Toyota 4Runner 1984–1989 Service & Repair Manual Set

Use the factory volume for in-vehicle service and the articles for additional bench-overhaul applications. Match the exact year, drive type, and transmission code before selecting parts or procedures.

Coverage limits: The factory volume covers its listed 1988 RN-series models. The other model/year applications are gearbox-overhaul coverage. The Mitchell articles refer lubrication and adjustment, basic troubleshooting, axle service, and vehicle removal/installation to separate articles that are not included.

PDF Search, Bookmarks and Wiring Detail

Text search and diagram viewing: The factory manual has 28 section bookmarks but no PDF text search. The three overhaul articles have searchable body text and no embedded bookmarks; text within their illustrations is not consistently searchable. Small labels in the factory wiring diagrams require zooming.

The ZIP contains four printable PDFs totaling 1,539 pages. This total includes the factory volume’s two opening pages, 16 memo pages, and its service-specification, standard-torque, SST/SSM, automatic-transmission hydraulic-circuit, and electrical-wiring-diagram appendixes.

Engine Diagnosis, Vehicle Repairs and Gearbox Overhaul

This is a selected content preview, rather than a complete contents list. Other documented topics include cruise-control diagnosis and body/frame dimension drawings.

• Engine repair: Step-by-step procedures cover cylinder-head overhaul, timing-chain replacement, cylinder-block disassembly, piston and crankshaft inspection, and engine installation.

• Fuel and turbo diagnosis: Covers 22R carburetor overhaul, 22R-E/22R-TE EFI fault tracing, injector and fuel-pressure checks, emission-control tests, and turbocharger inspection.

• Manual transmissions: Covers vehicle removal/installation and bench overhaul of W46/W55/W56, G40/G57, G52/G53, and R150-family units, with W58 and R154 applications.

• Automatic transmissions: A43D and A340H sections provide diagnostic tests, valve-body service, internal overhaul, and transmission-specific hydraulic circuits.

• Clutch and driveline: Includes clutch hydraulic repairs and bleeding, transfer overhaul, propeller-shaft service, differential setup, and axle-bearing inspection.

• Chassis repairs: Separate procedures address suspension and steering components, front disc and rear drum brakes, brake bleeding, and load-sensing valve pressure checks.

• Electrical and air conditioning: Includes starter and alternator repairs, body-circuit testing, wiring diagrams, refrigeration diagnosis, and compressor disassembly and assembly.

Suited to experienced technicians, particularly for internal overhaul work requiring presses, pullers, special service tools, and precision measuring equipment.

Engine, Fuel and Cooling Work

Internal engine repair: The factory procedures extend through valve-guide and valve-seat work, piston-ring inspection, connecting-rod bushing replacement, crankshaft measurement, bearing selection, and cylinder boring/honing data.

Fault tracing: EFI diagnostic-code tables, ECU connector views, and volt/ohmmeter flowcharts link symptoms to component and circuit checks. These references help distinguish fuel-delivery, sensor, wiring, and ignition faults before parts are selected.

The 22R section includes carburetor float, choke, accelerator-pump, and mixture adjustments. Cooling and lubrication coverage adds thermostat and radiator checks, water-pump replacement, oil-pressure testing, and oil-pump inspection.

Automatic Transmission and Transfer Diagnosis

The A43D/2WD and A340H/4WD sections include stall, time-lag, hydraulic, and road-test information. A340H diagnosis separates electrical-control faults from mechanical problems through diagnostic codes, manual-shifting tests, sensor checks, and solenoid tests.

Overhaul coverage includes oil pumps, clutch and brake assemblies, planetary components, valve bodies, and the A340H transfer assemblies. The separate manual-transfer chapter covers removal, disassembly, inspection, assembly, and installation.

Manual Gearbox Teardown and Setup

The factory manual opens its gearbox section with FIPG precautions and a basic hard-shift/jump-out troubleshooting chart. Bench procedures cover the intermediate plate, input shaft, output shaft/mainshaft, countershaft, reverse idler gear, shift forks and rails, detents, interlock pins, clutch hubs, synchronizer rings, bearings, sleeves, and snap rings.

Build differences: The articles distinguish 2WD extension housings and speedometer-drive components from 4WD transfer adapters and sleeve yokes. G52/G53 shift-rail layouts differ, and ABS-equipped W58 and R154 units add rear speed-sensor procedures.

Assembly checks: Correct inner-race orientation, synchronizer-slot alignment, staggered key-spring gaps, and snap-ring selection are followed by shaft-rotation, interlock, and shift checks.

Clamping the intermediate plate directly can damage its sealing surface; the G52/G53 instructions specify bolts, nuts, and reversed washers as vise supports. W-series disassembly also cautions against rear-bearing roller contact with the counter fifth gear and puller-jaw loading of the shifting-key retainer.

G52/G53 major joints use new gaskets, while the R150 and W-series articles specify Three Bond 1281 FIPG for major housings. Sealing practice should not be transferred between families.

The gearbox is heavy; securely support the vehicle and transmission before the crossmember or bellhousing is released.

Axles, Brakes, Steering and Body Service

Chassis work: Procedures distinguish 2WD and 4WD front hubs, free-wheeling and automatic-locking hubs, drive shafts, front and rear differentials, suspension arms, torsion bars, and rear leaf springs.

Brake coverage includes master-cylinder and caliper repairs, rear wheel-cylinder service, parking-brake adjustment, and load-sensing proportioning/bypass-valve testing. Steering sections add pump and gear-housing overhaul, pressure checks, bleeding, and progressive power-steering diagnosis.

Body and comfort systems: Includes back-door power-window and wiper testing, door-lock circuits, glass and regulator work, refrigeration manifold-gauge diagnosis, compressor and magnetic-clutch repairs, and evaporator service.

Gearbox Figures, Tools and Selection Tables

The articles include Engagements of 150F Manual Transmission Gears, Exploded View of Shift Forks & Shafts, and Sectional View of 5th Countershaft Gear & No. 3 Hub Sleeve. Other figures include the five-part Exploded View of Transmission Assembly, Identifying Output & Countershaft Measuring Points, and Measuring Shift Fork & Synchro Ring Assemblies.

Family-specific tool references include 09313-30021, 09213-27010, 09213-31021, 09950-20017, 09312-20011, 09608-35014, and 09316-60010. Technical illustrations in the Mitchell articles are credited to Toyota Motor Sales, U.S.A., Inc.

Setup tables cover input-shaft, output-shaft, rear-bearing, countershaft, reverse-gear, fifth-gear, and hub-sleeve snap rings. Inspection data includes gear thrust and lateral movement, gear-to-shaft oil clearance, shaft runout, bearing-surface dimensions, synchronizer clearance, shift-fork wear, and component-specific torque specifications. W-series third-gear lateral-movement data distinguishes 1983–1992 from 1993–1994 builds.

Preview of Gearbox Clearance Specifications

For G52/G53 transmissions, the countershaft fifth-gear thrust-clearance table specifies a standard range of 0.10–0.30 mm and a maximum of 0.30 mm.

The R150-series article gives a minimum synchronizer-ring-to-gear-spline clearance of 0.60 mm. The W-series article specifies 0.50 mm minimum for that inspection.