Toyota 4Runner 1996-2002 factory workshop and repair manual download
Toyota 4Runner 1996-2002 factory workshop and repair manual download
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Engine 5VZ-FE
Brakes
Electrical
Steering
Suspension
Transmission
Axles
Heating
Diagnostics
Air-Conditioning
Transfer System
Transmission
Propeller Shaft
Engine
Wiring Diagrams
Body
Service Specs
Air-Conditioning
Body Mechanical
Cooling
Diagnostics
Emission Control
Lubrication
Axles
Toyota 4Runner 1996-2002 factory workshop and repair online download
Following the February 2004 introduction of this 2005 design season Tacoma, the seventh generation Hilux was unveiled on March 2, 2005 in Buenos Aires, Argentina. Marketplace release later on began in April 2005. The Tacoma ended up being on the basis of the 4Runner framework, although the Hilux rides on an revamped version of the ladder frame entirely on previous versions. The Hilux enhanced in proportions and then became categorized as a mid-size pick-up. The Tacoma have a unique 4.0 L V6 motor that produces 176 kW (236 hp) and 361 N*m (266 lb*ft) of torque. Its design ended up being nearly the same as the 4Runner.
Hilux systems marketed in Australian, Middle Eastern, and Asian areas are built and assembled in Thailand, where in fact the automobile is called the Hilux Vigo, or just Vigo. For European and South African areas the Hilux is made in Durban, South Africa. By December 2009, it will be the most popular automobile in Southern Africa. Those offered in south usa are manufactured in Argentina, just like the prior generation Hilux. However, the machines are designed in Japan (where also used in the Prado) rather than Argentina. In Asia, the Hilux Vigo platform was made use of whilst the basis for Toyota's IMV system which spawned the Innova MPV and Fortuner SUV/PPV.
Interior
In Malaysia, the Hilux is only available in 2.5 L aided by the alternative of single cab or two fold taxi. The dual taxi design has actually an automatic transmission variant. They uses similar motor as other parts of asia (in-line, 4-cylinder, 16-valve, DOHC Turbo Diesel with common rail direct injections), however engines used in Malaysia differ inside their greatest production of 75 kW (101 hp) at 3600 rpm and maximum torque of 260 N*m (192 lbf*ft) at 1600--2400 rpm.
In Singapore, the Hilux is available as a single taxi utilizing the 2.5 L motor or a double cab with the 3.0 L system. Notable fleet consumers include personal taxi operators, for who the dual taxi design has further burden room flexibility, additionally the Singapore police and Pakistan authorities, which employs it as a patrol vehicle.
The Hilux will likely be built in Guangqi Toyota Automobile in Guangzhou when it comes to Chinese markets. The products for Asia will likely to be 4.0 L because of the choice of solitary taxi or dual cab. It uses exactly the same motor as Australia (V6, 24-valve, DOHC), nevertheless machines utilized in China is tuned as much as the utmost output of 246 kW (330 hp) at 6500 rpm and optimum torque of 405 N*m (299 lbf*ft) at 4000 rpm, and is mated to a 5-speed automatic transmission. Asia is the only Asian nation to obtain the V6 system.
Two Hilux pickups were entered recently regarding the Dakar Rally because of the Imperial Toyota staff of South Africa. Driver Giniel de Villiers realized 3rd place in 2012, 2nd put in general in 2013, 4th in 2014, and again second place in 2015. These but had been greatly altered non-production models built around a custom racing-only tubular framework and making use of a bigger capacity Toyota V8 motor.
The fourth-generation 4Runner incorporated really serious modifications toward framework and body of this automobile, but was targeted at about similar demographics as the third generation. Based on the Land Cruiser Prado 120 show, the latest 4Runner retained equivalent fundamental exterior design themes, and had been still promoted as a mid-size semi-luxury SUV with off-road capabilities. Available trims are the SR5, recreation version, and restricted designs. An all-new LEV certified 4.0 L 1GR-FE V6 which produces 245 hp (183 kW) and 282 lb*ft (382 N*m) of torque is standard, however for the very first time, a V8 became readily available, the ULEV certified 4.7 L 2UZ-FE motor which in the usa created 235 hp (175 kW) and 320 lb*ft (434 N*m) in model years 2003 and 2004, after that, with the help of VVT-i, 260 hp (194 kW) and 306 lb*ft (415 N*m) from design ages 2005--2009. Gas economy was calculated at 17 mpg town, 20 mpg highway when it comes to V6 and 15/19 mpg for V8. Pulling capacity try 5,000 lb (2,300 kg) on V6 products and 7,300 weight (3,300 kg) on RWD V8 brands (7000 weight w/4WD). The 4Runner very first joined supplier showrooms in October 2002 for 2003 design seasons. Three trims values were provided, SR5, athletics Edition, and restricted. When it was first launched the SR5 and Sport version products utilized gray vinyl cladding and bumpers. Recreation versions furthermore showcased a non-functional bonnet scoop.
The 1TR-FE is a 1,998 cc I4 gas system. They features DOHC, 16 valves and VVT-i . Their energy are 136 hp (101 kW) at 5,600 rpm, and 18.6 kg m (182 N*m) of torque at 4,000 rpm with redline of 6000 rpm.
The 2TR-FE was a 2693 cc I4 gas system. They features DOHC, 16 valves and VVT-i . Their energy is 159 hp (119 kW) at 5,200 rpm, and 180 lbf*ft (244 N*m) of torque at 3,800 rpm with redline of 5500 rpm. The bore and swing tend to be 95 mm 95 mm.
VVTL-i (adjustable Valve time and raise smart program) is an enhanced form of VVT-i that will modify device raise (and length) in addition to valve time. In the case of the 16 device 2ZZ-GE, the system head resembles a normal DOHC build, featuring split webcams for intake and exhaust and featuring two intake as well as 2 fatigue valves (four total) per cylinder. Unlike the standard design, each camshaft features two lobes per cylinder, one enhanced for lower rpm procedure and one optimized for higher rpm operation, with higher carry and longer extent. Each device set is controlled by one rocker arm, that is run by the camshaft. Each rocker arm features a slipper follower installed into the rocker arm with a spring, enabling the slipper follower to easily move up and straight down because of the large lobe without affecting the rocker supply. If the motor try operating below 6000-7000 rpm (influenced by 12 months, vehicle, and ECU setup), the low lobe are running the rocker supply and therefore the valves, together with slipper-follower was freewheeling beside the rocker arm. Whenever engine try running above the carry engagement point, the ECU activates an oil force turn which pushes a sliding pin under the slipper follower for each rocker supply. The rocker arm has become closed into slipper-follower's movements and therefore employs the movement associated with the highest rpm cam lobe, and can run using the large rpm cam profile before the pin was disengaged because of the ECU. The carry program is similar in theory to Honda VTEC process.
The system was initially utilized in 2000 Toyota Celica with 2ZZ-GE. Toyota has now stopped production of their VVTL-i motors for the majority of areas, due to the fact system does not satisfy Euro IV specifications for emissions. Consequently, this system was discontinued on some Toyota models, including compared to the Corolla T-Sport (European countries), Corolla Sportivo (Australia), Celica, Corolla XRS, Toyota Matrix XRS, as well as the Pontiac Vibe GT, all of which had the 2ZZ-GE motor installed. The Lotus Elise consistently provide 2ZZ-GE while the 1ZZ-FE engine, even though the Exige supplies the system with a supercharger. The Toyota Yaris utilizes VVT-i on their fuel motors.
2005 2.0 L gasoline VVT-i DOHC I4 (South Africa, Indonesia and center East)
2005 2.5 L diesel D-4D DOHC I4, 76 kW (102 hp) -- 107 kW (145 PS; 143 hp) (Asia, European countries, Southern Africa, South America)
2005 2.7 L gas VVT-i DOHC I4, 119 kW (162 PS; 160 hp) (Australia, Arabian Peninsula, The Philippines, Southern Africa, Venezuela)
2005 3.0 L diesel D-4D DOHC I4, Turbodiesel, commonrail 16-valve direct injection, 121 kW (165 PS; 162 hp) (Asia, South Africa, south usa, Australia, Europe). This variation is manufactured at Toyota's premises in Zrate, Argentina.
2005 4.0 L gasoline VVT-i DOHC V6, 170 kW (231 PS; 228 hp) -- 176 kW (236 hp) (Australia, South Africa, Venezuela, China)
2008 4.0 L Supercharged DOHC V6 225 kW (306 PS; 302 hp) (Australian Continent best, TRD edition)
A facelifted version of the Hilux ended up being revealed by Toyota's Malaysian suppliers, UMW Toyota engine, in August 2008. Toyota have released a left-hand drive facelifted Hilux Vigo in August 2008 while the right hand drive facelifted model is expected becoming revealed in September 2008. These facelifted models are launched toward Philippines in October 2008.
Toyota furthermore launched a rear access program called "practical Cab" to replace all Xtra taxi versions in E and G level. The practical Cab models are just when it comes to Thailand domestic markets.
2011 facelift
On 13 July 2011, Toyota established that the Hilux would obtain an update, including a redesigned forward end as well as other outside styling adjustment, adjustment into indoor and a unique turbocharged diesel engine with the capacity of 106 kW (142 hp) and 343 N*m (253 lb*ft) of torque, and lower fuel consumption set alongside the past design. This modify was initially launched in Thailand. The Thailand type of 2012 Toyota Hilux Vigo "Champ" try a substantial "minor" change with a new forward looks and a revamped inside to strengthen observed luxuriousness. The leading is redesigned from the A pillar forwards. With the exception of doorways, roofs and tailgates, everything else are brand new: latest protections, new headlights, brand new bumper, brand new bonnet, latest three-bar grille, new taillights, a unique backside bumper, newer models badge also. There are new mirrors and latest alloy wheel design. The inner features a new higher dashboard design with a new horizontal centre tool cluster. Perceived quality is improved through the adoption of uniformly darker completes with a better colour persistence through the indoor. The high-end Double taxi variation today comes with DVD player, back camera and Bluetooth functionality., Cristiano Ronaldo is presenter for Hilux Vigo Champ in Thailand, these are generally established brand new "Diamond Tech" technology for commonrail in 2.5 L and 3.0 L diesel version, with enhanced 32-bit ECU and injector, however they are perhaps not confirmed that passed away Euro IV compilation which used in Thailand from January 1, 2012. Neymar are presenter for Hilux Vigo Champ in Thailand, they have been advertising in 2014 FIFA globe glass.
In the united kingdom it is for sale in 3 body designs: 2-door, 2-seat solitary taxi; 2-door, 4-seat extra taxi and 4-door, 4-seat double taxi It is available for sale in asia Asian and center East areas. The Innova was released in November 2008 within the Philippines as well as on January 28, 2009 in Asia. In Indonesia, the facelifted models are the age variation, which now features the section from first-generation G variant.
The latest Hilux vehicle is one of five newly created motors inside the IMV (Innovative Overseas Multipurpose car) venture becoming promoted by Toyota Motor firm (TMC). Creation of IMV task products started in Thailand and Indonesia this past year and in the Philippines and India in February for this season, creating Argentina the fifth IMV manufacturing base.
TASA celebrated the production of initial product of the latest Hilux at a Line-Off Ceremony that took place on Feb. 28 at Zarate Plant, Buenos Aires with all the attendance of around 300 guests, like Argentine President Nstor Carlos Kirchner, . Purchases regarding the new model is set to quickly begin.
TMC features situated TASA as its supply base for pickup trucks and SUVs when it comes to Latin-American markets, and, aside from the latest Hilux, TASA plans to create an IMV show SUV through the last half of this 12 months. TASA's total manufacturing capacity for those two IMV brands is 65,000 units per year about 70percent which is anticipated to-be exported to about 20 nations in Latin America, including Brazil.
oth right-hand Drive Toyota Hilux Vigo 2009 and Left Hand Drive Toyota Hilux Vigo 2009 renovation minor changes systems are a success, Toyota has now relased a minimal changes 2010 design which is available these days at Soni Motors Thailand. Little changed from 2009 to 2010. Toyota Hilux Vigo 2009 had encountered a small change and here is the contrast between 2008 Toyota Hilux Vigo and 2009 Toyota Hilux Vigo. This is actually the overview of modifications:
There is certainly a brand new robust front side barbeque grill and front bumper
High quality brake system plus efficient under-structure
Indoor panelling is changed from Ivory to Sand beige
Toyota Hilux Vigo 2009 features encountered a changes and this is actually the comparison between 2008 Toyota Hilux Vigo and 2009 Toyota Hilux Vigo. Here is the overview of changes:
There's a brand new robust front side grill and front side bumper
Heavy-duty brake system and more efficient under-structure
Internal panelling happens to be changed from Ivory to Sand beige
Unique left-hand Drive Toyota Hilux Vigo 2009 and right-hand Drive Toyota Hilux Vigo 2009 possess after properties:
FORTUNER STEERING with AUDIO CONTROLS & SHOW CONTROLS
OPTITRON METER with DIMMER (METER LIGHT ADJUSTER): Optitron lighting gauge offers quality of sight in most information and enables modification of lighting based on preference
HEATER (the RHD cannot incorporate heater)
SILVER PART STRIPES on FRONT PANEL
BETTER BRAKING PROGRAM (as with Toyota Fortuner 2009). LHD Vigo won't have all high-end braking qualities
CRUISE CONTROLS: Cruise control to maintain speeds, increasing benefits and decreasing tiredness from lengthy drives, in addition to conserves gas excellently from keeping a stable rate
FRONT LIGHTS (best huge difference try side signal inside lamp ended up being ORANGE in 2008 Vigo it is WHITE last year Vigo)
NEW FRONT BUMPER: forward bumper recently designed to boost toughness CHROME REAR BUMPER: added design
NEW GRILL with CHROME on the top: Front grille strengthened with chromium, the exact same design as deluxe SUVs
unique ALLOY WHEEL DESIGN (In LHD 15") In RHD Sixteen-inch alloy wheels (215/65R 16C) when it comes to dual Cab 4x2 and 17-inch rims (265/65R17) for dual taxi 4x4 and Double Cab PreRunner.
COVER PIECE FOR CRASH DEFENSE: avoid collisions for the underbody while increasing security
SEMI-ELLIPTIC SPRINGS: greater human anatomy from the surface to-drive through obstacles, a greater levels as compared to each and every day pick-up truck
Unique CRYSTAL TOWER BACK LIGHTS to boost safety and offer better rear vision
SAND BEIGE STORAGE SPACE: Controls from the door are metallic, gear shift covered with leather, tyre covered with fabric, leather-based seats and leather-padded door panels
COMFORT OF AN EXTRAVAGANCE SUV: willing to face every challenge with double the convenience with a large passenger taxi and plenty of resources for virtually any purpose
ELECTRICALLY ADJUSTABLE MOTORIST'S SEAT: Electrically flexible motorist's seat, adjustable in six instructions for perfect place, relaxing on every journey.
Toyota Hilux Vigo 2009 will come in Single Cab 2009 model, practical taxi Extra taxi 2009 design and dual Cab 2009 design. Extra taxi was named practical taxi for grounds, it today has an additional home that opens backward for easier usage of back once again sitting.
Soni engines Thailand is proud to be Thailand's largest exporter of Double taxi Toyota Hilux Vigo while Jim 4x4 Thailand try Thailand's biggest exporter of nearly brand-new or high quality used 2004 2005 2006 2007 2008 Double taxi Toyota Hilux Vigo or 1998 1999, 2000, 2001, 2002, 2003 and 2004 Toyota Hilux Tiger. Please note it is dual taxi and never twice Cap as some have been recognized to misspell it. Click on this link for information on 2009 Toyota Hilux Vigo and right here for info on 2009 Toyota Hilux Vigo solitary taxi and additional Cab, 2009 Toyota Hilux Vigo Smart additional Cab and 2009 Toyota Hilux Vigo Double taxi. Follow this link for the primary Vigo page. Photos of some of the vehicles we've recently exported have reached http://www.sonirodban.com/pics.html. Toyota Vigo remains our top vendor since its production in belated 2004. Vigo both new and put are nevertheless selling like hotcakes from Africa toward Americas.
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- Goal: remove, inspect, (adjust if applicable), and/or replace rocker arms on a Toyota 4Runner. Rocker arms transfer cam motion to the valves; worn/damaged rockers or lash issues cause ticking, poor idle, loss of power. Work slowly and follow safety steps.
Safety and prep
- Disconnect battery negative terminal: prevents accidental starter engagement and shorts.
- Work on a cold engine: hot heads and valve covers can burn you.
- Use eye protection and gloves: protects from solvents, metal chips, fluids.
- Support vehicle safely if you need to access from below: use a rated jack and jack stands on a level surface. Never rely on a hydraulic jack alone.
- Keep a clean, well-lit workspace and a magnetic tray for fasteners.
Tools (every tool described and how to use it)
- Socket set (6-point and 12-point sockets, metric sizes): used to remove bolts (valve cover, intake bolts, rocker arm bolts). Choose the correct metric size to avoid rounding heads. Use 6-point for high-torque bolts; use 12-point for clearance when needed.
- Ratchet (1/4", 3/8", 1/2" drive): used with sockets for loosening/tightening. Use longer handle for more leverage; turn slowly and steadily.
- Extensions and universal joint (socket extension / swivel): reach recessed bolts and keep ratchet at a comfortable angle.
- Torque wrench (click-type or beam) with correct drive size: used to tighten critical bolts to factory torque to prevent leaks or stripped bolt heads. Set desired torque, snug bolt, then tighten until wrench clicks.
- Breaker bar (long non-ratcheting bar): use to initially break loose very tight bolts safely without damaging ratchet.
- Combination wrenches (metric): for bolts where a socket cannot reach or to hold a nut while turning bolt.
- Screwdrivers (flathead and Phillips): to remove clamps, pry loose old gaskets carefully. Use small controlled force to avoid gouging sealing surfaces.
- Pliers (needle-nose and slip-joint): pull out clips, hoses, or to hold small parts. Needle-nose for precision.
- Feeler gauge set (metric): used only if your engine uses adjustable rockers (mechanical tappets) — insert correct thickness between valve stem and rocker to set valve lash. Use light pressure and recheck.
- Small pry bar or gasket scraper (plastic or brass preferred): to carefully remove old gasket material from mating surfaces. Avoid scratching the head.
- Torque-angle meter or torque-to-yield spec tool: only needed if manual calls for angle tightening; most rocker bolts use torque values, not angle.
- Magnetic parts tray or small containers: keep bolts and parts organized and prevent loss.
- Clean rags, brake cleaner or parts cleaner: clean mating surfaces and oil passages. Avoid getting solvent into electrical components.
- Shop manual or factory service manual (paper or electronic): contains engine-specific removal sequence, torque specs, and lash specs — essential.
- Replacement valve cover gasket and O-rings (engine-specific): valve cover removal commonly requires a new gasket to ensure a leak-free seal.
- Anti-seize or thread locker (if specified): some manufacturers call for Loctite on certain bolts; consult manual. Don’t apply thread locker unless specified.
- New rocker arms or rocker assembly (OEM or quality aftermarket) and new rocker bolts (if specified): replace worn rockers or seized assemblies. Many Toyota engines recommend replacing bolts if they are torque-to-yield (single-use) or show damage.
- Hydraulic lifters (if applicable) or pushrods (if your engine uses them): if lifters are noisy or collapsed, replacement is necessary.
- Gasket sealant (RTV) only where manual specifies: small beads in corners may be required; follow the manual.
How to identify whether your 4Runner’s rockers are adjustable or hydraulic (brief, no questions)
- Look at the top of the rocker near the valve stem: if there is an adjuster screw and locknut, the rockers are adjustable (mechanical tappets) and require valve lash setting with a feeler gauge.
- If there is no adjuster and rockers sit on a shaft or pedestal with lifters under the cam, the system is likely hydraulic and self-adjusting; you will not set lash — you inspect and replace worn parts.
Step-by-step procedure (general; follow your factory manual for model-year specifics)
- Remove negative battery cable.
- Remove any plastic engine covers or components obstructing valve cover access (air intake tube, breather hoses, ignition coils): label connectors and hoses if needed.
- Disconnect ignition coils or spark plug wires as needed to keep area clear; for coil-on-plug, unbolt and lift coils off (store them upright).
- Remove any brackets or fuel rail/injector components only if they obstruct valve cover; fuel lines typically do not need removal on many 4Runners—refer to manual.
- Remove valve cover bolts in a cross pattern and lift off valve cover. Pry gently at corners if needed; take care not to damage mating surface.
- Inspect rocker arms and surrounding area:
- For hydraulic lifter systems: look for excessive wear on rocker faces, cracked or broken rockers, metal debris, collapsed lifters, oil sludge or clogged oil passages. Check for play in rocker to pushrod contact and cam contact.
- For adjustable rockers: check the adjuster screws and nut condition and wear on the tips and valve stems. Check valve train oiling.
- If adjustment is required (mechanical tappets):
- Rotate engine to TDC on cylinder of interest (use crank pulley mark and manual procedure).
- Use feeler gauge between valve stem tip and rocker adjuster screw. Turn adjuster until correct feeler gauge thickness is a light drag, then hold adjuster and tighten locknut while maintaining clearance. Recheck clearance after tightening.
- Repeat for all valves per firing order and manual sequence.
- If replacing rocker arms or assemblies:
- Follow loosen/tighten sequence in the manual. Remove rocker shaft or individual rocker bolts carefully; keep parts in order.
- Clean mating surfaces and oil passages with lint-free rag and parts cleaner. Ensure no debris falls into the head — cover exposed ports if time-consuming.
- Install new rockers/new shaft using assembly lube on contact surfaces and follow torque sequence for bolts. Replace bolts if specified as single-use or if damaged.
- Reinstall valve cover with new gasket; torque bolts in the manual-specified pattern and values.
- Reinstall ignition coils, intake components, and reconnect battery.
- Start engine, listen for abnormal noise, and check for oil leaks. Re-torque valve cover bolts after a short run if manual advises.
When replacement is required and why
- Replace rocker arms when:
- Tip surfaces are deeply scored or cracked (causes poor valve movement and noise).
- Rocker shaft or pivot is worn, creating excessive lateral play.
- Hydraulic lifters are collapsed or noisy (hydraulic lifters are internal and must be replaced).
- Excessive metal debris is present—inspect cam lobes and lifters as well.
- Replace valve cover gasket whenever the cover is removed: old gaskets compress and leak.
- Replace rocker arm bolts if they are torque-to-yield or show stretch/damage: they may not hold correct clamping force if reused.
- Replace pushrods if bent, worn, or with pitted ends.
- Consider replacing the rocker assembly as a kit (shaft, rockers, bolts) if multiple components show wear — easier and more reliable than piecemeal swapping.
Why extra tools might be required
- Feeler gauge is only required if your engine has adjustable rockers; without it you cannot set accurate lash.
- Torque wrench is required because valve cover and rocker bolts must be tightened to a specified torque; over- or under-tightening causes leaks or stripped threads.
- Larger engine disassembly (intake manifold removal) sometimes requires longer extensions, additional sockets, and patience; you may need to remove manifold bolts that are hard to reach.
- If camshaft or lifters need removal, you may need specialized pullers or cam timing tools per the service manual — these are required to maintain correct timing and avoid engine damage.
- Thread locker or anti-seize only if specified: used to ensure bolts do not loosen or to prevent galling on reassembly.
Common replacement parts and notes
- Valve cover gasket kit (most common, always replace when cover removed)
- Rocker arms or rocker arm shaft assembly (OEM or quality aftermarket)
- Rocker arm bolts (if specified single-use or damaged)
- Pushrods (if applicable)
- Hydraulic lifters (if hydraulic system and lifters are noisy/collapsed)
- Gasket sealant (RTV) only if manual specifies specific locations
- Engine oil and oil filter (recommended to refresh oil if you found debris or performed significant repairs)
Final checks
- Verify torque specs and bolt sequences for your specific model/year in the Toyota factory service manual before final torquing.
- Prime oiling if lifters or rocker shafts were dry: crank engine with fuel disabled (or follow manual) to circulate oil before initial start if specified.
- After startup, check for leaks and listen for valve train noise. Recheck any adjustments if mechanical lash was set.
Quick reminders (no fluff)
- Always use the factory service manual for your 4Runner’s year and engine — it contains the exact procedures and torque/lash specs.
- Replace the valve cover gasket when removed.
- Use a torque wrench for all critical bolts.
- If unsure about lifter/cam damage or timing-related work, consider professional help — incorrect timing cam work can cause severe engine damage.