Market Segment:
Mid-size station wagon / Sport Wagon
Target Audience:
Families, enthusiasts seeking a practical yet sporty vehicle
Key Competitors:
Subaru Legacy/Outback, Nissan Stagea, Mitsubishi Airtrek (later Outlander), Mazda Atenza Wagon
Vehicle Features:
Available AWD, powerful turbocharged engine option (GT-Four), spacious interior, versatile cargo area, comfortable ride
Manual Value Proposition:
Provides comprehensive DIY repair and maintenance capabilities, essential for enthusiasts and cost-conscious owners
Engine Coverage:
All gasoline engines including 1ZZ-FE (1.8L), 1AZ-FSE (2.0L D-4 DOHC), 2AZ-FSE (2.4L D-4 DOHC), 3S-GTE (2.0L Turbocharged)
Transmission Coverage:
All automatic transmissions (e.g., Super ECT) and manual transmissions
Drivetrain Coverage:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) variants
Body Style Coverage:
Wagon
Trim Level Coverage:
All trim levels (e.g., X, G, GT, GT-Four)
Estimated Page Count:
Extensive; typically over 2000 pages for a complete factory service manual
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Digital (PDF) - Searchable and printable
Engine Mechanical:
Engine overhaul, cylinder head, block assembly, lubrication system, cooling system, fuel system, ignition system, emission control systems
Engine Performance:
Engine tuning, diagnostics, performance adjustments for all included engines
Transmission Mechanical:
Automatic transmission overhaul (Super ECT), manual transmission repair, clutch system, transfer case (for AWD)
Drivetrain Components:
Axles, differentials (front and rear), driveshafts, CV joints, AWD coupling
Suspension Steering:
Front and rear suspension systems, struts, shocks, control arms, ball joints, steering gear, power steering system
Brake System:
Disc brakes (front and rear), ABS system, parking brake, brake fluid specifications and bleeding procedures
Electrical System:
Starting system, charging system, battery, ignition system, lighting system, power windows, power door locks, interior electronics
Body And Interior:
Body panel removal and installation, interior trim, seats, HVAC system, door mechanisms, tailgate, bumpers
Climate Control:
Air conditioning (A/C) system, heater, ventilation, refrigerant handling
Safety Systems:
Airbag system (SRS), seat belts, pre-tensioners
Diagnostic Troubleshooting:
Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting guides, wiring diagrams
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter replacement
Repair Procedures:
Engine component replacement (e.g., water pump, alternator, starter), transmission service, brake pad/rotor replacement, suspension component replacement, exhaust system repair
Overhaul Procedures:
Complete engine rebuilds, transmission overhauls, differential rebuilds
Diagnostics:
Step-by-step diagnostic routines for various systems, including ECU troubleshooting and sensor testing
Electrical Troubleshooting:
Wiring diagrams for all electrical circuits, fuse and relay identification, circuit testing procedures
Special Tools:
Identification and usage of specific Toyota special tools required for certain procedures
Technical Depth:
Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and electrical schematics
Engine 1 Displacement:
1.8L (1794 cc)
Engine 1 Configuration:
Inline 4-cylinder, DOHC, VVT-i
Engine 1 Power Hp:
Approx. 130-140 HP
Engine 1 Torque Lb Ft:
Approx. 125-130 lb-ft
Engine 2 Displacement:
2.0L (1998 cc)
Engine 2 Configuration:
Inline 4-cylinder, DOHC, D-4 (Direct Injection)
Engine 2 Power Hp:
Approx. 150 HP
Engine 2 Torque Lb Ft:
Approx. 140 lb-ft
Engine 3 Displacement:
2.4L (2362 cc)
Engine 3 Configuration:
Inline 4-cylinder, DOHC, D-4 (Direct Injection), VVT-i
Engine 3 Power Hp:
Approx. 160 HP
Engine 3 Torque Lb Ft:
Approx. 165 lb-ft
Engine 4:
3S-GTE (GT-Four)
Engine 4 Displacement:
2.0L (1998 cc)
Engine 4 Configuration:
Inline 4-cylinder, DOHC, Turbocharged, Intercooled
Engine 4 Power Hp:
Approx. 260 HP
Engine 4 Torque Lb Ft:
Approx. 255 lb-ft
Fuel Type:
Unleaded Gasoline
Injection System:
Electronic Fuel Injection (EFI) / D-4 Direct Injection for some engines
Safety Ratings General:
Refer to specific JNCAP or equivalent crash test data for model year
Active Safety:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), BA (Brake Assist), TRC (Traction Control System), VSC (Vehicle Stability Control - often optional or on higher trims)
Passive Safety:
Front airbags, side airbags (optional), curtain airbags (optional), seatbelt pre-tensioners, crumple zones
Infotainment Systems Available:
Factory AM/FM/CD players, optional premium audio systems, early navigation systems on some higher trims
Driver Assistance Features:
Cruise control, ABS, optional VSC/TRC
Connectivity Features:
Limited by modern standards; basic audio connectivity
Engine Oil Change Interval:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type
Air Filter Replacement Interval:
Every 20,000-40,000 km or as needed based on inspection
Spark Plug Replacement Interval:
Iridium plugs: 100,000 km; Platinum plugs: 60,000 km (check specific engine)
Coolant Replacement Interval:
Initial: 160,000 km; Subsequent: 80,000 km (Toyota Super Long Life Coolant)
Transmission Fluid Change Interval:
Automatic: Approx. 40,000-80,000 km; Manual: Approx. 80,000-100,000 km (check specific fluid type)
Engine Oil Specification:
API SL/SM or ILSAC GF-3/GF-4; Viscosity 0W-20, 5W-20, 5W-30 (refer to manual for specific engine recommendations)
Engine Oil Capacity:
Approx. 3.7 - 4.2 Liters (depending on engine)
Coolant Specification:
Toyota Super Long Life Coolant (Pink)
Transmission Fluid Automatic:
Toyota ATF WS (World Standard) or equivalent
Transmission Fluid Manual:
Toyota Gear Oil GL-4 or GL-5 (viscosity depending on climate, e.g., 75W-90)
Brake Fluid Specification:
DOT 3 or DOT 4
Common Issues Engine 1Zz Fe:
Oil consumption concerns in higher mileage units, potential for carbon buildup
Common Issues Turbocharged 3Sgte:
Turbocharger wear, intercooler efficiency, timing belt replacement is critical
Common Issues D4 Engines:
Potential for carbon buildup on intake valves due to direct injection; requires periodic cleaning
Common Issues Suspension Steering:
Worn bushings, strut mounts, tie rod ends typical for age and mileage
Common Issues Electrical:
Faulty door lock actuators, minor interior electrical gremlins
Toyota Heritage:
Toyota's reputation for reliability, quality, and innovation
Caldina Generations:
First generation (T190, 1992-1997), Second generation (T210, 1997-2002), Third generation (T240, 2002-2007)
Third Generation Design:
Introduced a more modern, rounded design compared to the angular second generation. Focused on comfort and practicality.
Production Location:
Japan
Production Period:
2002-2007 (for the T240 series covered by this manual)
