TOYOTA DYNA REPAIR MANUAL FOR CHASSIS & BODY INTRODUCTION MIS CLUTCH MANUAL TRANSMISSION PROPELLER SHAFT MiGaal FRONT AXLE AND SUSPENSION BG REAR AXLE AND SUSPENSION [GIN BRAKE SYSTEM [EGS STEERING BEGl DUMP MECHANISM BI BODY ELECTRICAL SYSTEM Bll BoDY Ea AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONS [EW STANDARD BOLT TIGHTENING TORQUE Hoa SST AND SSM ELECTRICAL WIRING DIAGRAMS [GE JOTOR CORPORATION This book may not be ied, in whole or in part, permission of ToyotaTOYOTA DYNA REPAIR MANUAL FOR CHASSIS & BODY INTRODUCTION MIS CLUTCH MANUAL TRANSMISSION PROPELLER SHAFT MiGGal FRONT AXLE AND SUSPENSION BG REAR AXLE AND SUSPENSION [GIN BRAKE SYSTEM [Gia STEERING BEGl DUMP MECHANISM BI BODY ELECTRICAL SYSTEM [Ell BoDY Ea AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONS [EW STANDARD BOLT TIGHTENING TORQUE Hoa SST AND SSM ELECTRICAL WIRING DIAGRAMS [GE ]OTOR CORPORATION This book may not be iad, in whole or in part permission of ToyotaIN-2 INTRODUCTION — How To Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through the manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the first page of each section to guide you to the item to be repaired. At the beginning of each section, PRECAUTIONS are given that pertain or a/f repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy col- umn to quickly lead you to the solution. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Kg-em (fib, Nam] : Tightening torque Lock Nut [3:100 24,3041] |r waser | ‘Companion FlangeINTRODUCTION — How To Use This Manual IN-3 Mustration: what to do and where ‘The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it. © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: __ Task heading: what to do - CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANGE (a) Align the marks on the flanges and connect the flanges with four bolts and nuts, (b) Torque four bolts and nuts. ~ Detail text: how to do it Torque: 600 — 750 kg-cm (44 — 54 ft-lb, 59 — 73 Nm) ~ Specification This format enables the experienced technician to have a FAST ‘TRACK. He can read the task headings and only refer to the detailed text when he needs it. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However when they are required you are given the page to go to. SPECIFICATIONS Specifications are presented in bold type throughout the text in the applicable step. You never have to leave the procedure to look up your specs. All specifications are also found in Appen- dix A, Specifications for quick reference. WARNINGS, CAUTIONS, NOTES: © WARNINGS are presented in bold type, and indicate there is a possibility of injury to you or other people. © CAUTIONS are also presented in bold type, and indicate the Possibility of damage to the components being repaired. © NOTES are separated from the text but do not appear in bold. They provide ‘additional information to help you effi- ciently perform the repair.IN-4 INTRODUCTION — Identification Information, General Repair Instructions: IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER ‘The vehicle identification number is stamped on the base of the passenger seat. It is also stamped on the frame near the righ: front fender. ENGINE SERIAL NUMBER The engine serial number is stamped on the cylinder block, 2s shown. GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in order to facilitam reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect cable from the battery terminal. {b) If itis necessary to disconnect the battery for ins tion or repair, always disconnect the cable from negative (-) terminal which is grounded to the vet cle body, (@) To prevent damage to the battery terminal loosen the terminal nut and raise the cable straight without twisting it or prying it. {d) Clean the battery terminal posts and cable termi with @ shop rag. Do not scrape them with a file such.INTRODUCTION — General Repair Instructions IN-5. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer or such to tap the terminal onfo the post. (f) Be sure the cover for the positive (+) terminal is pro- perly in place. 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. Non-reusable Parts (a) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (b)Non-reusable parts are indicated in the component illustrations by the symbol "#”. 6. Precoated Parts Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory. | 2) Ifa precoated part is retightened, loosened or caused Seal Lock Adhesive to move in any way, it must be recoated with the specified adhesive. (b) Recoating of Precoated Parts (1) Clean off the old adhesive from the bolt, nut or installation part threads. (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the bolt or nut threads. {c) Precoated parts are indicated in the component illustrations by the symbol “*”, 7. When necessary, use a sealer on gaskets to prevent leaks. 8. Carefully observe all specifications for bolt tightening tor- ques. Always use a torque wrench. 9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the back of this manual. 10. When replacing fuses, be sure the new fuse is the correct amperage rating. DO NOT exceed the fuse amp rating or use one of a lower rating. 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the Proper locations (See page IN-6) (2) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on the vehicle raised on jack alone, even for a small job that can be finished quickly.