball joint axial play exceeds .008" (2 mm), ball joint must be replaced.

PEUGEOT

All Models - When moving ball pin some friction torque should be felt. If ball pin can be moved without resistance end play is shown, replace ball joint.

RENAULT

All Models - Inspect ball joints for wear or excessive play. Replace ball joints as necessary.

SAAB

All Models - if ball joint exhibits excessive play, it must be replaced as a complete unit.

SUBARU

All Models - Check ball joint for excessive play by pushing and pulling on ball joint stud. Allowable looseness is less than .012". If play exceeds this specification, ball joint must be replaced.

TOYOTA

Corona and Pickup - To check lower ball joint, jack up lower suspension arm and check for ball joint looseness by moving wheel vertically and horizontally. Movement limit in vertical direction should be less than .04" (1 mm) Corona and .20" (5.0 mm) Pickup. Movement limit in horizontal direction should be less than .08" (2 mm). Corona and .09" (2.3 mm) Pickup.
NOTE -  Ensure other suspension parts are tight before checking ball joints. To check upper ball joints. disconnect upper suspension arm from steering knuckle. Turn ball stud and check for excessive looseness or tightness. Replace ball joint if it is excessively loose or tight.

All Other Models - Check for excessive looseness, proper operation and damaged ball stud. Replace as necessary.

TRIUMPH

All Models - Inspect ball joints for excessive wear or play. Replace ball joint as necessary.

VOLKSWAGEN

Type 1 - Raise front of behicle and turn steering to one side. Place pry bar tool over nut or bolt head mounting steering knucle to strut. Compress ball joint spring and place vernier caliper over top of ball joint and over bottom stud. Note caliper reading, then release lever and record caliper travel. Increase reading is ball joint play. Replace ball joints as necessary

Type 2 - Raise front of vehicle and turn steering to one side. Insert pry bar tool VW 281a (or equivalent) under lower control arm and over top of strut mounting. Fit a vernier caliper on lower or upper torsion arm and steering knuckle. Record measurement. Press down with lever and measure travel of vernier caliper. IF travel exceeds specifications, replace ball joint.

All Other Models - Raise and support, then turn steering to one side. Install suitable levering tool so that ball joint spirng may be compressed. With spring compressed, position a vernier caliper with lower jaw on ball joint stud and upper jaw on top of clamping bolt for ball joint stud. Note reading. Slowly release tension from spring and not travel of caliper. This reading indicates ball joint play. If specified play is exceeded replace ball joint.

VOLVO

All Models - Maximum permitted axial play for lower ball joint is 12" (3 mm). Check ball joint by prying back and forth with a bar. If specifications are exceeded, replace ball joints.

Toyota Supra 1982 Wiring Diagrams

Manufacturer: Toyota
Model: Supra
Year: 1982

4 Pages Wiring Diagrams

- Engine Compartment

- Fuse Block

- Underdash

- Instrument Panel 

- Rear Compartment

DOWNLOAD

File Size: 324 KB

File Type: PDF

Toyota Starlet 1982 Wiring Diagrams

Manufacturer: Toyota

Model: Starlet

Year: 1982

2 Pages Wiring Diagrams

- Engine Compartment

- Fuse Block

- Underdash

- Instrument Panel

- Rear Compartment

DOWNLOAD

File Size: 149 KB

File Type: PDF

Toyota Pickup and Diesel Pickup 1982 Wiring Diagrams

Manufacturer: Toyota
Model: Pickup and Diesel Pickup
Year: 1982

4 Pages Wiring Diagrams

- Engine Compartment

- Fuse Block

- Under Dash

- Instrument Panel

- Rear Compartment

DOWNLOAD

File Size: 259 KB

File Type: PDF

Toyota Cressida 1982 Wiring Diagrams

Manufacturer: Toyota
Model: Cressida
Year: 1982

4 Pages Wiring Diagrams

- Engine Compartment

- Fuse Block

- Under Dash

- Instrument Panel

- Rear Compartment

- Accessories

DOWNLOAD

File Size: 306 KB

File Type: PDF

Toyota Corona 1982 Wiring Diagrams

Manufacturer: Toyota
Model: Corona
Year: 1982

4 Pages Wiring Diagrams

-Engine Compartment

- Fuse Block

-Under Dash

-Instrument Panel 

-Rear Compartment

DOWNLOAD

File Size: 269 KB

File Type: PDF