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Toyota 22R-E, Service Manual

The Toyota 22R-E Service Manual is an essential resource for any Toyota 22R-E owner or mechanic. This comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips to ensure optimal performance and maintenance of the 22R-E engine. Download it for free at 88.208.23.73:8080 and empower yourself with expert knowledge.

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The 22R–E engine is in–line 4–cylinder engine with the cylinders numbered 1–2–3–4 from
the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearing are
made of kelmet.
The crankshaft is integrated with 4 weights which are cast with it for balance. Oil holes are made
in the center of the crankshaft to supply oil to the connecting rods, bearing, pistons and other
components.
The firing order is 1–3–4–2. The cylinder head is made of aluminum alloy, with a cross flow
type intake and exhaust layout and with pent roof type combustion chambers. The spark plugs
are located to the left of the combustion chambers.
Coolant is introduced into the intake manifold, improving drivability during engine warm up.
Exhaust and intake valves are equipped with springs made, of special valve spring carbon steel
which are capable of following no matter what the engine speed.
The camshaft is driven by a timing chain. The cam journal is supported at 3 places, located at the
center and the front and rear of ends of each cylinder head. Lubrication of the cam journal gear
is accomplished by oil supplied through the oil passage in the cylinder head.
Adjustment of the valve clearance is done by means of an adjusting screw on the rocker arm for
easy adjustment.
The timing chain cover is made of aluminum alloy, with a water pump and oil pump on the outside.
Pistons are made of highly temperature–resistant aluminum alloy, and a depression is built into
the piston head to prevent interference with valves.
Piston pins are the full–floating type, with the pins fastened to neither the connecting rods nor
the piston boss, but with a snap ring fitted to both ends of each pin to prevent it from slipping out.
The No. 1 compression ring is made of stainless steel and the No. 2 compression ring is made of
cast iron. The oil ring is made of stainless steel. The outer diameter of each piston ring is slightly
larger than the diameter of the piston and the flexibility of the rings allows them to hug the
cylinder walls when they are mounted on the piston. No. 1 and No. 2 compression rings work to
prevent leakage of gas from the cylinder and the oil ring works to scrape oil off the cylinder walls
to prevent it from entering the combustion chambers.
The cylinder block is made of cast iron. It has 4 cylinders which are approximately 2 times the
length of the piston stroke. The top of each cylinder is closed off by the cylinder head and in the
lower end of the cylinders the crankshaft is installed, supported by 5 journals. In addition, the
cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders.
The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of
pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the
bottom of the pan even when the vehicle is tilted. The dividing plate prevents the intake of air and
allows oil circulation to be maintained even if the oil forms waves when the vehicle brakes
suddenly.

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ENGINE

ENGINE MECHANICAL

EG1–3

Summary of Contents for 22R-E

Page 1: ...INTRODUCTION INTRODUCTION IN 1 ...

Page 2: ...ion Read these precautions before starting any repair task TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause PREPARATION Preparation lists the SST Special Service Tools recommended tools equipment lubricant and SSM Special Service Materials which should be prepared before beginning the operation and explains the purpose of each ...

Page 3: ... have to leave the procedure to look up your specifications They are also found at the end of each section for quick reference This format provides the experienced technician with a FAST TRACK to the information needed The upper case task heading can be read at a glance when necessary and the text below it provides detailed information Important specifications and warnings always stand out in bold...

Page 4: ...FICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label A Vehicle Identification Number Plate B Certification Label The UNITS given in this manual are primarily expressed according to the SI UNIT Internationai System of Unit and alternately expressed in the metric system and in the English Sy...

Page 5: ...minals with a clean shop rag Do not scrape them with a file or other abrasive objects e Install the cable terminal to the battery post with the nut loose and tighten the nut after installa tion Do not use a hammer to tap the terminal onto the post f Be sure the cover for the positive terminal is properly in place 4 Check hose and wiring connectors to make sure that they are secure and correct 5 No...

Page 6: ... 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 proce dure A list of SST and SSM can be found in the preparation part at the front of each section in this manual 10 When replacing fuses be sure the new fuse has the correct amperage rating DO NOT exceed the rating or use ...

Page 7: ...when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the proper locations See page IN 9 a If the vehicle is to be jacked up only at the front or rear end be sure to block the wheels at the opposite end in order to ensure safety 6 After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on a vehicle raised on a jack alo...

Page 8: ...f and prolonged braking 7 Do not dispose of used catalyst along with parts contaminated with gasoline or oil IN 01 FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT IN ANTI THEFT SYSTEM Audio System displaying the sign ANTI THEFT SYSTEM shown on the left has a built in anti theft system which makes the audio system soundless if stolen If the power source for the audio system is cut even once the anti t...

Page 9: ...VEHICLE LIFT AND SUPPORT LOCATIONS INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS IN 9 ...

Page 10: ...ance Before Top Dead Center Intake Manifold Valve Automatic Transmission Formed in Place Gasket Electronic Control Unit Special Service Tools Manual Transmission Over Head Camshaft Single Rear Wheel Double Rear Wheel Cab and Chassis Power Steering Junction Block Circuit Breaker Multipurpose Right Hand Fusible Link Left Hand LSP BV 0 D OD Overdrive California Maximum Minimum Dash Pot Standard Overs...

Page 11: ... Four Wheel Drive Vehicles 4 x 4 Vacuum Transmitting Valve Vacuum Switching Valve Vacuum Control Valve Top Dead Center Temperature Transmission Undersize Without TEMP 4WD TCCS w o T M With 2WD TDC U S VCV VSV VTV INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL IN 11 ...

Page 12: ...ecirculation EGR Heated Oxygen Sensor H02S Engine Coolant Temperature Direct Fuel Injection Diesel SAE ABBRE VIATIONS Continuous Trap Oxidizer Continuous Fuel Injection Engine Modification EM Diagnostic Trouble Code Exhaust Gas Recirculation Battery Positive Voltage Secondary Air Injection Heated Oxygen Sensor Engine Control Module Early Fuel Evaporation Closed Throttle Position Diagnostic Test Mo...

Page 13: ...ertrain Control Module Service Reminder Indicator Manifold Absolute Pressure Torque Converter Clutch Power Steering Pressure Random Access Memory Ignition Control Module Multiport Fuel Injection System Readiness Test Idle Speed Control ISC Intake Air Temperature Periodic Trap Oxidizer Park Neutral Position On Board Diagnostic Indirect Fuel Injection Manifold Vacuum Zone Supercharger Bypass Transmi...

Page 14: ...e Speed Sensor Read Switch Type Warm Up Oxidation Catalytic Converter Three Way Catalytic Converter Vehicle Speed Sensor Thermal Vacuum Valve Wide Open Throttle Voltage Regulator Voltage Regulator Manifold Converter Volume Air Flow Air Flow Meter Full Throttle Fourth Gear CCR CCo Third Gear WU TWC TWC OC WU OC wot twc TVV VAF 3GR 4GR VSS INTRODUCTION GLOSSARY OF SAE AND TOYOTA TERMS IN 14 ...

Page 15: ...lt HOW TO DETERMINE BOLT STRENGTH 4T 5T fiT 7T 8T 9T 10T 11T Two protruding lines Four protruding lines Three protruding lines Two protruding lines Hexagon head bolt Hexagon head bolt Hexagon head bolt Hexagon head bolt Welded bolt Stud bolt No mark No mark Class Class Mark Mark INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS IN 15 ...

Page 16: ...SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter mm Pitch mm Class 1 OT 11T INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS IN 16 ...

Page 17: ... belt V Ribbed type Cracks on the ribbed side of the belt are considered acceptable If the belt has chunks missing from the ribs it should be replaced b Using a belt tension gauge check the drive belt ten sion Belt tension gauge Nippondenso BTG 20 95506 00020 or Borroughs No BT 33 73F Drive belt tension 22R E Used belt 80 20 lbf New belt 125 25 lbf 3VZ E Generator Used belt 100 20 lbf New belt 160...

Page 18: ...AIR FILTER a Visually check that the air cleaner element is not excessively dirty damaged or oily HINT Oiliness may indicate a stuck PCV valve If necessary replace the air cleaner element b Clean the element with compressed air First blow from back side thoroughly then blow off the front side of the element 5 REPLACE AIR FILTER Replace the used air cleaner element with a new one 6 REPLACE ENGINE O...

Page 19: ...a good brand of ethylene glycol base coo lant mixed according to the manufacturer s in structions Using coolant which has more than 50 ethyl ene glycol but not more than 70 is recom mended NOTICE Do not use an alcohol type coolant The coolant should be mixed with demineralized water or distilled water 22 R E w o Oil filter change 3 8 liters 4 0 US qts 3 3 Imp qts w Oil filter change 4 3 liters 4 5...

Page 20: ...to the tank pipe and check that air flows without resistance from the other pipes 2 Blow air 4 71 kPa 48 gf cm2 0 68 psi into the purge pipe and check that air does not flow from the other pipes If a problem is found replace the charcoal canister d Clean filter in canister 1 Clean the filter by blowing 294kPa 3 kgf cm2 43 psi of compressed air into the tank pipe while holding the purge pipe closed...

Page 21: ...sor and cover 4WD to the exhaust pipe Torque 20 N m 200 kgf cm 14 ft lbf d Inspect oxygen sensor operation Inspect feedback control 22R E See page EG 212 3VZ E See page EG 252 11 INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes hangers and connections for severe corrosion leaks or damage 12 3VZ E ENGINE ADJUST VALVE CLEARANCE See page EG 18 MAINTENANCE MAINTENANCE OPERATIONS MA 10 ...

Page 22: ...evolution 360 and align timing marks in the manner mentioned above Adjust only the valves indicated by arrows f Reinstall the cylinder head cover 16 ADJUST IDLE SPEED a Preparation Install air cleaner Connect all pipes and hoses of air intake system Use a thickness gauge to measure between the valve stem and rocker arm Loosen the lock nut and turn the adjusting screw to set the proper clearance Ho...

Page 23: ...ters are not compatible with this ignition system we recommend that you confirm the compatibility of your unit before use BRAKES 16 INSPECT BRAKE LINE PIPES AND HOSES HINT Inspect in a well lighted area Inspect the entire circumference and length of the brake hoses using a mirror as required Turn the front wheels fully right or left before inspecting the front brake a Check all brake lines and hos...

Page 24: ...a Check the thickness of the disc brake pad and check for irregular wear Minimum lining thickness 1 0 mm 0 039 in b Check the disc for wear Minimum disc thickness 2WD FS17 type 21 0 mm 0 827 in FS18 type 20 0 mm 0 787 in PD60 type 23 0 mm 0 906 in PD66 type 28 0 m m 1 102 in 4WD S 12 12 Type 18 0 mm 0 790 in HINT If a squealing or scraping noise occurs from the brake during driving check the pad w...

Page 25: ...ring or wear Maximum drum inside diameter 2WD 256 0 mm 10 079 in 4WD 297 0 mm 11 693 in c Clean the brake parts with a damp cloth NOTICE Do not use compressed air to clean the brake parts 18 INSPECT REAR BRAKE LININGS AND DRUMS See BR section a Check the lining to drum contact condition and lining wear Minimum lining thickness 1 0 mm 0 0039 in c Check the disc for runout Minimum disc runout Ex C C...

Page 26: ...G Check the steering gear housing for oil leaks If leakage is found check for cause and repair 22 INSPECT BALL JOINTS AND DUST COVERS a Inspect the ball joints for excessive looseness See SA section b Inspect the dust cover for damage 21 4WD INSPECT DRIVE SHAFT BOOTS Inspect the drive shaft boots for clamp looseness grease leakage or damage MAINTENANCE MAINTENANCE OPERATIONS MA 15 ...

Page 27: ...GL 4 or GL 5 Viscosity SAE 75W 90 Remove the filler plug and feel inside the hole with your finger Check that the oil comes to within 5 mm 0 20 in of the bottom edge of the hole If the level is low add oil until it begins to run out of the filler hole Differential oil Oil grade AN GL 5 hypoid gear oil Viscosity Above 18 C 0 F SAE 90 Below 18 C 0 F SAE 80W 90 or 80W Check the automatic transmission...

Page 28: ...e API GL 4 or GL 5 Viscosity SAE 75W 90 Remove the filler plug and feel inside the hole with your finger Check that the oil comes to within 5 mm 0 20 in of the bottom edge of the hole If the level is low add oil until it begins to run out of the filler hole Transfer oil Ex 3vZ E A T Oil grade AN GL 4 or GL 5 Viscosity SAE 75W 90 Transfer fluid 3VZ E A T ATF DEXRON II Check the automatic transmissi...

Page 29: ...ve 18 C 0 F SAE 90 Below 18 C 0 F SAE 80W 90 or 80W A D D Oil grade Toyota GEAR OIL SUPER oil or hypoid gear oil API GL 5 Viscosity SAE 75W 90 25 REPLACE MANUAL TRANSMISSION TRANSFER 4 WD AND DIFFERENTIAL OIL a Transfer Remove the transfer cover b Using SST A340H Transfer remove the drain plug and drain the oil SST 09043 38100 c Reinstall drain plug securely d Add new oil until it begins to run ou...

Page 30: ...G58 3 9 liters 4 1 US qts 3 4 Imp qts W56 2 9 liters 3 1 US qts 2 5 Imp qts RI 50F 3 0 liters 3 2 US qts 2 6 Imp qts Transfer Counter Gear Type 1 6 liters 1 7 US qts 1 4 Imp qts Planetary Gear Type 1 1 liters 1 2 US qts 1 0 Imp qts A340H 0 8 liters 0 8 US qts 0 7 Imp qts MAINTENANCE MAINTENANCE OPERATIONS MA 19 ...

Page 31: ...ters 2 1 US qts 1 8 Imp qts Differential 2WD 7 5 in 1 35 liters 1 4 US qts 1 2 Imp qts 8 0 in 1 8 liters 1 9 US qts 1 6 Imp qts 4WD Front Standard differential 1 6 liters 1 7 US qts 1 4 Imp qts A D D 1 86 liters 2 0 US qts 1 6 Imp qts Rear 2 2 liters 2 3 US qts 1 9 Imp qts d Start the engine and shift the selector into ail posi tions from P through L and then shift into P e A340H Shift the transfe...

Page 32: ... 4 OIbf 4WD Grease grade Lithium base multipurpose grease NLGI No 2 Wheel bearing friction preload at starting 27 55 N 2 8 5 6 kgf 6 2 12 3 lbf b Repack the drive shaft thrust bush grease See SA section 28 4WD LUBRICATE PROPELLER SHAFT Lubricate propeller shaft referring to the lubrication chart Before pumping in grease wipe off any mud and dust on the grease fitting Grease grade Propeller shaft e...

Page 33: ...he above maintenance items check for loose or missing bolts and nuts on the following Steering system Drive train 29 TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts Seat mounting bolts Torque 37 N m 375 kgf cm 27 ft lbf Strut bar bracket to frame mounting bolts 2 WD Torque 52 N m 530 kgf cm 38 ft Ibf MAINTENANCE MAINTENANCE OPERATIONS MA 22 ...

Page 34: ...eat adjusts easily and locks securely in any positions Seat backs lock securely at any angle Fold down seat backs lock securely b Road test Engine and chassis parts do not have abnormal noises Vehicle does not wander or pull to one side Brakes work properly and do not drag c Be sure to deliver a clean vehicle and especially check Steering wheel Shift lever knob All switch knobs Door handles Seats ...

Page 35: ...22R E ENGINE ENGINE EG1 1 ...

Page 36: ...DESCRIPTION The 22R E engine is an in line 4 cylinder 2 4 liter OHC 8 valve engine ENGINE MECHANICAL ENGINE ENGINE MECHANICAL EG1 2 ...

Page 37: ...a depression is built into the piston head to prevent interference with valves Piston pins are the full floating type with the pins fastened to neither the connecting rods nor the piston boss but with a snap ring fitted to both ends of each pin to prevent it from slipping out The No 1 compression ring is made of stainless steel and the No 2 compression ring is made of cast iron The oil ring is mad...

Page 38: ...th Bolt 09201 60011 Valve Guide Bushing Remover Replacer 09213 60017 Crankshaft Pulley Gear Puller Set 09223 50010 Crankhaft Front oil Seal Replacer 09213 31021 Crankshaft Pulley Puller 09223 41020 Crankshaft Rear Oil Seal Replacer 09213 70010 Crankshaft Pulley Holding Tool 09202 43013 Valve Spring Compressor 09213 36020 Timing Gear Remover Camshaft oil seal ENGINE ENGINE MECHANICAL EG1 4 ...

Page 39: ... fuel hose etc 09843 18020 Diagnosis Check Wire Battery specific gravity gauge 09090 04010 Engine Sling Device 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set 09904 00010 Expander Set Connecting rod aligner EQUIPMENT Compression gauge Belt tension gauge For suspension engine Cylinder gauge Crankshaft pulley CO HC meter Caliper gauge Dial indicator ENGINE ENGINE MECHANICAL EG1 5 ...

Page 40: ...Rear oil sear retainer 08826 00080 Seal packing or equivalent Piston ring compressor Precision straight edge Engine tune up tester Piston ring expander Valve seat cutter Magnetic finger Vernier calipers Torque wrench Dye penetrant Spring tester Thermometer Steel square Micrometer Plastigage Valve spring Valve spring Soft brush Heater ENGINE ENGINE MECHANICAL EG1 6 ...

Page 41: ...s Idle Air Control Valve High engine idle speed Fuel Pressure Regulator Under normal condition Main Oxygen Sensor Circuit Low engine idle speed Knock Sensor Circuit Engine does not crank Engine Coolant Temp Sensor Circuit Starter keeps running During A C operation Engine cranks slowly No initial combustion RPM Signal Circuit STA Signal Circuit Soon after starting Cold Start System Poor fuel econom...

Page 42: ... and Radiator Cap No initial combustion Flywheel or Drive Plate Crankshaft Bearing Engine stall Poor fuel economy Symptom When N to D shift Incorrect first idle Throttle Opener High oil pressure Low oil pressure Engine overcool Engine overheat Poor drivability Valve Clearance Does not start Suspect area Difficult to start Cylinder Head Valve Timing Compression Timing Belt Water Pump Rough idling P...

Page 43: ...Cut System Coolant Leakage EFI Main Relay Cylinder Block Starter Relay Fuel Leakage EGR System Fuel Quality Oil Leakage Spark Plug Thermostat Distributor EG1 88 or 92 Generator Drive Belt AT or CL section Starter EG1 210 EG1 206 CH section EG1 219 BE section EG1 207 EG1 215 CH section ST section BE section EG1 235 EG1 228 EG1 225 ST section EG1 55 ECM IG 6 IG 7 ENGINE ENGINE MECHANICAL EG1 9 ...

Page 44: ...1 and 2 on page EG1 225 IDLE SPEED INSPECTION AND ADJUSTMENT See step 15 on page MA 11 HIGH TENSION CORD INSPECTION See page IG 6 ENGINE OIL INSPECTION See steps 1 and 2 on page EG1 235 SPARK PLUGS INSPECTION See page IG 8 AIR FILTER INSPECTION See step 4 on page MA 7 BATTERY INSPECTION See CM section DRIVE BELTS INSPECTION See step 2 on page MA 6 ENGINE ENGINE MECHANICAL EG1 10 ...

Page 45: ...HINT Adjust idle mixture as necessary ENGINE ENGINE MECHANICAL EG1 11 ...

Page 46: ...suction EGR sys tems etc should be properly connected f MFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral i Idle speed set correctly j Tachometer and CO HC meter calibrated and at hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 3 MINUTES 4 INSERT CO HC METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm 1 3 ft 5 IMMEDIATELY CHECK CO HC CONC...

Page 47: ...fuel return line Faulty volume air flow meter Defective engine coolant temp sensor Defective intake air temp sensor Faulty ECM Faulty injector Faulty cold start injector 1 Faulty ignition Incorrect timing Fouled shorted or improperly gapped plugs Open or crossed high tension cords Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve 4 Leaky exhaust valves 5 Leaky cylinder 1 Vacuum...

Page 48: ...o obtain at least 250 rpm d Repeat steps a through c for each cylinder Compression pressure 1 177 kPa 12 0 kgf cm2 171 psi Minimum pressure 981 kPa 10 0 kgf cm2 142 psi Difference between each cylinder 98 kPa 1 0 kgf cm2 14 psi or less e If cylinder compression in one or more cylinders is low pour a small amount of engine oil into the cylin der through the spark plug hole and repeat steps a throug...

Page 49: ...CYLINDER HEAD COMPONENTS ENGINE ENGINE MECHANICAL EG1 15 ...

Page 50: ...hoses from the thr ottle body m w Oil cooler Disconnect the No 1 oil cooler hose from the intake manifold w o Oil cooler Disconnect the No 1 water by pass hose from the intake manifold PREPARATION FOR REMOVAL 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DRAIN COOLANT FROM RADIATOR AND CYLIN DER BLOCK See step 3 on page EG1 225 3 REMOVE INTAKE AIR CONNECTOR 4 DISCONNECT EXHAUST PIPE FROM ...

Page 51: ...r wire b Oil pressure sender gauge wire c Starter wire terminal 50 d Transmission wires e with A C Compressor wires f Injector wires g Engine coolant temp sender gauge wire h A T OD temp switch wire i Igniter wire j VSV wires k Start injector time switch wire l Engine Coolant temp sensor wire 18 DISCONNECT FUEL HOSE FROM DELIVERY PIPE Remove the bolt union bolt and two gaskets 19 DISCONNECT BY PAS...

Page 52: ...ing in 2 REMOVE CAM SPROCKET BOLT a Turn the crankshaft until the No 1 cylinder position is set at TDC compression b Place matchmarks on the sprocket and chain c Remove the half circular plug 21 w PS DISCONNECT PS BRACKET FROM CYLINDER HEAD Remove the four bolts disconnect the ground strap and bracket 3 REMOVE DISTRIBUTOR DRIVE GEAR AND CAM SHAFT THRUST PLATE d Remove the cam sprocket bolt ENGINE ...

Page 53: ... wooden blocks on a bench HINT If the cylinder head is difficult to lift off pry with a screwdriver between the head and block sa liences NOTICE Be careful not to damage the cylinder head and block surfaces of the cylinder head gasket CYLINDER HEAD DISASSEMBLY See page EG1 15 1 REMOVE NO 1 SECONDARY AIR INJECTION MANIFOLD Remove the bolt four nuts No 1 secondary air in jection manifold and two gas...

Page 54: ...REMOVE EXHAUST MANIFOLD WITH NO 2 SEC ONDARY AIR INJECTION MANIFOLD a Remove the three bolts and No 2 exhaust manifold heat insulator b Remove the eight nuts exhaust manifold and No 2 secondary air injection manifold 5 REMOVE TWO ENGINE HANGERS AND GROUND STRAP 6 REMOVE CYLINDER HEAD REAR OVER 2 REMOVE INTAKE MANIFOLD WITH DELIVERY PIPE AND INJECTORS a Remove the two nuts and reed valve 3 REMOVE E...

Page 55: ...center Using a gasket scraper remove all the carbon from the piston tops b Using a gasket scraper remove all gasket material from the top of the block Blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high pressure sir 7 MEASURE CAMSHAFT THRUST CLEARANCE Using a dial gauge measure the camshaft thrust clearance Standard clearance 0 08 0 18 mm 0 0031 0 0071 in Maximum clea...

Page 56: ...r than maximum replace the cyl inder head 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the combustion chambers NOTICE Be careful not to scratch the head gasket con tact surface 5 CLEAN CYLINDER HEAD Using a soft brush and solvent clean the head NOTICE Do not clean the head in a hot tank as this will seriously damage it 4 CLEAN VALVE GUIDE BUSHINGS Using a valve guide b...

Page 57: ... 0 10 mm 0 0039 in If the clearance is greater than maximum replace the valve and guide bushing 7 INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant check the combustion cham bers intake and exhaust ports head surface and the top of the head for cracks If a crack is found replace the head 9 INSPECT VALVE STEMS AND GUIDE BUSHINGS a Using a caliper gauge measure the inside diameter of the valve ...

Page 58: ...liper gauge measure the valve guide bus hing bore of the cylinder head 10 IF NECESSARY REPLACE VALVE GUIDE BUSH INGS a Using a brass bar and hammer break the valve guide bushing c Using SST and a hammer drive out valve guide bus hing SST 09201 60011 b Gradually heat the cylinder head to approx 90 C 194 F 13 000 13 018 0 5118 0 5125 Bushing bore mm in Bore intake and exhaust Over 13 018 0 5125 Use ...

Page 59: ...s contact with the cylinder head SST 09201 6001 1 11 INSPECT AND GRIND VALVES a Grind the valve only enough to remove pits and carbon b Check that valve is ground to the correct valve face angle Valve face angle 44 5 c Check the valve head margin thickness Standard margin thickness 1 0 mm 0 039 in Minimum margin thickness 0 6 mm 0 024 in If the valve head margin thickness is less than mini mum rep...

Page 60: ...he seat contact is on the middle of the valve face with the following width 1 2 1 6 mm 0 047 0 063 in If not correct the valve seat as follows e Check the valve overall length Standard overall length Intake 113 5 mm 4 468 in Exhaust 112 4 mm 4 425 in Minimum overall length Intake 113 0 mm 4 449 in Exhaust 111 9 mm 4 406 in If the valve overall length is less than minimum re place the valve 12 INSP...

Page 61: ...a Using a steel square measure the squareness of the valve spring Maximum squareness 1 6 mm 0 063 in If squareness is greater than maximum replace the valve spring b Using vernier calipers measure the free length of the valve spring Free length 48 5 mm 1 909 in If the free length is not within specification replace the valve spring If seating is too low on the valve face use 60 IN or 65 EX and 45 ...

Page 62: ... Do not turn the camshaft while the Plastigags is in place 14 INSPECT CAMSHAFT AND BEARING CAPS a Place the cam shaft on V blocks and using a dial indicator measure the circle runout at the center journal Maximum circle runout 0 2 mm 0 008 in If the circle runout is greater than maximum replace the camshaft 15 INSPECT CAMSHAFT OIL CLEARANCE a Clean the bearing caps and camshaft journal b Place the...

Page 63: ...Slide the rocker stands spring and rocker arms off the shafts b Using a dial indicator or telescoping gauge measure the inside diameter of the rocker arm Standard inside diameter 16 000 16 018 mm 0 6299 0 6306 in c Using a micrometer measure the outside diameter of the shaft Standard diameter 15 97 15 99 mm 0 6287 0 6295 in d Subtract the shaft diameter measurement from the rocker arm diameter mea...

Page 64: ...n Maximum exhaust warpage 0 7 mm 0 28 in Maximum air intake chamber warpage 0 2 mm 0 008 in If warpage is greater than maximum replace the manifold and or air intake chamber CYLINDER HEAD ASSEMBLY See page EG1 15 HINT Thoroughly clean all parts to be assembled Before installing the parts apply new engine oil to all sliding and rotating surfaces Replace all gaskets and oil seals with new parts ENGI...

Page 65: ... two keepers around the valve stem SST 09202 43013 2 INSTALL CAMSHAFT a Place the camshaft in the cylinder head and install the bearing caps in numbered order from the front with arrows pointed toward the front b Install and torque the cap bolts Torque 20N m 200kgf cm 14ft Ibf c Turn the camshaft to position the dowel at the top 3 INSTALL CYLINDER HEAD REAR COVER Install a new gasket cylinder head...

Page 66: ...r It will act as a sealer or binding agent only when applied to threads etc and air is cut off 7 INSTALL EXHAUST MANIFOLD a Position a new gasket on the cylinder head b Install the exhaust manifold with the eight nuts Torque the nuts Torque 44N m 450kgf cm 33ft lbf 6 INSTALL PLUG PATE Install a new gasket and plug plate with the two bolts HINT Attach the flat side of the gasket to the cylinder hea...

Page 67: ...ACKING TO CYLINDER BLOCK a Apply seal packing to two locations as shown Seal packing Part No 08826 00080 or equivalent b Place a new head gasket over dowels on the cylinder block 2 INSTALL CYLINDER HEAD 10 INSTALL NO 1 SECONDARY AIR INJECTION MANIFOLD a Position new gaskets on the PAIR valve and No 1 secondary air injection pipe b Install the No 1 secondary air injection pipe with the four nuts an...

Page 68: ...tall and tighten the head bolts gradually in three passes in the sequence shown Torque the bolts on the final pass Torque 78N m 800kgf cm 58ft Ibf 5 INSTALL DISTRIBUTOR DRIVE GEAR AND CAM SHAFT THRUST PLATE Place the distributor drive gear and camshaft thrust plate over the chain sprocket Torque the bolt Torque 78N m 800kgf cm 58ft Ibf a If the sprocket was removed align the alignment marks placed...

Page 69: ... HINT After installing the cylinder head warm up the engine and adjust the valve clearance Use a thickness gauge to measure between the valve stern and rocker arm Loosen the lock nut and turn the adjusting screw to set the proper clearance Hold the adjusting screw in position and tighten the lock nut Torque 25N m 250kgf cm 18ft lbf Recheck the clearance The thickness gauge should move with a very ...

Page 70: ...ll new gaskets and the fuel hose with union bolt Torque 44N m 450kgf cm 33ft lbf 5 CONNECT FOLLOWING WIRES a Engine coolant temp sensor wire b Cold start injector time switch wire c VSV wires d Igniter wire b Install the gasket to the cylinder head c Place the head cover on the cylinder head and install the four seals and nuts Torque 5 9N m 60kgf cm 52in Ibf 8 INSTALL HEAD COVER a Apply seal packi...

Page 71: ...start injector wire 9 INSTALL EGR VACUUM MODULATOR 10 CONNECT FOLLOWING PARTS a w Oil cooler Connect the No 1 oil cooler hose to the intake man ifold w o Oil cooler Connect the No 1 water by pass hose to the intake manifold b No 2 and No 3 water by pass hoses to the throttle body c Vacuum hoses to throttle body d Pressure regulator hose e Fuel pressure up hose f PAIR valve hose g EGR valve hose e ...

Page 72: ...exhaust manifold with the three nuts b Install the exhaust pipe clamp 19 INSTALL INTAKE AIR CONNECTOR 20 FILL WITH ENGINE OIL See step 3 on page EG1 236 21 FILL WITH COOLANT See step 3 on page EG1 225 22 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 23 START ENGINE Warm up the engine and inspect for leaks 24 PERFORM ENGINE ADJUSTMENT See page EG1 10 25 RECHECK COOLANT AND ENGINE OIL LEVEL 26 ROAD ...

Page 73: ...he engine approx 25 mm 0 98 in d Remove the sixteen bolts and nuts e Using SST and brass bar separate the oil pan from the cylinder block PREPARATION OF REMOVAL 1 REMOVE CYLINDER HEAD See page EG1 16 2 REMOVE RADIATOR See page EG1 230 3 4WD REMOVE FRONT DIFFERENTIAL See SA section TIMING CHAIN COMPONENTS ENGINE ENGINE MECHANICAL EG1 39 ...

Page 74: ...BELT 2 with A C REMOVE A C BELT COMPRESSOR AND BRACKET 4 REMOVE CRANKSHAFT PULLEY a with A C w o Air pump or w PS w Air pump Remove the No 2 crankshaft pulley b Using SST to hold the crankshaft pulley loosen the pulley bolt SST 09213 70010 and 09330 00021 c Using SST remove the crankshaft pulley SST 09213 310231 HINT If the front seal is to be replaced see page EG1 236 SST 09032 00100 HINT When re...

Page 75: ... w PS Remove the bolt and PS lower bracket b Remove the three bolts and bar 7 DISCONNECT HEATER WATER OUTLET PIPE Remove the two bolts and disconnect heater water outlet pipe 9 REMOVE CHAIN AND CAMSHAFT SPROCKET a Remove the chain from the damper b Remove the cam sprocket and chain together 5 REMOVE NO 1 WATER BY PASS PIPE Remove the two bolts and pipe ENGINE ENGINE MECHANICAL EG1 41 ...

Page 76: ... minimum 113 8 mm 4 480 in If the measurement is less than minimum replace the chain and two sprockets 10 REMOVE PUMP DRIVE SPLINE AND CRANKSHAFT SPROCKET If the oil pump drive spline and sprocket cannot be removed by hand use SST to remove them together SST 09213 36020 11 REMOVE GASKET MATERIAL ON CYLINDER BLOCK 2 MEASURE CHAIN TENSIONER Using a caliper gauge measure the tensioner as shown Tensio...

Page 77: ...130kgf cm 9ft Ibf 10 mm bolt 13 N m 400kgf cm 29ft lbf 2 PLACE CHAIN ON CAMSHAFT SPROCKET a Place the timing chain on the sprocket so that the bright chain link is aligned with the timing mark on the sprocket b Make sure the chain is positioned between the dam pers c Turn the camshaft sprocket counterclockwise to take the slack out of the chain 5 INSTALL FAN BELT ADJUSTING BAR a Temporarily instal...

Page 78: ...STALL OIL PAN a Remove any old packing material and be careful not to drop any oil on the contacting surfaces of the oil pan and cylinder block 8 INSTALL CRANKSHAFT PULLEY a Install the crankshaft pulley and bolt b Using SST to hole the crankshaft pulley torque the bolt SST 09213 70010 and 09660 00021 Torque 157N m 1 600kgf cm 116ft lbf c with A C Install the NO 2 crankshaft pulley 6 INSTALL HEATE...

Page 79: ...the sixteen bolts and two nuts Torque the bolts and nuts Torque 13N m 130kgf cm 9ft lbf e Lower the engine and install the engine mounting bolts f Install the engine under cover Using a razor blade and gasket scraper remove all the packing FIPG material from the gasket surfaces Thoroughly clean all components to remove all the loose material Clean both sealing surfaces with a non residue solvent N...

Page 80: ...CYLINDER BLOCK COMPONENTS ENGINE ENGINE MECHANICAL EG1 46 ...

Page 81: ...PULLEY See step 3 on page EG1 40 11 DISCONNECT FOLLOWING WIRES AND CONNEC TORS a Ground strap from LH fender apron b Generator connector and wire c Igniter connector d Generator wires e High tension cord for ignition coil f Distributor wire from igniter g Ground strap from engine rear side h ECM connectors i M T Starter relay connector j Check connector k with A C A C compressor connector 12 DISCO...

Page 82: ...remove the drive belt 6 Remove the compressor on the front side without disconnecting the hoses 17 DISCONNECT GROUND STRAPS FROM ENGINE REAR SIDE AND RH SIDE 18 M T REMOVE SHIFT LEVER S FROM INSIDE OF VEHI CLE 19 REMOVE REAR PROPELLER SHAFT See PR section 20 2WD A T DISCONNECT MANUAL SHIFT LINKAGE FROM PNP SWITCH 21 4WD A T DISCONNECT TRANSFER SHIFT LINKAGE a Disconnect the No 1 and No 2 transfer ...

Page 83: ... 26 REMOVE NO 1 FRAME CROSSMEMBER 28 M T REMOVE CLUTCH RELEASE CYLINDER WITH BRACKET FROM TRANSMISSION 29 4WD REMOVE NO 1 FRONT FLOOR HEAT INSULATOR AND BRAKE TUBE HEAT INSULATOR 30 2WD REMOVE ENGINE REAR MOUNTING AND BRACKET a Remove the four bolts from the engine rear mounting b Raise the transmission slightly by raising the engine with a jack c Remove the four bolts from the support member b Re...

Page 84: ... Remove the two stiffener plates and exhaust pipe bracket from engine d Remove the transmission from the engine 34 M T REMOVE CLUTCH COVER AND DISC CYLINDER BLOCK DISASSEMBLY See page EG1 46 1 REMOVE FLYWHEEL OR DRIVE PLATE 2 REMOVE REAR END PLATE 3 INSTALL ENGINE STAND FOR DISASSEMBLY 4 REMOVE CYLINDER HEAD See page EG1 18 5 REMOVE TIMING CHAIN See page EG1 40 6 REMOVE GENERATOR See CH section 7 ...

Page 85: ...d cap HINT Keep the bearing inserted in the cap d Clean the bearing and crankshaft pins e Inspect each bearing for pitting and radial scratches If bearing are damaged replace the bearings 19 MEASURE CONNECTING ROD OIL CLEARANCE a Using a punch or numbering stamp mark connecting rods and caps to ensure correct reassembly b Remove the rod cap nuts 17 REMOVE REAR OIL SEAL RETAINER Remove the five bol...

Page 86: ...the cap Install and torque the cap nuts Torque 69 N m 700 kgf cm 51 ft lbf HINT Do not turn the crankshaft Apply a light coat of engine oil on the nut threads and under the nut before installation f Lay a strip of Plastigage across the crankshaft pin Bearing Center Wall Thickness Big End Inner Diameter Crank Pin Diameter mm in U S 0 25 Size HINT If replacing a standard size bearing replace with on...

Page 87: ...kshaft Thrust washer thickness Standard 2 690 2 740 mm 0 1059 0 1079 in 0 S 1 25 2 753 2 803 mm 0 1084 0 1104 in 4 S 2 50 2 815 2 865 mm 0 1108 0 1128 in 20 PUSH OUT PISTON AND CONNECTING ROD AS SEMBLY a Remove all the carbon from top of the bore to the top of the cylinder b Cover the rod bolts with a short piece of hose to protect the crank pin from damage c Push the piston and connecting rod ass...

Page 88: ...ngs for pitting and scr atches If the journal or bearing is damaged grind or replace the crankshaft and replace the bearing h Install the main bearing caps with the front mark facing forward lnstall and torque the cap bolts Torque 103 N m 1 050 kgf cm 76 ft lbf HINT Do not turn the crankshaft Apply a light coat of engine oil on the bolt threads before installation f Install the upper main bearings...

Page 89: ...having the same number as marked on the cylinder block There are three sizes of standard bearings marked 3 4 5 accordingly CYLINDER BLOCK INSPECTION 1 REMOVE GASKET MATERIAL Using a gasket scraper remove all gasket material from cylinder block surfaces 2 CLEAN CYLINDER BLOCK Using a soft brush and solvent clean the block 23 REMOVE CRANKSHAFT a Lift out the crankshaft b Remove the upper main bearin...

Page 90: ...0 93 00 93 03 mm 3 6614 3 6626 in 5 MEASURE CYLINDER BORE HINT There are three sizes of the standard cylinder bore diameter marked 1 2 and 3 accordingly The mark is stamped on the cylinder block 3 INSPECT CYLINDERS Visually inspect cylinders for vertical scratches If deep scratches are present rebore all four cylinders See page EG1 66 4 INSPECT CYLINDER BLOCK WARPAGE Warpage limit 0 5 mm 0 0020 in...

Page 91: ...n 0 S 1 00 93 23 mm 3 6705 in If the diameter is greater than maximum rebore all four cylinders or replace the cylinder block b Remove the two side rails and oil ring expander by hand HINT Keep the rings for each cylinder separated 6 REMOVE CYLINDER RIDGE If wear is less than 0 2 mm 0 008 in use a ridge reamer to machine the top of the cylinder 2 REMOVE PISTON RINGS a Using a piston ring expander ...

Page 92: ...d set Keep the piston pin rings and connecting rod together for each cylinder 3 DISCONNECT CONNECTING ROD FROM PISTON a Using needle nose pliers remove the snap rings from the piston c Using a plastic faced hammer and brass bar lightly tap out the piston pin from the piston b Heat the piston in hot water approx 60 C 140 F ENGINE ENGINE MECHANICAL EG1 58 ...

Page 93: ...tance 33 mm 1 30 in HINT There are three sizes of the standard piston diameter marked 1 2 and 3 accordingly The mark is stamped on the top of the piston c Using solvent and a brush thoroughly clean the piston NOTICE Do not use a wire brush b Using a groove cleaning tool or broken ring clean the ring grooves 2 INSPECT PISTON DIAMETER AND OIL CLEARANCE ENGINE ENGINE MECHANICAL EG1 59 ...

Page 94: ...d bore diameter mark on the cylinder block 3 MEASURE CLEARANCE BETWEEN PISTON GROOVE AND PISTON RING Using a thickness gauge measure the clearance be tween the piston ring and the ring land Standard ring groove clearance 0 03 0 07 mm 0 0012 0 0028 in Maximum ring groove clearance 0 2 mm 0 008 in If the clearance is greater than maximum replace the piston ring and or piston Piston diameter STD Mark...

Page 95: ...heck the connecting rod align ment If the rod is bent or twisted replace the connecting rod Check that the rod is not bent Maximum bend 0 05 mm 0 0020 in per 100 mm 3 94 in 5 INSPECT PISTON PIN FIT At 80 C 176 F you should able to push the pin into the piston with your thumb If the pin can be installed at a lower temperature replace it and the piston 4 MEASURE RING END GAP a Insert the piston ring...

Page 96: ...D BUSHING Using SST install the rod bushing to the connecting rod SST 09222 30010 HINT Align the bushing oil hole with the connecting rod oil hole ROD BUSHING REPLACEMENT 1 REMOVE ROD BUSHING Using SST remove the rod bushing from the conne cting rod SST 09222 30010 b Measure the oil clearance between the rod bushing and piston pin Using an inside dial indicator measure the inside diameter of the r...

Page 97: ... runout 0 1 mm 0 004 in If the runout is greater than maximum replace the crankshaft HINT Use a long spindle on the dial gauge 2 INSPECT MAIN JOURNALS AND CRANK PINS a Using a micrometer measure the diameter of the main journal and crank pin Main journal diameter 59 984 60 000 mm 2 3616 2 3622 in Crank pin diameter 52 988 53 000 mm 2 0861 2 0866 in If journals are worn regrind or replace the crank...

Page 98: ...oil seal a Using a knife cut off the oil seal lip b Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screwdriver tip OIL SEALS REPLACEMENT HINT There are two ways of oil seal replacement in accordance with the timing chain cover or rear oil seal retainer condition 1 IF TIMING CHAIN COVER IS REMOVED FROM CYLINDER BLOCK Replacement of front oil seal a ...

Page 99: ...ap in the oil seal until its surface is flush with the timing chain cover edge SST 09223 50010 c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 41020 3 IF REAR OIL SEAL RETAINER IS REMOVED FROM CYLINDER BLOCK Replacement of rear oil seal a Using a screwdriver remove the oil seal b Apply MP...

Page 100: ... 0 0008 in NOTICE Excess honing will destroy the finished round ness CYLINDERS BORING 1 SELECT OVERSIZED PISTON O S pistons with pins are available in the sizes listed Replace pistons in matched sets Take the largest bore measured and select the oversized piston for that bore Bore all cylinders for the oversized piston sel ected PISTON AND CONNECTING ROD ASSEMBLY 1 ASSEMBLE PISTON AND CONNECTING R...

Page 101: ...with the mark on the rod and push the piston pin in with your thumb d Install a new snap ring on the other side of the pin c Position the piston rings so that the ring end gaps are as shown NOTICE Do not align the end gaps b Using a ring expander install the two compression rings with the code marks facing upward 2 PLACE RINGS ON PISTON a Install the oil ring expander and two side rails by hand EN...

Page 102: ...e cylinder block and bearing caps NOTICE Install the upper bearing with the oil hole in the block 4 INSTALL MAIN BEARING CAPS WITH LOWER THRUST WASHERS HINT Each bearing cap is numbered a Install the thrust washers on the No 3 bearing cap with the grooves facing outward 2 INSTALL UPPER THRUST WASHERS Install the thrust washers under the No 3 main bearing cap position of the block with the oil groo...

Page 103: ...d gently tap the correctly numbered piston and rod assembly into its cylinders with a wooden hammer handle or like object Make sure the notch and mark are facing forward HINT If the ring compressor is wound too tightly around the piston the bottom edge of the ring com pressor will catch against the beveled surface at the top of the cylinder when tapping the piston in 6 INSTALL CONNECTING ROD CAPS ...

Page 104: ...NE MOUNTING BRACKET 12 INSTALL TIMING CHAIN See page EG1 43 13 INSTALL GENERATOR 14 INSTALL CYLINDER HEAD See page EG1 34 15 REMOVE ENGINE STAND 16 INSTALL REAR END PLATE 17 INSTALL FLYWHEEL OR DRIVE PLATE Install the flywheel M T or spacer drive plate spacer A T on the crankshaft with the six bolts Torque the bolts c Apply a light coat of engine oil on the threads and under the rod nuts d Install...

Page 105: ...AME BRACK ET a Align the engine mounting and frame bracket b Install the engine mounting bolts on each side of the engine c Remove the hoist chain 7 2WD INSTALL ENGINE REAR MOUNTING AND BRACKET a Raise the transmission slightly by raising the engine with a jack and a wooden block under the transmis sion b Install the engine rear mounting bracket to the sup port member Torque the bolts Torque 13 N ...

Page 106: ...LL NO 2 FRAME CROSSMEMBER a Raise the transmission slightly with a jack b Install the No 2 frame crossmember to the side frame with the bolts Torque the bolts Torque 95 N m 970 kgf cm 70 ft lbf c Lower the transmission and transfer d Install the four mounting bolts to the engine rear mounting Torque the bolts Torque 13 N m 130 kgf cm 9 ft lbf 8 4WD INSTALL BRAKE TUBE HEAT INSULATOR AND NO 1 FRONT ...

Page 107: ...ROUND STRAP FOR PS PUMP BRA CKET 24 w PS INSTALL PS PUMP WITH PS PUMP BRACKET Install the PS pump with the four bolts 25 CONNECT FOLLOWING CABLES a A T Throttle cable c Connect the No 1 and No 2 transfer shift linkage to the cross shaft 17 A T CONNECT MANUAL SHIFT LINKAGE TO PNP SWITCH 18 INSTALL PROPELLER SHAFT See PR section 19 R150 INSTALL SHIFT LEVER RETAINER 16 4WD A T CONNECT TRANSFER SHIFT ...

Page 108: ...p to LH fender apron 28 INSTALL FAN PULLEY BELT GUIDE FLUID COU PLING AND GENERATOR DRIVE BELT See step 9 on page EG1 44 29 with A C INSTALL A C BELT see step 2 on page MA 6 30 INSTALL PS PUMP AND BELT a Place the PS drive belt onto each pulley b Stretch the belt tight and tighten the nuts c Torque the PS pump pulley lock nut Torque 43 N m 440 kgf cm 32 ft lbf d adjust the belt tension See step 2 ...

Page 109: ...39 PERFORM ENGINE ADJUSTMENT See page EG1 10 40 ROAD TEST Road test the vehicle 41 RECHECK COOLANT AND ENGINE OIL LEVEL ENGINE ENGINE MECHANICAL EG1 75 ...

Page 110: ...EXHAUST SYSTEM COMPONENTS ENGINE ENGINE MECHANICAL EG1 76 ...

Page 111: ...ke chamber STD Intake Exhaust Limit Intake Exhaust Intake Exhaust Contacting angle Contacting width Crankshaft sprocket wear Camshaft sprocket wear Stem end refacing Stem oil clearance Valve face angle Stem diameter Valve head edge thickness Compression pressure Valve guide bushing Rocker arm and shaft Chain and sprocket Valve overall length Intake Exhaust Intake Exhaust Intake Exhaust Inner diame...

Page 112: ...TD Piston to cylinder clearance Ring to ring groove clearance Journal diameter Circle runout Cam height Connecting rod and bearing Piston pin installing temperature Tension and damper STD Limit STD Limit Piston and piston ring Bearing oil clearance STD Limit STD Piston ring end gap Journal oil clearance Limit Limit Limit Thrust clearance Thrust clearance Piston diameter Cylinder block Camshaft Lim...

Page 113: ...aring center wall thickness STD Main journal diameter Main journal finished diameter Crank pin diameter Crank pin finished diameter Connecting rod and bearing cont d Connecting rod bearing center wall thickness Pin to bushing oil clearance Main journal oil clearance STD Limit STD Thrust washer thickness Big end inner diameter STD Limit STD Thrust clearance Crankshaft STD ENGINE ENGINE MECHANICAL E...

Page 114: ...Oil cooler relief valve x Cylinder block Cylinder head x Cylinder head cover Air intake chamber x Intake manifold Cylinder block x Rear oil seal retainer Cylinder block x Fuel filter bracket Cylinder head x Exhaust manifold Cylinder block x Engine mounting Camshaft x Distributor drive gear Cylinder block x Chain tensioner Valve clearance adjusting screw Air intake chamber x EGR pipe Crankshaft x C...

Page 115: ...EM PURPOSE 09082 00015 TOYOTA Electrical Tester 09843 18024 Diagnosis Check Wire Fuel evaporative emission control Three way catalytic converter Pulsed secondary air injection Positive crankcase ventilation Reduces blow by gas HC Reduces HC CO and NOx Multiport fuel injection EQUIPMENT Exhaust gas recirculation Reduces evaporative HC Reduces HC and CO Torque wrench Vacuum gauge Thermometer Tachome...

Page 116: ...LAYOUT AND SCHEMATIC DRAWING Federal and Canada ENGINE EMISSION CONTROL SYSTEMS EG1 82 ...

Page 117: ...LAYOUT AND SCHEMATIC DRAWING Calif ENGINE EMISSION CONTROL SYSTEMS EG1 83 ...

Page 118: ...POSITIVE CRANKCASE VENTILATION PCV SYSTEM ENGINE EMISSION CONTROL SYSTEMS EG1 84 ...

Page 119: ...ough the valve Petroleum substances inside the valve are harmful PCV HOSES AND CONNECTIONS INSPECTION VISUALLY INSPECT HOSES CONNECTIONS AND GAS KETS Check for cracks leaks or damage 4 BLOW AIR FROM INTAKE MANIFOLD SIDE Check that air passes through with difficulty If the PCV valve fails either check replace it 5 REINSTALL PCV VALVE ENGINE EMISSION CONTROL SYSTEMS EG1 85 ...

Page 120: ...hrottle body for combustion in the cylinders EVAPORATIVE EMISSION EVAP CONTROL SYSTEM HC from tank is absorbed in the canister HC from tank is absorbed in the canister HC from canister is led into throttle body Check Valve in Charcoal Canister Check Valve in Fuel Tank Cap Positioned below purge port Positioned above purge port Air is led into the tank Throttle Valve Opening High pressure in tank E...

Page 121: ...FILTER IN CANISTER Clean the filter by blowing 294 kPa 3 kgf cm2 43psi of compressed air into the tank pipe while holding the purge pipe closed HINT Do not attempt to wash the canister No activated carbon should come out 5 INSTALL CHARCOAL CANISTER CHARCOAL CANISTER INSPECTION 1 REMOVE CHARCOAL CANISTER 2 VISUALLY INSPECT CHARCOAL CANISTER CASE Look for cracks or damage 3 VISUALLY INSPECT FUEL TAN...

Page 122: ...EXHAUST GAS RECIRCULATION EGR SYSTEM Federal and Canada ENGINE EMISSION CONTROL SYSTEMS EG1 88 ...

Page 123: ...VACUUM MODULATOR a Check the filter for contamination or damage b Using compressed air clean the filter 2 PREPARATION Disconnect the vacuum hose from the EGR valve and using a three way union connect a vacuum gauge to it 3 CHECK SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle 5 CHECK TVV AND EGR VACUUM MODULATOR WITH HOT ENGINE a Warm up the engine b Check t...

Page 124: ...J to the air filter e Heat the TVV to above 44 C 111 F f Check that the air flows from pipe J to pipe K g Apply sealant to the threads of the TVV and reinstall Sealant Part No 08833 00070 THREE BOND 1324 or equivalent h Fill the radiator with coolant If a problem is found replace the TVV 6 CHECK EGR VALVE a Apply vacuum directly to the EGR valve with the engine idling b Check that the engine runs ...

Page 125: ... REMOVE EGR VALVE Check the valve for sticking and heavy carbon de posits If a problem is found replace it 2 INSTALL EGR VALVE WITH NEW GASKET EGR VALVE INSPECTION ENGINE EMISSION CONTROL SYSTEMS EG1 91 ...

Page 126: ...EXHAUST GAS RECIRCULATION EGR SYSTEM Calif ENGINE EMISSION CONTROL SYSTEMS EG1 92 ...

Page 127: ...valve and using a three way union connect a vacuum gauge to it 3 CHECK SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle 5 CHECK VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE a Warm up the engine b Check that the vacuum gauge indicates low vacuum at 3 500 rpm EGR SYSTEM INSPECTION 1 CHECK AND CLEAN FILTER IN EGR VACUUM MODULATOR a Check the filter for contamina...

Page 128: ... locations IF NO PROBLEM IS FOUND WITH THIS INSPECTION THE SYSTEM IS OKAY OTHERWISE INSPECT EACH PART VSV INSPECTION 1 CHECK VACUUM CIRCUIT CONTINUITY IN THE VSV BY BLOWING AIR INTO PIPE a Connect the VSV terminals to the battery terminals as illustrated b Blow air into a pipe and check that the VSV is open d Start the engine and maintain the speed at 3 500 rpm e Repeat the above test Check that t...

Page 129: ...ithin specification replace the VSV EGR VALVE INSPECTION 1 REMOVE EGR VALVE Check the valve for sticking and heavy carbon de posits If a problem is found replace it 2 INSTALL EGR VALVE WITH NEW GASKET 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between the terminals and the VSV body ENGINE EMISSION CONTROL SYSTEMS EG1 95 ...

Page 130: ...SECONDARY AIR INJECTION PAIR SYSTEM Below 1 000 rpm Above 1 000 rpm Below 4 km h 2 mph Above 4 km h 2 mph Above 40 C 104 F Below 30 C 86 F Throttle valve position Below 3 600 rpm Below 1 000 rpm Above 3 600 rpm Above 1 000 rpm Coolant Temp Vehicle speed Normal driving Deceleration Engine RPM Condition OFF ON OFF ON Idling PAIR OFF OFF vsv ENGINE EMISSION CONTROL SYSTEMS EG1 96 ...

Page 131: ...IR VALVE INSPECTION CHECK PAIR VALVE BY BLOWING AIR INTO PIPE a Apply vacuum to the pair valve diaphragm b Blow air into a pipe and check that the pair valve is c Release the vacuum and check that the pair valve is closed 3 CHECK PAIR SYSTEM WITH WARM ENGINE a Warm up the engine to above 40 C 104 F b With the engine idling check that a bubbling noise is not heard from the NO 1 hose c Race the engi...

Page 132: ...flow from the black pipe to the orange pipe 3 CHECK FOR OPEN CIRCUIT Using an ohmmeter measure the resistance between the terminals as shown Specified resistance 30 50 Ω at 20 C 68 F If the resistance is not within specification replace the VSV 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between the terminal and the VSV body If there is continuity replace the VSV ...

Page 133: ...f any part of the protector is damaged or dented to the extent that it contacts the catalytic converter repair or replace it To reduce HC CO and NOx emissions they are oxidized reduced and converted to nitrogen N2 carbon dioxide C02 and water H2O by the catalytic converter THREE WAY CATALYTIC CONVERTER TWC SYSTEM Exhaust Port Exhaust Gas TWC ENGINE EMISSION CONTROL SYSTEMS EG1 99 ...

Page 134: ...haust pipes b Torque the bolts Torque Catalytic converter Exhaust pipe 39 N m 400kgf cm 29ft lbf c Reinstall the bracket bolts and tighten them HEAT INSULATOR INSPECTION 1 CHECK HEAT INSULATOR FOR DAMAGE 2 CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS No 1 Air Injection Manifold x PAIR Reed Valve Intake Manifold x PAIR Reed...

Page 135: ...MFI SYSTEM DESCRIPTION ENGINE MFI SYSTEM EG1 101 ...

Page 136: ...unction or abnormalities in the sensor network it lights the Mal function Indicator Lamp in the combination meter At the same time the trouble is identified and a diagnostic trouble code is recorded by the ECM The diagnostic trouble code can be read by the number of blinks of the malfunction Indicator lamp when terminals TE1 and E1 are connected The diagnostic trouble codes are explained on pages ...

Page 137: ... 14 x 17 mm Wrench Set RECOMMENDED TOOLS Plug for the vacuum hose fuel hose etc 09268 41045 Injection Measuring Tool Set 09082 00015 TOYOTA Electrical Tester 09842 30070 Wiring F EFI Inspection 09268 45012 EFI Fuel Pressure Gauge 09843 18020 Diagnosis Check Wire 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Fuel line flare nut ENGINE MFI SYSTEM EG1 103 ...

Page 138: ...EQUIPMENT Graduated cylinder Carburetor cleaner Vacuum gauge Torque wrench Sound scope Tachometer Throttle body Throttle body Soft brush Injector Injector ENGINE MFI SYSTEM EG1 104 ...

Page 139: ... Handle high tension cords carefully c After repair work check that the ignition coil termi nals and all other ignition system lines are reconne cted securely d When cleaning the engine compartment be especially careful to protect the electrical system from water MAINTENANCE PRECAUTIONS 1 CHECK CORRECT ENGINE TUNE UP 2 PRECAUTION WHEN CONNECTING GAUGE a When a tachometer is connected to the system...

Page 140: ...specially do not wind them together c Check that the feeder and antenna are properly adj usted d Do not equip your vehicle with a powerful mobile radio system e Do not open the cover or the ECM unless absolutely necessary If the terminals are touched the IC may be destroyed by static electricity AIR INDUCTION SYSTEM 1 Separation of the engine oil dipstick oil filler cap PCV hose etc may cause the ...

Page 141: ...ke care to prevent entry of water Also when the engine compartment prevent water from getting on the MFI parts and wiring connectors 7 Parts should be replaced as an assembly 9 When inspecting a connector with a volt ohmme ter a Carefully take out the water proofing rubber if it is a water proof type connector 8 Sufficient care is required when pulling out and inserting wiring connectors a To pull...

Page 142: ...cified torque Torque 30 N m 310 kgf cm 22 ft Ibf Flare nut type a Apply a light coat of engine oil to the flare and tighten the flare nut by hand b Then using SST tighten the nut to the specified torque SST 09631 22020 Torque 27 N m 280 kgf cm 20 ft lbf HINT use a torque with a fulcrum length of 30 cm 11 81 in b Insert tester probe into the connector from the wiring side when checking the continui...

Page 143: ...stalling the injectors a Never re use the O ring b When placing a new 0 ring on the injector take care not to damage it in any way c Lubricate the O ring spindle oil or gasoline before installing never use engine gear or brake oil 5 Check that there are no fuel leaks after performing any maintenance on the fuel system a With engine stopped turn the ignition switch On b Using SST connect terminals ...

Page 144: ...icator Lamp in the combination meter informs the driver that a malfunction has been detected The light goes automatically when the malfunction has been corrected DIAGNOSTIC TROUBLE CODES OUTPUT To obtain an output of diagnostic trouble codes proceed as follows 1 Initial conditions a Battery voltage 11 volts or more b Throttle valve fully closed throttle position sensor IDL points closed c Transmis...

Page 145: ...number of trouble codes indication will begin from the small value and continue to the larger in order d Accessories switched OFF e Engine at normal operating temperature 2 Turn the ignition switch ON Do not start the engine 3 Using SST connect terminals TE and E of the DLC 1 SST 09843 18020 HINT The DLC1 is located near the No 2 relay block 4 Read the diagnostic trouble code as indicated by the n...

Page 146: ...removal of the battery terminal a check must first be made to see if a diagnostic trouble code has been recorded 2 After cancellation road test the vehicle if neces sary confirm that a normal code is now read on the Malfunction Indicator Lamp If the same diagnostic trouble code appears it in dicates that the trouble area has not been repaired thoroughly c 2 trip detection logic The diagnostic trou...

Page 147: ...odes except for code No 51 and No 53 will be retained in memory by the ECM from the time of detection until canceled out 3 Once the malfunction is cleared the Malfunction In dicator Lamp on the instrument panel will go off but the diagnostic trouble code s remain stored in ECM memory except for code 51 and 53 ENGINE MFI SYSTEM EG1 113 ...

Page 148: ...f main oxygen sensor signal OX 1 is reduced to between 0 35 0 70 V continuously for 60 secs or more 6 2 trip detection logic 2 NE signal is not input to ECM for 300 msec or more when engine speed is 1 500 rpm or more Open or short in intake air temp sensor circuit for 500 rnsec or more THA Open or short in heater circuit of main oxygen sensor Main oxygen sensor heater ECM Open or short in main oxy...

Page 149: ...nges with the check terminals E1 and TE1 con nected SPD signal is not input to the ECM for at least 8 seconds during high load driving with engine speed between 2 200 rpm and 5 000 rpm Short or open in sub oxygen sensor circuit Sub oxygen sensor Open or short in sub oxygen sensor heater ECM Open or short in starter signal circuit Open or short in IG SW or main relay circuit ECM Starter signal STA ...

Page 150: ...icle running for 1 2 min after starting acceleration 6 After driving stop at a safe place and turn the IG switch OFF for 3 sec or more 7 Start the engine and perform steps 3 4 and 5 again HINT If a malfunction is detected the Malfunction Indicator Lamp will light up during step 7 NOTICE If this procedure is not strictly followed you can not detect the malfunctions DIAGNOSTIC TROUBLE CODE DETECTION...

Page 151: ...steps 2 3 4 and 5 again HINT 1f a malfunction is detected the Malfunction Indicator Lamp will light up during step NOTICE If this procedure is not strictly followed you can not detect the malfunctions DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check ...

Page 152: ...Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected Malfunction Open or Short in Oxygen Sensor Open or Short in Injector Leak Blockage Air Fuel Ratio Lean Malfunction CALIFORNIA Air Fue...

Page 153: ... sec or more Start the engine and perform steps 3 4 and 5 again DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected Sub Oxygen S...

Page 154: ... CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected Malfunction Short in VSV Circuit for EGR Loose EGR Hose Valve Stuck EGR System Malfunction DTC...

Page 155: ...lfunction Indicator Lamp come on when ignition switch is at ON INSPECTION OF DIAGNOSIS CIRCUIT Does MIL go off when the engine is started Does MIL go off after repair according to malfunction code Check wiring between ECM and MIL Check wiring between ECM terminal E1 and body ground Cancel out diagnostic trouble code Further repair required Repair or replace Repair or replace Try another ECM Try an...

Page 156: ... simple check of the fuses fusible links and connecting condition of the connectors before making your inspection according to the procedures listed The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component outside the computer or a short circuit within the computer If engine trouble occurs even though proper operat...

Page 157: ...HEATER SUB MALFUNCTION INDICATOR LAMP FUEL PRESSURE CONTROL VSV THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR INTAKE AIR TEMP SENSOR VOLUME AIR FLOW METER VOLUME AIR FLOW METER OXYGEN SENSOR MAIN OXYGEN SENSOR SUB EGR GAS TEMP SENSOR COLD START INJECTOR STOP LIGHT SWITCH STARTER SWITCH SENSOR GROUND SENSOR GROUND ENGINE GROUND ENGINE GROUND ENGINE GROUND DISTRIBUTOR SP...

Page 158: ...Measuring plate fully open Ignition switch START position Throttle valve fully closed Throttle valve fully open Stop light switch ON Ignition switch ON Throttle valve open Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON STD voltage Condition Terminals i EG1 135 See page EG1 134 EG1 137 EG1 129 EG1 136 EG1 127 EG1 132 EG1 131 EG1 125 EG1 133 Idling Idl...

Page 159: ...nals BATT and E1 3 Check wiring between ECM terminal E1 and body ground Check wiring between fuse and ECM Check fuse and fusible link Ignition switch ON Try another ECM Repair or replace Repair or replace BATT E 1 STD Voltage No voltage Terminals Condition Replace Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 125 ...

Page 160: ...etween ECM terminal E1 and body ground Check wiring between EFI main relay and ECM terminal B B1 Check wiring between EFI main relay and battery Check fuse fusible link and ignition switch Try another ECM Check EFI main relay B B1 E 1 Repair or replace Repair or replace Repair or replace Repair or replace Replace BAD BAD BAD BAD BAD NO ENGINE MFI SYSTEM EG1 126 ...

Page 161: ...body ground Check wiring between ECM and throttle position sensor Replace or repair throttle position sensor Check throttle position sensor Throttle valve fully closed Throttle valve fully open IDL E2 E21 Throttle valve open Ignition switch ON Try another ECM Replace or repair Replace or repair Refer to No 1 STD Voltage No voltage Terminals Condition Trouble F13877 BAD BAD BAD BAD No ENGINE MFI SY...

Page 162: ...between ECM terminals Vcc and E2 E21 IG SW ON Check throttle position sensor Check wiring between ECM and throttle position sensor Check wiring between ECM and throttle position sensor 2 Check throttle position sensor Perform inspection of Vcc E2 E21 Repair or replace wiring VTA E2 E21 Vcc E2 E21 Try another ECM Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 1 BA...

Page 163: ...ume air flow meter Intake air temperature 20 C 68 F 3 Check volume air flow meter Replace or repair volume air flow meter Replace or repair wiring Measuring plate fully closed Measuring plate fully open Ignition switch ON Try another ECM Vc E2 E21 Ignition switch ON Refer to No 1 STD Voltage Terminals No voltage Condition Trouble Idling BAD BAD No ENGINE MFI SYSTEM EG1 129 ...

Page 164: ...between ECM terminals Vs and E2 E21 IG SW ON Check wiring between ECM and intake air temp sensor Check wiring between ECM and volume air flow meter Check intake air temp sensor 3 Check volume air flow meter Repair or replace wiring Replace volume air flow meter Refer to Vc E2 E21 THA E2 E21 Try another ECM Try another ECM Vs E2 E21 Repair or replace Repair or replace Repair or replace Refer to No ...

Page 165: ...een ECM terminal E1 and body ground Check wiring between ECM and engine coolant temp sensor 3 Check engine coolant temp sensor Coolant temperature 80 C 176 F Replace engine coolant temp sensor Ignition switch ON Try another ECM Repair or replace Repair or replace Refer to No 1 STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 131 ...

Page 166: ...en ECM terminal E1 an body ground Check wiring between ignition switch ST1 terminal and starter terminal 50 Check wiring between ECM and ignition switch terminal ST Ignition switch START position Check starter See ST section Check starter operation Repair or replace Try another ECM Repair or replace Repair or replace STD Voltage STA E 1 Condition No voltage Terminals 6 12v Trouble BAD BAD BAD BAD ...

Page 167: ...l E01 and or E02 and body ground 3 Check resistance of magnetic coil in each injector STD resistance 13 4 14 2 Check wiring between ECM terminal No 10 and or No 20 and battery Check fusible link and ignition switch Ignition switch ON Try another ECM Repair or replace Repair or replace Repair or replace Replace injector No voltage STD Voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SY...

Page 168: ...nal E1 and body ground Check wiring between ECM and igniter Check wiring between igniter and distributor Try another ECM Repair or replace Repair or replace Repair or replace Repair or replace Check distributor Refer to No 1 Check igniter STD Voltage 0 7 1 0 v IGt E1 No voltage Terminals Condition Replace Trouble Idling BAD BAD BAD BAD BAD BAD No ENGINE MFI SYSTEM EG1 134 ...

Page 169: ...g between ECM terminal E1 and body ground Check wiring between ECM terminal W and fuse Fuse blows again No trouble MIL off and engine running Check GAUGE fuse 10 A and MIL Try another ECM Repair or replace Repair or replace Repair or replace STD Voltage No voltage 9 14V Terminals Condition W E1 Trouble BAD BAD No BAD ENGINE MFI SYSTEM EG1 135 ...

Page 170: ...between ECM terminal E1 and body ground Check wiring between ECM and cold start injector Coolant temperature 80 C 176 F 3 Check cold start injector Replace cold start injector Repair or replace wiring Ignition switch START position Try another ECM Refer to No 1 STD Voltage STJ E 1 No voltage Condition Terminal 6 12V Trouble BAD BAD No ENGINE MFI SYSTEM EG1 136 ...

Page 171: ...y ground 1 There is no voltage between ECM terminals STP and E1 Check STOP fuse 15A and stop light switch Check wiring between ECM terminal STP and battery Stop light switch ON Try another ECM Repair or replace Repair or replace Repair or replace 7 5 14 V STD Voltage No voltage STP E1 Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 137 ...

Page 172: ...k wiring between ECM terminal E1 and body ground OK CONTINUED ON PAGE EG1 139 Is air leaking into air induction system Check distributor and ignition system California Vehicles only Try another ECM Check spark plugs Repair or replace Repair or replace Repair or replace Repair air leak BAD BAD YES BAD ENGINE MFI SYSTEM EG1 138 ...

Page 173: ...n of oxygen sensor Check volume air flow meter Check cold start injector Replace oxygen sensor Rich malfunction only Check fuel pressure Repair or replace Repair or replace Repair or replace Repair or replace Check injector System normal Repair wiring BAD BAD BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 139 ...

Page 174: ...d body ground IG SW ON Check wiring between ECM terminal E1 and body ground Check wiring between ECM and EGR gas temp sensor Replace EGR gas temp sensor 3 Check EGR gas temp sensor California Vehicles only Check EGR system Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 1 BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 140 ...

Page 175: ...TOR LAMP BATTERY POSITIVE VOLTAGE THROTTLE POSITION SENSOR FUEL PRESSURE CONTROL VSV THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR INTAKE AIR TEMP SENSOR VOLUME AIR FLOW METER VOLUME AIR FLOW METER OXYGEN SENSOR MAIN OXYGEN SENSOR SUB EGR GAS TEMP SENSOR COLD START INJECTOR STOP LIGHT SWITCH California only STARTER SWITCH SENSOR GROUND ENGINE GROUND ENGINE GROUND ENGINE GROUND SENSOR GROUND KN...

Page 176: ...ed Measuring plate fully open Throttle valve fully closed Throttle valve fully open Ignition switch START position Stop light switch ON Ignition switch ON Ignition switch ON Throttle valve open Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON STD voltage See page Terminals Condition EG1 152 EG1 150 EG1 155 EG1 151 EG1 153 EG1 145 EG1 149 EG1 147 EG1 143 EG1 154 Idling Id...

Page 177: ...and body ground 1 There is no voltage between ECM terminals BATT and E1 Check wiring between fuse and ECM Check fuse and fusible link Ignition switch ON Try another ECM Repair or replace Repair or replace BATT E 1 STD Voltage No voltage Terminals Condition Replace Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 143 ...

Page 178: ...g between ECM terminal E1 and body ground Check wiring between EFI main relay and ECM terminal B B1 Check wiring between EFI main relay and battery Check fuse fusible link and ignition switch Check EFI main relay Try another ECM B B1 E1 Repair or replace Repair or replace Repair or replace Repair or replace Replace BAD BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 144 ...

Page 179: ...ound Check wiring between ECM and throttle position sensor Replace or repair throttle position sensor 3 Check throttle position sensor Throttle valve fully closed Throttle valve fully open IDL E2 E21 Throttle valve open Ignition switch ON Try another ECM Replace or repair Replace or repair Refer to No 1 Condition STD Voltage No voltage Terminals Trouble BAD BAD BAD BAD No ENGINE MFI SYSTEM EG1 145...

Page 180: ...oltage between ECM terminals B B1 and E1 IG SW ON Check wiring between ECM and throttle position sensor Check wiring between ECM and throttle position sensor Perform inspection of Vcc E1 E21 2 Check throttle position sensor 3 Check throttle position sensor Repair or replace wiring VTA E2 E21 Vcc E2 E21 Try another ECM Try another ECM Repair or replace Repair or replace Repair or replace Refer to N...

Page 181: ...ume air flow meter Intake air temperature 20 C 68 F 1 Check volume air flow meter Replace or repair volume air flow meter Measuring plate fully closed Measuring plate fully open Replace or repair wiring Ignition switch ON Try another ECM Ignition switch ON Vc E2 E21 Refer to No 1 STD Voltage No voltage Terminals Condition Trouble Idling BAD BAD No ENGINE MFI SYSTEM EG1 147 ...

Page 182: ... ECM terminal B B1 and body ground IG SW ON Check wiring between ECM and intake air temp sensor Check wiring between ECM and volume air flow meter 2 Check intake air temp sensor 3 Check volume air flow meter THA E2 E21 Repair or replace wiring Replace volume air flow meter Refer to Vc E2 E21 Try another ECM Try another ECM Vs E2 E21 Repair or replace Repair or replace Repair or replace Refer to No...

Page 183: ...tween ECM terminal E1 and body ground Check engine coolant temp sensor Check wiring between ECM and engine coolant temp sensor Coolant temperature 80 C 176 Replace engine coolant temp sensor Repair or replace Ignition switch ON Try another ECM Repair or replace Refer to No 1 STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 149 ...

Page 184: ...between ignition switch ST1 terminal and starter terminal 50 Check wiring between ECM and ignition switch terminal ST Check fusible link battery wiring and ignition switch Ignition switch START position Check starter See ST section Check starter operation Try another ECM Repair or replace Repair or replace Repair or replace STD Voltage No voltage OK Terminals Condition Trouble BAD BAD BAD BAD No E...

Page 185: ...l E01 and or E02 and body ground 3 Check resistance of magnetic coil in each injector STD resistance 13 4 14 2 Check wiring between ECM terminal No 10 and or No 20 and battery Check fusible link and ignition switch Repair or replace Try another ECM Ignition switch ON Repair or replace Repair or replace Replace injector STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SY...

Page 186: ...CM terminal E1 and body ground Check wiring between ECM and igniter Check wiring between igniter and distributor Try another ECM Repair or replace Repair or replace Repair or replace Check distributor Repair or replace Refer to No 1 Check igniter STD Voltage No voltage Terminals Condition Replace Trouble Idling BAD BAD BAD BAD BAD BAD No ENGINE MFI SYSTEM EG1 152 ...

Page 187: ... wiring between ECM terminal E1 and body ground No trouble MIL off and engine running Check wiring between ECM terminal W and fuse Fuse blows again Check GAUGE fuse 10 A and MIL Try another ECM Repair or replace Repair or replace Repair or replace STD Voltage No voltage Trouble Terminals Condition BAD BAD No BAD ENGINE MFI SYSTEM EG1 153 ...

Page 188: ... wiring between ECM terminal E1 and body ground Check wiring between ECM and cold start injector Coolant temperature 80 C 176 F 3 Check cold start injector Replace cold start injector Repair or replace wiring Ignition switch ST position Try another ECM Refer to No 1 STD Voltage No voltage Condition Terminal Trouble BAD BAD No ENGINE MFI SYSTEM EG1 154 ...

Page 189: ...and body ground 1 There is no voltage between ECM terminals STP and E1 Check STOP fuse 15A and stop light switch Check wiring between ECM terminal STP and battery Repair or replace Try another ECM Stop tight switch ON Repair or replace Repair or replace STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 155 ...

Page 190: ...VF and E1 OK CONTINUED ON PAGE EG1 157 Check wiring between ECM terminal E1 and body ground Is air leaking into air induction system Check distributor and ignition system Try another ECM Check spark plugs Repair or replace Repair or replace Repair or replace Repair air leak BAD BAD BAD YES ENGINE MFI SYSTEM EG1 156 ...

Page 191: ... of oxygen sensor Check volume air flow meter Check cold start injector Replace oxygen sensor Rich malfunction only Check fuel pressure Repair or replace Repair or replace Repair or replace Repair or replace Check injector System normal Repair wiring BAD BAD BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 157 ...

Page 192: ...minal B B1 and body ground IG SW ON Check wiring between ECM terminal E and body ground Check wiring between ECM and EGR gas temp sensor Replace EGR gas temp sensor 3 Check EGR gas temp sensor Check EGR system Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 1 BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 158 ...

Page 193: ...R TRANSFER POSITION SWITCH CRUISE CONTROL COMPUTER THROTTLE POSITION SENSOR CRUISE CONTROL COMPUTER BATTERY POSITIVE VOLTAGE THROTTLE POSITION SENSOR INTAKE AIR TEMP SENSOR VOLUME AIR FLOW METER VOLUME AIR FLOW METER OXYGEN SENSOR MAIN PATTERN SELECT SWITCH OXYGEN SENSOR SUB EGR GAS TEMP SENSOR COLD START INJECTOR STOP LIGHT SWITCH STARTER SWITCH SENSOR GROUND SENSOR GROUND ENGINE GROUND ENGINE GR...

Page 194: ... plate fully closed Measuring plate fully open Throttle valve fully closed Throttle valve fully open Ignition switch START position Throttle valve open Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON STD voltage Terminals See page Condition EG1 167 EG1 161 EG1 170 EG1 163 EG1 171 EG1 165 EG1 168 EG1 173 EG1 169 EG1 172 Idling Idling...

Page 195: ...and body ground 1 There is no voltage between ECM terminals BATT and E1 Check wiring between fuse and ECM Try another ECM Check fuse and fusible link Ignition switch ON Repair or replace Repair or replace BATT E 1 BAD STD Voltage No voltage Terminals Condition Replace Trouble BAD BAD No ENGINE MFI SYSTEM EG1 161 ...

Page 196: ...g between ECM terminal E1 and body ground Check wiring between EM main relay and ECM terminal B B1 Check wiring between EFI main relay and battery Check fuse fusible link and ignition switch Check EF I main relay Try another ECM B B E1 Repair or replace Repair or replace Repair or replace Repair or replace Replace BAD BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 162 ...

Page 197: ...ck wiring between ECM and throttle position sensor Replace or repair throttle position sensor 3 Check throttle position sensor Throttle valve fully dosed Throttle valve fully open Throttle valve open IDL E2 E21 Ignition switch ON Try another ECM Replace or repair Replace or repair Refer to No 1 4 5 5 5 V STD Voltage 3 2 4 9 V 0 3 0 8 V No voltage 9 14V Condition Terminals Trouble BAD BAD BAD BAD N...

Page 198: ...ge between ECM terminals Vcc and E2 IG SW ON Check wiring between ECM and throttle position sensor Check wiring between ECM and throttle position sensor 3 Check throttle position sensor Check throttle position sensor Perform inspection of Vcc E2 E21 Repair or replace wiring VTA E2 E21 Vcc E2 E21 Try another ECM Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 11 BA...

Page 199: ...ume air flow meter Intake air temperature 20 C 68 F 3 Check volume air flow meter Replace or repair volume air flow meter Measuring plate fully closed Measuring plate fully open Replace or repair wiring Ignition switch ON Vc E2 E21 Try another ECM Ignition switch ON Refer to No 1 STD Voltage No voltage Terminals Condition Trouble Idling BAD BAD No ENGINE MFI SYSTEM EG1 165 ...

Page 200: ...n ECM terminal B B1 and body ground IG SW ON 2 Check intake air temp sensor Check wiring between ECM and intake air temp sensor Check wiring between ECM and volume air flow meter Check volume air flow meter Replace volume air flow meter Repair or replace wiring Refer to Vcc E2 E21 THA E2 E21 Try another ECM Try another ECM Vs E2 E21 Repair or replace Repair or replace Repair or replace Refer to No...

Page 201: ...ween ECM terminal E1 and body ground Check wiring between ECM and engine coolant temp sensor Check engine coolant temp sensor Coolant temperature 80 C 176 F Replace engine coolant temp sensor Ignition switch ON Try another ECM Repair or replace Repair or replace Refer to No 1 STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 167 ...

Page 202: ...ignition switch ST1 terminal and starter terminal 50 Check wiring between ECM and ignition switch terminal ST Check fusible link battery wiring and ignition switch Ignition switch START position Check starter See ST section Try another ECM Check starter operation Repair or replace Repair or replace Repair or replace STD Voltage STA E 1 No voltage Terminals Condition 6 12V Trouble BAD BAD BAD BAD N...

Page 203: ...l E01 and or E02 and body ground 3 Check resistance of magnetic coil in each injector STD resistance 13 4 14 2 Ω Check wiring between ECM terminal No 10 and or No 20 and battery Check fusible link and ignition switch Ignition switch ON Try another ECM Repair or replace Repair or replace Repair or replace Replace injector STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI ...

Page 204: ...ECM terminal E1 and body ground Check wiring between ECM and igniter Check wiring between igniter and distributor Try another ECM Repair or replace Repair or replace Repair or replace Repair or replace Check distributor Refer to No 1 Check igniter STD Voltage No voltage Terminals Condition Replace Trouble Idling BAD BAD BAD BAD BAD BAD No ENGINE MFI SYSTEM EG1 170 ...

Page 205: ... wiring between ECM terminal E1 and body ground Fuse blows again Check wiring between ECM terminal W and fuse No trouble MIL off and engine running Check GAUGE fuse 10 A and MIL Try another ECM Repair or replace Repair or replace Repair or replace STD Voltage No voltage Terminals Condition Trouble BAD BAD No BAD ENGINE MFI SYSTEM EG1 171 ...

Page 206: ... wiring between ECM terminal E1 and body ground Check wiring between ECM and cold start injector Coolant temperature 80 C 176 F 3 Check cold start injector Replace cold start injector Repair or replace wiring Ignition switch START position Try another ECM Refer to No 1 STD Voltage No voltage Condition Terminal Trouble BAD BAD No ENGINE MFI SYSTEM EG1 172 ...

Page 207: ... and body ground 1 There is no voltage between ECM terminals STP and E1 Check STOP fuse 15A and stop light switch Check wiring between ECM terminal STP and battery Repair or replace Stop light switch ON Try another ECM Repair or replace Repair or replace STD Voltage Condition No voltage Terminals Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG1 173 ...

Page 208: ...F and E1 3 Check wiring between ECM terminal E1 and body ground OK CONTINUED 4N PAGE EG1 175 Is air leaking into air induction system Check distributor and ignition system Try another ECM Check spark plugs Repair or replace Repair or replace Repair or replace Repair air leak BAD BAD BAD YES ENGINE MFI SYSTEM EG1 174 ...

Page 209: ... of oxygen sensor Check volume air flow meter Check cold start injector Rich malfunction only Replace oxygen sensor Check fuel pressure Repair or replace Repair or replace Repair or replace Repair or replace Check injector System normal Repair wiring BAD BAD BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 175 ...

Page 210: ...minal B B1 and body ground IG SW ON Check wiring between ECM terminal E1 and body ground Check wiring between ECM and EGR gas temp sensor Replace EGR gas temp sensor Check EGR gas temp sensor Check EGR system Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 1 BAD BAD BAD BAD ENGINE MFI SYSTEM EG1 176 ...

Page 211: ...FUEL PUMP ENGINE MFI SYSTEM EG1 177 ...

Page 212: ...Disconnect the cable from the negative terminal of the battery ON VEHICLE INSPECTION 1 CHECK FUEL PUMP OPERATION a Turn the ignition switch ON HINT Do not start the engine b Using SST connect terminals Fp and B of the DLC1 SST 09843 18020 HINT The DLC1 is located near the No 2 relay block d Put a suitable container or shop towel under the cold start injector pipe e Slowly loosen the union bolts of...

Page 213: ...38 44 psi q Reconnect the vacuum hose to the pressure regulator r Measure the fuel pressure at idling Fuel pressure 226 265 kPa 2 3 2 6 kgf cm2 33 37 psi If not within the specified pressure check the vacuum hose and pressure regulator s Stop the engine Check that the fuel pressure remains above 147 kPa 1 5 kgf cm2 21 psi for 5 minutes after the engine is turned off g Install a gasket SST another ...

Page 214: ...econnect the cold start injector pipe to the delivery pipe and cold start injector v Connect the wiring connector to the cold start injec tor w Start the engine and check for fuel leakage FUEL PUMP REMOVAL 1 DRAIN FUEL FROM FUEL TANK CAUTION Do not smoke or work near an open flame when working on the fuel pump 2 REMOVE FUEL TANK 3 REMOVE FUEL PUMP BRACKET a Remove the seven bolts b Pull out the fu...

Page 215: ... a Place the bracket with a new gasket on the fuel tank b Install and torque the seven screws Torque 3 8 N m 40 kgf cm 34 in lbf 4 INSTALL FUEL TANK NOTICE Tighten the fuel tank mounting bolts etc to the specified torque 4 REMOVE FUEL PUMP a Remove the two nuts and disconnect the wires from the fuel pump b Pull off the fuel pump from the lower side of the bracket c Remove the fuel pump from the fu...

Page 216: ...to the specified torque Push in the pipe and insert type hose to the spe cified position and install the clip to the specified location If reusing the hose reinstall the clip at the original location 5 REFILL WITH FUEL ENGINE MFI SYSTEM EG1 182 ...

Page 217: ...olts and cold start injector with the gasket ON VEHICLE INSPECTION MEASURE RESISTANCE OF COLD START INJECTOR a Disconnect the cold start injector connector b Using ohmmeter check the resistance of the injector Resistance 2 4 c Connect the cold start injector connector COLD START INJECTOR REMOVAL 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT COLD START INJECTOR CONNEC TOR COLD S...

Page 218: ...e Put a container under the injector f Turn the ignition switch ON HINT Do not start the engine h Connect the test probes of the SST to the battery and check that the fuel injection is as shown SST 09842 30050 NOTICE Perform this check within the shortest possible time COLD START INJECTOR INSPECTION CHECK INJECTION OF COLD START INJECTOR HINT The engine should be cold a Remove the cold start injec...

Page 219: ...ew gaskets Torque 19 N m 195 kgf cm 14 ft lbf 2 CONNECT COLD START INJECTOR CONNECTOR 3 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 4 CHECK FOR FUEL LEAKAGE i Disconnect the test probes from the battery and check fuel leakage from the injector Fuel drop One drop or less per minute j After checking remove SST and restore the following parts to their original conditions DLC1 Ignition switch Cold s...

Page 220: ...NECT VACUUM SENSING HOSE 3 DISCONNECT FUEL HOSE a Put a suitable container or shop towel under the pressure regulator b Disconnect the fuel hose the pressure regulator 4 REMOVE PRESSURE REGULATOR Loosen the lock nut and remove pressure regulator PRESSURE REGULATOR REMOVAL 1 DISCONNECT VACUUM SENSING HOSE 2 REMOVE NO 1 EGR PIPE ON VEHICLE INSPECTION CHECK FUEL PRESSURE See page EG1 178 FUEL PRESSUR...

Page 221: ...to engine rpm b If you have no sound scope you can check the in jector transmission operation with you finger If no sound or an unusual sound is head check the wiring connector injector or injection signal from ECM 2 MEASURE RESISTANCE OF INJECTOR a Unplug the wiring connector from the injector b Using an ohmmeter measure the resistance of both terminals Resistance 13 4 14 2 INJECTOR ENGINE MFI SY...

Page 222: ...INJECTOR CAUTION Keep injector clear of sparks during the test a Disconnect the fuel hose from the fuel filter outlet b Connect SST Union to the fuel filter outlet SST 09268 41045 90405 09015 HINT Use the vehicle s fuel filter 6 REMOVE DELIVERY PIPE WITH INJECTORS Remove two bolts and then remove the delivery pipe with the injectors 5 DISCONNECT FUEL HOSE FROM DELIVERY PIPE Remove the bolt union b...

Page 223: ... cylinder Test each injector two or three times SST 09842 30070 Volume 45 55 cm3 15 sec 2 7 3 4 cu in Difference between each injector 6 cm3 0 4 cu in or less If not within specified volume replace the injector 2 CHECK LEAKAGE a In the condition above disconnect SST from the battery and check for fuel leakage from the injector nozzle SST 09842 30060 Fuel drop One drop or less per minute b Disconne...

Page 224: ...e may be incorrect installation of O rings Re place O rings again after removing the injectors INJECTORS INSTALLATION 1 INSTALL INJECTORS INTO DELIVERY PIPE a Install the grommet and anew 0 ring to the injector c Make sure that the injectors rotate smoothly HINT If the injectors do not rotate smoothly the O rings are probably incorrectly installed Replace the O rings b Apply a light coat of gasoli...

Page 225: ...n page EG1 225 7 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 3 CONNECT FUEL HOSE TO DELIVERY PIPE a Install the fuel hose with a bolt b Install the union bolt and new gaskets Torque the union bolt Torque 44 N m 450 kgf cm 33 ft lbf 4 CONNECT WIRES See step 5 on page EG1 36 Turn the injector so that the injector positioning guide is aligned with the positioning rib of the delivery pipe d install ...

Page 226: ...FUEL TANK AND LINE COMPONENTS ENGINE MFI SYSTEM EG1 192 ...

Page 227: ...s or damage c Inspect the fuel tank for deformations cracks or fuel leakage d Inspect the filler neck for damage or fuel leakage e Hose and tube connections are as shown in the il lustration If a problem is found repair or replace the parts as necessary PRECAUTIONS 1 Always use new gaskets when replacing the fuel tank or component part 2 Apply the proper torque to all parts tightened ENGINE MFI SY...

Page 228: ...hmmeter measure the resistance between each terminal ON VEHICLE INSPECTION MEASURE RESISTANCE OF VOLUME AIR FLOW METER If not within specification replace the volume air flow meter VOLUME AIR FLOW VAF METER Between terminals Temperature Resistance ENGINE MFI SYSTEM EG1 194 ...

Page 229: ...and bolt Torque the nuts and bolt 2 INSTALL AIR CLEANER CAP WITH VAF METER a Install the air cleaner cap with VAF meter to the air cleaner case b Connect the VAF meter connector VAF METER INSPECTION MEASURE RESISTANCE OF VAF METER Using an ohmmeter measure the resistance between each terminal by moving the measuring plate HINT Resistance between terminals E2 and Vs will change in a wave pattern as...

Page 230: ...3 INSTALL INTAKE AIR CONNECTOR ENGINE MFI SYSTEM EG1 196 ...

Page 231: ...nd stop lever Using an ohmmeter check the resistance between each terminal ON VEHICLE INSPECTION 1 INSPECT THROTTLE BODY a Check that the throttle linkage moves smoothly b Check the vacuum at each port Start the engine Check the vacuum with your finger THROTTLE BODY At 3 500 rpm No vacuum No vacuum No vacuum Port name At idling Vacuum Vacuum Vacuum ENGINE MFI SYSTEM EG1 197 ...

Page 232: ...ngine speed at 2 500 rpm b Plug the VTV hole with your finger c Release the throttle valve d Check the DP is set DP setting speed 2 000 rpm C Remove cap filter and separator from DP Clearance between lever and stop screw Throttle valve fully open 0 57 mm 10 0224 in 0 85 mm 0 0335 in 3 1 12 1 k 0 47 8 1 k Between terminals 2 3 k or less 3 9 9 4 k 0 mm 10 in Resistance VTA E2 VTA E2 Vcc E2 IDL E2 ID...

Page 233: ...rm up engine Allow the engine to warm up to normal operating temperature B Check idle speed Idle speed 2WD 750 50 rpm 4WD 850 50 rpm C Check and adjust throttle opener setting speed a Disconnect the vacuum hose from the throttle opener and plug the hose end a Disconnect the vacuum hose from the throttle opener and plug the hose end c Release the throttle valve d Check that the throttle opener is s...

Page 234: ...T THROTTLE SENSOR CONNECTOR THROTTLE BODY REMOVAL 1 REMOVE INTAKE AIR CONNECTOR 2 DRAIN COOLANT 3 DISCONNECT ACCELERATOR CABLE 6 REMOVE THROTTLE BODY Remove the three bolts and but and remove the throttle body and gasket e If not as specified adjust with the throttle opener adjusting screw f Reconnect the vacuum hose to the throttle opener ENGINE MFI SYSTEM EG1 200 ...

Page 235: ...ully closed 3 CHECK THROTTLE POSITION SENSOR See step 2 on page EG1 197 c Gradually turn the sensor clockwise until the ohm meter deflects and secure the sensor with the two screws d Using a thickness gauge recheck the continuity be tween terminals IDL and E2 b Insert a thickness gauge 0 70 mm or 0 0276 in between the throttle stop screw and lever and con nect the ohmmeter to terminals IDL and E2 ...

Page 236: ...tration c Turn the sensor clockwise and temporarily install the two screws 5 ADJUST THROTTLE POSITION SENSOR See step 4 on page EG1 202 2 REMOVE AUXILIARY AIR VALVE Remove the four screws air valve and O ring 3 M T REMOVE DASH POT 4 A T REMOVE THROTTLE OPENER THROTTLE BODY INSTALLATION 1 INSTALL THROTTLE BODY Using a new gasket install the throttle body three bolts and nut Torque 19 N m 195 kgf cm...

Page 237: ...TOR 3 CONNECT FOLLOWING HOSES a Emission control hoses b No 2 and No 3 water by pass hoses c PCV hose d with A C A C idle up hose 4 CONNECT ACCELERATOR CABLE 5 INSTALL AIR INTAKE CONNECTOR 6 FILL WITH COOLANT ENGINE MFI SYSTEM EG1 203 ...

Page 238: ... screw is in the engine rpm should drop After warm up When the idle speed adjusting screw is in the engine rpm should drop below idle speed stop AUXILIARY AIR VALVE REMOVAL 1 REMOVE THROTTLE BODY See page EG1 200 2 REMOVE AUXILIARY AIR VALVE See step 2 on page EG1 202 AUXILIARY AIR VALVE INSTALLATION w 1 INSTALL AUXILIARY AIR VALVE See step 2 on page EG1 202 AUXILIARY AIR VALVE ENGINE MFI SYSTEM E...

Page 239: ...2 INSTALL THROTTLE BODY See page EG1 202 ELECTRONIC PARTS LOCATION ENGINE MFI SYSTEM EG1 205 ...

Page 240: ... terminals 2 and 4 c Check that there is no continuity between terminals 3 and 4 If operation is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as specified replace the relay EFI MAIN RELAY ENGINE MFI SYSTEM EG1 206 ...

Page 241: ...etween terminals B and FP If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals STA and E1 b Using an ohmmeter check that there is continuity between terminals B and FP c Apply battery voltage across terminals B and FC d Check that there is continuity between terminals B and FP If operation is not as specified replace the relay CIRCU...

Page 242: ... SWITCH a Disconnect the connector b Using an ohmmeter measure the resistance between terminals COLD START INJECTOR TIME SWITCH Coolant temperature below 10 C 54 F above 30 C 86 F Between terminals Resistance Ω STA Ground STA STJ 65 90 30 50 30 90 V01952 ENGINE MFI SYSTEM EG1 208 ...

Page 243: ...ERATURE ECT SENSOR INSPECTION a Disconnect the connector b Using an ohmmeter measure the resistance between the terminals Resistance Refer to the chart above ENGINE COOLANT TEMPERATURE ECT SENSOR ENGINE MFI SYSTEM EG1 209 ...

Page 244: ...heck that air comes out of pipe G 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between the terminal and the VSV body If there is continuity replace the VSV c Disconnect the battery d Blow air into pipe E and check that air comes out of pipe F If a problem is found repair or replace the VSV FUEL PRESSURE CONTROL SYSTEM ENGINE MFI SYSTEM EG1 210 ...

Page 245: ...EN CIRCUIT Using an ohmmeter measure the resistance between both terminals as illustrated Specified resistance 30 50 Ω at 20 C 68 F If resistance is not within specification replace the VSV ENGINE MFI SYSTEM EG1 211 ...

Page 246: ...ygen sensor with the engine at 2 500 rpm for approx 94 seconds And maintain engine speed at 2 500 rpm Disconnect terminals TE1 and E1 of the DLC 1 And maintain engine speed 2 500pm Connect terminals TE1 and E1 of the DLC1 And maintain engine speed at 2 500 rpm Warm p the oxygen sensor with the engine at 2 500 rpm for approx 90 seconds Check the number of times the voltometer needle fluctuates in 1...

Page 247: ...e 26 Malfunction code s ex code 21 code 25 and code 261 Connect terminals TE1 and E 1of the DLC 1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VFI and E1 Read and record diagnostic trouble codes Normal code code 21 code 25 and code 26 CONTINUED FROM PAGE EG1 212 Repair the re...

Page 248: ...TEMP SENSOR Using an ohmmeter measure the resistance between both terminals Resistance 69 89 k at 50 C 122 F 11 15 k at 100 C 212 F 2 4 k at 150 C 302 F If the resistance is not as specified replace the sensor EGR GAS TEMPERATURE SENSOR ENGINE MFI SYSTEM EG1 214 ...

Page 249: ...each terminal HINT Perform all voltage measurements with the con nectors connected Verify that the battery voltage is 11 V or more when the ignition switch is ON ENGINE CONTROL MODULE ECM ECM INSPECTION HINT The MFI circuit can be checked by measuring the voltage and resistance at the wiring connectors of the ECM ENGINE MFI SYSTEM EG1 215 ...

Page 250: ...losed Ignition switch START position Measuring plate fully closed Ignition switch START position Measuring plate fully open Throttle valve fully open Stop light switch ON Throttle valve open Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON ECM Terminals STD voltage Terminals Condition Idling Idling ENGINE MFI SYSTEM EG1 216 ...

Page 251: ...inals The tester probe should be inserted into the wiring connector from the wiring side Check the resistance between each terminal of the wiring connectors Disconnect the connectors from the ECM Measure the resistance at each terminal ENGINE MFI SYSTEM EG1 217 ...

Page 252: ...ake air temperature 20 C 68 F Measuring plate fully closed Measuring plate fully open Throttle valve fully closed Throttle valve fully closed Throttle valve fully open Throttle valve open Resistance 4k 1 ECM Terminals Terminals Condition Cold Hot ENGINE MFI SYSTEM EG1 218 ...

Page 253: ...le with this ignition system we recommend that you confirm the compatibility of yours before use 3 INSPECT FUEL CUT OPERATION a Increase the engine speed to at least 2 500 rpm b Check for injector operating sound c Check that when the throttle lever is released injector operation sound stops momentarily and then res umes HINT The vehicle should be stopped Accessories switched OFF 2WD A T stop ligh...

Page 254: ... fully closed angle Throttle valve fully open position Throttle position sensor Engine coolant temp sensor Start injector time switch Resistance Fuel leakage Volume Air Flow Meter Cold start injector Pressure regulator Fuel pressure Throttle body STA Ground at No vacuum VSV FPU STA STJ Resistance Resistance Resistance Resistance Injector ENGINE MFl SYSTEM EG1 220 ...

Page 255: ...ications Cont d Coolant temperature 80 C 1 76 F Coolant temperature 80 C 176 F Intake air temperature 20 C 68 F Measuring plate fully closed Ignition SW START position Measuring plate fully open Throttle valve fully closed Ignition SW START position Throttle valve fully open Oxygen sensor heater EGR gas temp sensor Stop light switch ON Throttle valve open Ignition SW ON Ignition SW ON Ignition SW ...

Page 256: ...plate fully open Delivery pipe x Intake manifold Fuel pipe x Cold start injector Throttle valve fully closed Throttle valve fully closed Fuel filter x Fuel filter bracket Throttle valve fully open Fuel hose x Fuel main tube Delivery pipe x Fuel pipe Delivery pipe x Fuel tube ECM Resistance Throttle valve open Fuel hose x Fuel filter Resistance k Fuel tank x Body Fuel drain plug Part tightened Term...

Page 257: ...lief valve is opened by the pressure and lets steam escape through pipe The vacuum valve opens to allow atmos pheric air to enter to alleviate the vacuum which develops in the cooling system after the engine is stopped and the coolant temperature drops RESERVOIR TANK The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric expansion when the coolant ...

Page 258: ... of coolant through the engine and thus permitting the engine to warm up rapidly When the coolant temperature has risen the valve opens allowing the coolant in the engine to circulate through the radiator Wax inside the thermostat expands when heated and contracts when cooled Heating the wax thus generates pressure which overpowers the force of the spring which keeps the valve closed thus opening ...

Page 259: ... capacity w heater or air conditioner Ex 4WD A T 8 4 liters 8 9 US qts 7 4 Imp qts 4WD A T 9 1 liters 9 6 US qts 8 0 Imp qts e Install the radiator cap f Start the engine and check for leaks g Recheck the coolant level and refill as necessary COOLANT CHECK AND REPLACEMENT 1 CHECK ENGINE COOLANT LEVEL IN RESERVOIR TANK The coolant level should be between the LOW and Full lines If low check for leak...

Page 260: ...DRAIN COOLANT See step 3 on page EG1 225 2 w PS REMOVE PS BELT 3 with A C REMOVE A C BELT 4 REMOVE FLUID COUPLING WITH FAN AND WATER PUMP PULLEY See step 3 on page EG1 40 WATER PUMP COMPONENTS ENGINE COOLING SYSTEM EG1 226 ...

Page 261: ... on page EG1 44 3 with A C INSTALL A C BELT See page MA 6 4 w PS INSTALL PS BELT See page MA 6 5 REFILL COOLANT See page EG1 225 WATER PUMP INSPECTION 1 INSPECT WATER PUMP BEARING Check that the water pump bearing moves smoothly and quietly 5 REMOVE WATER PUMP Remove the six bolts three nuts water pump and gasket 2 INSPECT FLUID COUPLING Check the fluid coupling for damage and silicone oil leakage...

Page 262: ...closed and replace if it is not tight THERMOSTAT INSTALLATION 1 PLACE THERMOSTAT IN INTAKE MANIFOLD a Place a new gasket to the thermostat b Install the thermostat to the intake manifold c Install the water outlet with the two bolts Torque 19 N m 195 kgf cm 14 ft lbf 2 CONNECT RADIATOR INLET HOSE 3 CONNECT FOLLOWING HOSES 3 DISCONNECT RADIATOR INLET HOSE 4 REMOVE THERMOSTAT a Remove the two bolts ...

Page 263: ...replace the radiator cap RADIATOR RADIATOR CLEANING Using water or a steam cleaner remove mud and dirt from the radiator core NOTICE If using a high pressure type cleaner be car eful not to deform the fins of the radiator core For example keep a distance of more than 40 50 cm 15 75 19 69 in between the radiator core and cleaner nozzle when the cleaner nozzle pressure is 2 942 3 432 kPa 30 35 kgf c...

Page 264: ...iator with coolant and attach a radiator cap tester b Warm up the engine c Pump it to 118 kPa 1 2 kgf cm2 17 1 psi and check that the pressure does not drop If the pressure drops check for leaks from the hoses radiator or water pump If no external leaks are found check the heater core block and intake manifold RADIATOR REMOVAL 1 DRAIN COOLANT 2 REMOVE ENGINE UNDER COVER 3 REMOVE AIR INTAKE CONNECT...

Page 265: ...Valve opening temperature Starts to open at Fully opens at Valve opening travel TORQUE SPECIFICATIONS Water Outlet x Intake Manifold Relief valve opening pressure Part tightened STD Limit Thermostat Radiator ENGINE COOLING SYSTEM EG1 231 ...

Page 266: ...DESCRIPTION A fully pressurized fully filtered lubrication system is used in this engine LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM EG1 232 ...

Page 267: ...GULATOR RELIEF VALVE At high engine speeds the oil pump supplies more oil to each part than is necessary For this reason an oil pressure regulator which works to prevent an oversupply oil is installed on the oil pump During normal oil supply a coil spring and valve keep the by pass closed but when too much oil is being supplied the pressures become extremely high over powering the force of the spr...

Page 268: ...eplacer RECOMMENDED TOOLS 09213 36020 Timing Gear Remover 09090 04000 Engine Sting Device 09200 00010 Engine Adjust Kit 09032 00100 Oil Pan Seal Cutter 09905 00013 Snap Ring Pliers 09228 07500 Oil Filter Wrench LUBRICANT EQUIPMENT For suspending engine Oil pressure gauge Crankshaft front oil seal Torque wrench Classification 3 3 3 8 4 2 4 0 4 5 5 1 3 8 4 3 4 8 Capacity Imp qts US qts Liters Item E...

Page 269: ... the oil pressure sender gauge OIL PRESSURE CHECK 1 CHECK OIL QUALITY Check the oil for deterioration entry of water disco loring or thinning If oil quality is poor replace Oil grade API grade SG Energy Conserving ll multigr ade engine oil Recommended viscosity is as shown 2 CHECK OIL LEVEL The oil level should be between the L and F marks on the level gauge If low check for leakage and add oil up...

Page 270: ... not use gasoline thinners or solvents In order to preserve the environment used oil and used oil filters must be disposed of only at desig nated disposal sites 1 DRAIN ENGINE OIL a Remove the oil filter cap b Remove the oil dipstick c Remove the oil drain plug and drain the oil into a container 2 REPLACE OIL FILTER a Using SST remove the oil filter located on right side of the engine block SST 09...

Page 271: ...s necessary HINT Insert the oil dipstick with the curved tip poi nted toward the engine Oil capacity Drain and refill w o Oil filter change 3 8 liters 4 0 US qts 3 3 Imp qts w Oil filter change 4 3 liters 4 5 US qts 3 8 Imp qts Dry fill 4 8 liters 5 1 US qts 4 2 Imp qts ENGINE LUBRICATION SYSTEM EG1 237 ...

Page 272: ...leaned 1 REMOVE OIL PAN See steps 3 and 4 on page EG1 39 2 REMOVE OIL STRAINER Remove the four bolts holding the oil strainer 3 REMOVE DRIVE BELTS 4 REMOVE CRANKSHAFT PULLEY See steps 4 on page EG1 40 5 with A C REMOVE A C COMPRESSOR AND BRACKET OIL PUMP COMPONENTS ENGINE LUBRICATION SYSTEM EG1 238 ...

Page 273: ...rew the relief valve plug and gasket and remove the spring and the relief valve 2 REMOVE DRIVEN AND DRIVE GEARS 7 REMOVE OIL PUMP DRIVE SPLINE HINT If the oil pump drive spline cannot be removed by hand use SST to remove the pump drive spline and crankshaft together See page EG1 42 SST 09213 36020 b Remove the five bolts the oil pump assembly and O ring 6 REMOVE OIL PUMP ASSEMBLY a Loosen the oil ...

Page 274: ...shown Standard clearance 0 03 0 09 mm 0 00 12 0 0035 in Maximum clearance 0 15 mm 0 006 in If the clearance is greater than maximum replace the gears and or body PRESSURE REGULATOR INSPECTION Coat the valve piston with engine oil and check that it falls smoothly into the valve hole by its own weight If the valve does not fall smoothly replace the valve and or oil pump assembly FRONT OIL SEAL REPLA...

Page 275: ...ene or gasoline OIL PUMP ASSEMBLY See page EG1 238 a Install the relief valve and spring in the body and screw on the relief valve plug with a new gasket b Insert the drive and driven gears into the pump body b Apply sealant to 2 or 3 threads of the bolt end Sealant Part No 08833 00070 THREE BOND 1324 or equivalent HINT This adhesive will not harden while exposed to air It will act as a sealant or...

Page 276: ...gf cm 9 ft lbf d Torque the relief valve plug Torque 37 N m 375 kgf cm 27 ft Ibf 3 INSTALL CRANKSHAFT PULLEY See step 8 on page EG1 44 4 INSTALL AND ADJUST DRIVE BELT See page MA 6 5 INSTALL OIL STRAINER See step 2 on page EG1 70 6 INSTALL OIL PAN See step 13 on page EG1 44 ENGINE LUBRICATION SYSTEM EG1 242 ...

Page 277: ...r to crescent TORQUE SPECIFICATIONS STD Limit STD Limit STD Limit Cylinder Block x Oil Cooler Relief Valve Cylinder Block x Rear Oil Seal Retainer Relief valve operating pressure Cylinder Block x Oil Strainer Cylinder Block x Oil Pan Oil pan x Drain Plug Body clearance Side clearance Part tightened STD Limit Oil pump ENGINE LUBRICATION SYSTEM EG1 243 ...

Page 278: ...3VZ E ENGINE ENGINE EG2 1 ...

Page 279: ...DESCRIPTION The 3VZ E engine is a V 6 3 0 liter OHC 12 valve engine OPERATION ENGINE MECHANICAL ENGINE ENGINE MECHANICAL EG2 2 ...

Page 280: ...d of the resin type No 1 and No 2 above and below the fan bracket and the No 3 and No 4 which are made of steel sheet to make removal of the intake manifold easier The pistons are made of high temperature resistant aluminum alloy and the piston head is concaved to prevent interference with the valves The piston pins are the semi floating type with the connecting rods and pins pressure fitted so th...

Page 281: ...rankshaft Pulley Gear Replacer 09221 00181 B 09213 5 012 Crankshaft Pulley Holding Tool 09221 25024 Piston Pin Remover Replacer 09201 41020 Valve Stem Oil Seal Replacer 09202 43013 Valve Spring Compressor 09213 31021 Crankshaft Pulley Puller Crankshaft timing pulley Camshaft oil seal 09032 00100 Oil Pan Sea Cutter Oil pan Oil pan baffle plate ENGINE ENGINE MECHANICAL EG2 4 ...

Page 282: ...Replacer Oil pressure sender gauge 09248 55020 Valve Clearance Adjust Tool Set 09330 00021 Companion Flange Holding Tool 09309 37010 Transmission Bearing Replacer 09816 30010 Oil Pressure Switch Socket 09278 54012 Drive Shaft Holding Tool 09843 18020 Diagnosis Check Wire Camshaft timing pulley Crankshaft front oil seal Crankshaft pulley Knock sensor ENGINE ENGINE MECHANICAL EG2 5 ...

Page 283: ...cific gravity gauge 09258 00030 Hose Plug Set 09904 00010 Expander Set Engine tune up tester Piston ring compressor Connecting rod aligner EQUIPMENT Piston ring expander Compression gauge For suspending engine Belt tension gauge Magnetic finger Cylinder gauge Dye penetrant Caliper gauge CD HC meter Dial indicator Micrometer Heater ENGINE ENGINE MECHANICAL EG2 6 ...

Page 284: ...nd recommended viscosity oil 4 3 liters 4 5 US qts 3 8 Imp qts 4 0 liters 4 2 US qts 3 5 Imp qts 4 5 liters 4 8 US qts 4 0 Imp qts 4 2 liters 4 4 US qts 3 7 Imp qts 2WD M T A T 4WD M T A T COOLANT 5 4 liters 5 7 US qts 4 8 Imp qts 5 3 liters 5 6 US qts 4 7 Imp qts Torque wrench Precision straight edge Engine coolant LUBRICANT Ethylene glycol base Valve seat cutter Vernier calipers Spring tester St...

Page 285: ...ivalent Water outlet No 2 idler pulley Water pump No 1 water by pass pipe Camshaft bearing cap Cylinder head cover Rear oil seal retainer Oil pump Oil pan baffle plate Oil pan Oil pressure sender gauge 08826 00080 Seal packing or equivalent 08826 00080 Seal packing or equivalent Flywheel bolt Drive plate bolt ENGINE ENGINE MECHANICAL EG2 8 ...

Page 286: ...h engine idle speed Battery often discharge Low engine idle speed Knock Sensor Circuit Engine does not crank Fuel Pressure Regulator Idle Speed Control Valve Starter keeps running Engine cranks slowly During A C operation No initial combustion Engine Coolant Temp Sensor Circurt PNP Signal Circuit RPM Signal Circuit STA Signal Circuit Poor fuel economy Cold Start System A C Signal Circuit When N to...

Page 287: ...e Circuit Opening Relay PNP SW or Clutch Start SW Brakes drag even when released Cooling Fan System Accelerator Pedal Link Throttle Opener Fuel Cut System EFI Main Relay Valve Clearance Fuel Leakage Compression Starter Relay EGR System Fuel Quality Oil Leakage AT 83 144 CL 4 Spark Plug Distributor Dash Pot EG2 254 Starter EG2 245 EG2 246 EG2 148 EG2 249 EG2 238 EG2 257 Clutch EG2 237 EG2 30 EG2 18...

Page 288: ...wly Engine Coolant Temp Sender Gauge No initial combustion Oil Pressure Switch Flywheel or Drive Plate When N to D shift Crankshaft Bearing Poor fuel economy incorrect first idle High oil pressure Engine overcool Low oil pressure Poor drivability Engine overheat Suspect area Does not sta rt Cylinder Block Difficult to start Water Pump Valve Timing Cylinder Head Rough idling Engine stall Hot engine...

Page 289: ...according to the manufacturer s directions Using coolant which includes more than 50 ethylene glycol but not more than 70 is rec ommended NOTICE Do not use a alcohol type coolant The coolant should be mixed with demineralized water or distilled water c Reinstall the radiator cap TUNE UP 1 CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the LOW and FULL lines...

Page 290: ...liters 4 8 US qts 4 0 Imp qts w o Oil filter change 4 2 liters 4 4 US qts 3 7 Imp qts 1 REMOVE AIR FILTER 2 INSPECT AND CLEAN AIR FILTER a Visually check that the air filter is not excessively damaged or only HINT Oiliness may indicate a stuck PCV valve If necessary replace the air filter b Clean the air filter with compressed air First blow from the inside thoroughly then blow off the outside of ...

Page 291: ...are not loose or cor roded b Check the fusible link and fuses for continuity BATTERY INSPECTION 1 Ex Delco Battery CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL a Check the electrolyte quantity of each cell If insufficient refill with distilled or purified water b Check the specific gravity of each cell Standard specific gravity at 20 C 68 F 1 25 1 27 for 55D 23R type 1 27 1 29 for 80D 26R ...

Page 292: ... CORDS INSPECTION 1 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS Disconnect the high tension cords at the rubber boot Do not pull on the curds NOTICE Pulling on or bending the cords may damage the conductor inside 2 REMOVE DISTRIBUTOR CAP WITH HIGH TENSION CORDS 3 INSPECT HIGH TENSION CORD TERMINALS Check the terminals for corrosion breaks or distor tion Replace cords as required 5 REINSTALL DIS...

Page 293: ... plug for electrode wear thread damage and insulator damage If abnormal replace the spark plug Recommended spark plug K16R U for ND 8KR5EYA for NGK 5 ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the cor rect electrode gap Correct electrode gap 0 8 mm 0 031 in 3 CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush clean the spark plug 2 REMOVE SPARK PLUGS Using a 16 mm pl...

Page 294: ...f If necessary adjust the belt tension HINT New belt refers to a belt which has been used less than 5 minutes on a running engine Used belt refers to a belt which has been used on a running engine for 5 minutes or more After installing the belt check that it fits properly in the ribbed grooves Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley Afte...

Page 295: ...ide VALVE CLEARANCE INSPECTION AND ADJUSTMENT HINT Inspect and adjust the valve clearance when the engine is cold 4 REMOVE ENGINE WIRE Remove the two bolts and engine wire 5 REMOVE CYLINDER HEAD COVERS See step 35 on page EG2 58 2 REMOVE SPARK PLUGS Using a 16 mm plug wrench remove the six spark plugs 3 REMOVE AIR INTAKE CHAMBER See step 18 on pages EG2 53 to 55 ENGINE ENGINE MECHANICAL EG2 18 ...

Page 296: ...O TDC COMPRESSION a Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover b Check that the valve lifters on the No 1 cylinder are loose and valve lifters on the No 4 are tight If not turn the crankshaft one revolution 360 and align the mark as above b Turn the crankshaft 1 3 revolution 120 check the clearance of the IN No 1 and EX No 3 valves Measure the ...

Page 297: ...e valve clearance See procedure in step a e Turn the crankshaft 1 3 revolution 120 check the clearance of the IN No 4 and EX No 6 valves Measure the valve clearance See procedure in step a f Turn the crankshaft 1 3 revolution 120 check the clearance of the IN No 5 and EX No 1 valves Measure the valve clearance See procedure in step a Using SST A press down the valve lifter and place SST B between ...

Page 298: ...shim with a thickness as close as possible to the calculated value HINT Shims are available in twenty five sized in increments of 0 05 mm 0 0020 ire from 2 20 mm 0 09B4 in to 3 40 mm 0 1299 in c Install a new adjusting shim Place a new adjusting shim on the valve lifter Using SST A press down the valve lifter and remove SST B SST 09248 55020 09248 05011 09248 05021 HINT For easy removal of the shi...

Page 299: ... ENGINE ENGINE MECHANICAL EG2 22 ...

Page 300: ... ENGINE ENGINE MECHANICAL EG2 23 ...

Page 301: ... on page EG2 80 10 INSTALL ENGINE WIRE Install the engine wire with the two bolts 12 INSTALL SPARK PLUGS Using a 16 mm plug wrench install the six spark plugs Torque 18 N m 18a kgf cm 13 ft lbf 11 INSTALL AIR INTAKE CHAMBER See step 24 on pages EG2 84 to 87 ENGINE ENGINE MECHANICAL EG2 24 ...

Page 302: ...e use 3 ADJUST IGNITION TIMING a Using SST connect terminals TE1 and E1 of the the data link connector 1 SST 09843 18020 c Using a timing light check the ignition timing Ignition timing 10 BTDC idle Transmission in neutral position d Loosen the hold down bolt and adjust by turning the distributor e Tighten the hold down bolt and recheck the ignition timing Torque 18N m 185 kgf cm 13 ft lbf IGNITIO...

Page 303: ...N TIMING Check that the ignition timing advances Ignition timing 8 BTDC idle 5 DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE f Remove the SST from the data link connector 1 SST 09843 18020 ENGINE ENGINE MECHANICAL EG2 26 ...

Page 304: ...l position 2 CONNECT TACHOMETER Connect the test probe of a tachometer to terminal IG of the data link connector 1 NOTICE Never allow the tachometer terminal to touch ground as it could result in damage to the ign ter and or igni tion coil As some tachometers are not compatible with thi signition system we recommend that you confirm the compatibility of your unit before use 3 ADJUST IDLE SPEED a R...

Page 305: ...ld be properly connected f MFI system wiring connectors fully plugged g Ignition timing set correctly h Idle speed set correctly i Transmission in neutral position j Tachometer and CO HC meter calibrated by hand 4 INSERT CO HC METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm 1 3 ft DURING IDLING 5 IMMEDIATELY CHECK CO HC CONCENTRATION AT IDLE AND OR 2 500 RPM HINT When performing the 2 mode 2 500 ...

Page 306: ...e intake air temperature sensor Faulty ECM Faulty injector Faulty cold start injector Faulty throttle position sensor Faulty volume air flow meter 1 Faulty ignitions Incorrect timing Fouled shorted or improperly gapped plugs Open or crossed high tension cords Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve 4 Leaky intake and exhaust valves 5 Leaky cylinder 1 Vacuum leaks PCV ...

Page 307: ...ds may damage the conductor inside 7 CHECK CYLINDER COMPRESSION PRESSURE a Insert a compression gauge into the spark plug hole b Fully open the throttle c While cranking the engine measure the compression pressure HINT Always use a fully charged battery to obtain engine speed of 250 rpm or more d Repeat steps a through c for each cylinder NOTICE This measurement must be done in as short a time as ...

Page 308: ...hat the piston rings and or cylinder bore are worn or damage If pressure stays low a valve may be sticking or seating is improper or there may be leakage past the gasket 8 REINSTALL SPARK PLUGS Using a 16 mm plug wrench install the six spark plugs Torque 18 N m 780 kgf cm 13 ft lbf 9 RECONNECT HIGH TENSION CORDS TO SPARK PLUGS 10 CONNECT IGNITER CONNECTOR 11 CONNECT COLD START INJECTOR CONNECTOR 1...

Page 309: ... and fan bracket so that the fluid coupling can be replaced exactly as before 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 REMOVE ENGINE UNDER COVER 3 DRAIN ENGINE COOLANT 4 REMOVE RADIATOR a Disconnect the reservoir hose b A T only Disconnect the oil cooler hoses c Remove the radiator hoses TIMING BELT COMPONENTS ENGINE ENGINE MECHANICAL EG2 32 ...

Page 310: ...n shroud e Remove the four bolts and No 1 fan shroud f Remove the four bolts and radiator 5 DISCONNECT N0 2 AND NO 3 AIR HOSES FROM AIR PIPE 7 REMOVE SPARK PLUGS Using a 16 mm plug wrench remove the six spark plugs 8 REMOVE PS DRIVE BELT AND PUMP PULLEY 9 DISCONNECT PS PUMP FROM ENGINE 10 REMOVE A C DRIVE BELT 11 REMOVE COOLING FAN Remove the four nuts and cooling fan 12 REMOVE GENERATOR DRIVE BEL...

Page 311: ...place a new installation mark on the timing belt before removing each part 14 REMOVE NO 2 TIMING BELT COVER a Using a screwdriver disconnect the four high ten sion cord clamps from the mounting bolts of the No 2 timing belt cover c Remove the eleven bolts timing belt cover and three gaskets b Using the two water inlet nuts remove the two stud bolts 13 REMOVE WATER OUTLET Remove the two nuts and wa...

Page 312: ...lt to match the end of the No 1 timing belt cover b Check that the timing marks of the camshaft timing pulleys and No 3 timing belt cover are aligned If not turn the crankshaft pulley one revolution 360 16 SET NO 1 CYLINDER AT TDC COMPRESSION a Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover 17 REMOVE TIMING BELT TENSION ER Alternately loosen the tw...

Page 313: ... timing pulley and knock pin Remove the two timing pulleys SST 09278 54012 a Using SST loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise b Disconnect the timing belt from the camshaft timing pulleys 21 REMOVE CRANKSHAFT PULLEY a Remove the four bolts and PS drive belt pulley ENGINE ENGINE MECHANICAL EG2 36 ...

Page 314: ...belt with the end of the timing belt cover 24 REMOVE TIMING BELT HINT When re using timing belt If the installation marks have disappeared place a new installation mark on the timing belt to the match the dot mark of the crankshaft timing pulley d Using SST remove the pulley SST 09213 31021 23 REMOVE TIMING BELT GUIDE Remove the three bolts timing belt cover and gasket ENGINE ENGINE MECHANICAL EG2...

Page 315: ...ustration check the following points a Premature parting Check the proper installation Check the timing cover gasket f6r damage and proper installation 26 REMOVE CRANKSHAFT TIMING PULLEY If the timing pulley cannot be removed by hand use two screwdrivers HINT Position shop rags as shown to prevent damage 25 REMOVE No 1 IDLER PULLEY Using a 10 mm hexagon wrench remove the pivot bolt idler pulley an...

Page 316: ...ing belt c If there is noticeable wear or cracks on the belt face check to see if there are nicks on the side of the idle pulley lock d If there is wear or damage on only one side of the belt check the belt guide and the alignment of each pulley 2 INSPECT IDLER PULLEYS Check that the idler pulley turns smoothly If necessary replace the idler pulley ENGINE ENGINE MECHANICAL EG2 39 ...

Page 317: ...h hands and push the push rod firmly against the floor or wall to check that it doesn t move If the push rod moves replace the tensioner 3 INSPECT TIMING BELT TENSIONER a Visually check tensioner for oil leakage HINT If there is only the faintest trace of oil on the seal on the push rod side the tensioner is all right If leakage is found replace the tensioner ENGINE ENGINE MECHANICAL EG2 40 ...

Page 318: ... Install the timing belt on the crankshaft timing pulley and water pump pulley 2 INSTALL NO 1 IDLER PULLEY a Using a 10 mm hexagon wrench install the plate washer and idler pulley with the pivot bolt Torque 34 N m 350 kgf cm 25 ft lbf b Check that the pulley bracket moves smoothly 3 TEMPORARILY INSTALL TIMING BELT NOTICE The engine should be cold a Using the crankshaft pulley bolt turn the cranksh...

Page 319: ...stall the knock pin to the camshaft b Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley c Slide the timing pulley on the camshaft facing the flange side outward 5 INSTALL NO 1 TIMING BELT COVER a Install the gasket to the timing belt cover b Install the timing belt cover with the three bolts d Using SST install the pulley bolt SST 09278 54012 Torque 108 N m 1 ...

Page 320: ...e knock pin hole of the camshaft with the timing mark of the No 3 timing belt cover c LH Camshaft Pulley Position Turn the camshaft timing pulley align the timing marks of the camshaft timing pulley and No 3 timing belt cover 8 SET NO 1 CYLINDER TO TDC COMPRESSION a Crankshaft Position Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover 9 CONNECT TIMING...

Page 321: ... timing marks of the LH camshaft pulley and No 3 timing belt cover SST 09278 54012 e Check that the timing belt has tension between the crankshaft timing pulley and LH camshaft timing pulley e Using SST align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin SST 08278 54012 c Slide the RH camshaft timing pulley on the camshaft d Align the timing m...

Page 322: ... the press 13 INSTALL TIMING BELT TENSIONER a Temporarily install the belt tensioner with the two bolts b Alternately tighten the two bolts Torque 26 N m 270 kgf cm 20 ft lbf 11 INSTALL FAN BRACKET a Install the gasket to the fan pulley bracket b Install the fan bracket with the two bolts and nut Torque 41 N m 420 kgf cm 30 ft lbf c Using pliers remove the 1 5 mm hexagon wrench from the belt tensi...

Page 323: ...timing marks do not align remove the timing belt and reinstall it 14 CHECK VALVE TIMING a Slowly turn the crankshaft pulley two revolutions from TDC to TDC NOTICE Always turn the crankshaft pulley clockwise 15 INSTALL NO 2 TIMING BELT COVER a Install the gasket to the No 2 idler pulley b Install the gasket to the fan bracket c Install the gasket to the timing belt cover d Install the timing belt c...

Page 324: ...king to the sealing groove of the water outlet as shown in the illustration Seat packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap c Install the water outlet with the two b...

Page 325: ... 27 FILL WITH ENGINE COOLANT 28 START ENGINE AND CHECK FOR LEAKS 29 RECHECK ENGINE COOLANT LEVEL 25 INSTALL RADIATOR a Install the radiator with the four bolts b Install the No 1 fan shroud with the four bolts c Install the No 2 fan shroud with the two clips d Install the radiator hoses e A T only Connect the oil cooler hoses f Connect the reservoir tank hose 20 INSTALL PS PUMP 21 INSTALL PS PUMP ...

Page 326: ...CYLINDER HEAD COMPONENTS ENGINE ENGINE MECHANICAL EG2 49 ...

Page 327: ... ENGINE ENGINE MECHANICAL EG2 50 ...

Page 328: ...ct the oil cooler hoses c Remove the radiator hoses 6 REMOVE PS DRIVE BELT AND PUMP PULLEY 7 DISCONNECT PS PUMP FROM ENGINE 8 REMOVE A C DRIVE BELT d Remove the two clips and No 2 fan shroud e Remove the four bolts and No 1 fan shroud f Remove the four bolts and radiator 5 M T only DISCONNECT CLUTCH RELEASE CYLINDER HOSE CYLINDER HEADS REMOVAL ENGINE ENGINE MECHANICAL EG2 51 ...

Page 329: ...connector Data link connector 1 w ADD ADD switch connector b Disconnect the following hoses PS air hoses from gas filter and air pipe Brake booster hose w Cruise Control System Cruise control vacuum hose Charcoal canister hose from canister VSV vacuum hoses c Disconnect the following cables Accelerator cable A T only Throttle cable w Cruise Control System Cruise control cable 12 DISCONNECT HEATER ...

Page 330: ...on sensor connector b Disconnect the charcoal canister vacuum hose from the throttle body c Disconnect the vacuum and fuel hoses from the pre ssure regulator 14 REMOVE FRONT EXHAUST PIPE a Disconnect the heated oxygen sensor connector b Loosen the pipe clamp bolt w c Remove the two bolts and pipe bracket d Remove the three nuts and disconnect the exhaust pipe from the exhaust manifold Remove the g...

Page 331: ...s temperature sensor con nector k Disconnect the EGR vacuum hoses from the air pipe and EGR vacuum modulator e Disconnect the No 4 water by pass hose from the union of intake manifold f Remove the No 5 water by pass hose from the water by pass pipe i Remove the nut two bolts intake chamber stay and throttle cable bracket m Remove the two bolts and No 1 engine hanger ENGINE ENGINE MECHANICAL EG2 54...

Page 332: ...s sembly and two gaskets r Disconnect the four vacuum hoses from the air pipes s Remove the two bolts and accelerator cable bracket t Remove the six bolts two nuts intake chamber and gasket q Disconnect the No 1 air hose from the PAIR reed valve n Remove the nut bolt and PS pump bracket ENGINE ENGINE MECHANICAL EG2 55 ...

Page 333: ...m No 3 camshaft bearing cap Injector connectors 20 REMOVE NO 2 AND NO 3 FUEL PIPES a Disconnect the vacuum hose from the TVV b Remove the four union bolts eight gaskets No 2 and No 3 fuel pipes 21 REMOVE NO 4 TIMING BELT COVER Remove the four bolts and timing belt cover 22 REMOVE NO 2 IDLER PULLEY Remove the four bolts and idler pulley b Remove the two bolts and engine wire ENGINE ENGINE MECHANICA...

Page 334: ...g and grommet from each injector 27 REMOVE WATER BY PASS OUTLET a Disconnect the No 3 water hose from the No 1 water by pass pipe b Remove the two nuts water by pass outlet and gasket 24 REMOVE VSV BRACKET AND VSV FROM PAIR REED VALVE 25 REMOVE PAIR REED VALVE AND NO 1 AIR INJECTION MANIFOLD Remove the two bolts two nuts the PAIR reed valve injection manifold assembly and gasket 28 REMOVE INTAKE M...

Page 335: ...olts engine wire bracket cylin der head cover and gasket Remove the two cylinder head covers 33 REMOVE OIL DIPSTICK GUIDE AND DIPSTICK a Remove the oil dipstick b Remove the bolt and oil dipstick guide 30 REMOVE EXHAUST CROSSOVER PIPE Remove the six nuts crossover pipe and two gaskets 34 REMOVE NO 2 ENGINE HANGER FROM LH CYLINDER HEAD Remove the two bolts and engine hanger ENGINE ENGINE MECHANICAL...

Page 336: ...several passes in the sequence shown then do the other side as shown b Remove the ten camshaft bearing caps two oil seals and two camshafts 37 REMOVE CYLINDER HEADS a Remove the cylinder head 6 pointed head bolt from each cylinder head HINT Arrange the bearing caps in correct order ENGINE ENGINE MECHANICAL EG2 59 ...

Page 337: ...en the eight cylinder head bolts one side of each cylinder head in several passes in the sequence shown then do the other side as shown Remove the eighteen cylinder head bolts and plate washers NOTICE Head warpage or cracking could result from removing bolts in incorrect order 39 REMOVE EXHAUST MANIFOLD FROM RH CYLINDER HEAD a Remove the bolt nut and exhaust manifold heat in sulator b Remove the s...

Page 338: ...LINDER HEAD a Remove the three nuts and exhaust manifold heat insulator b Remove the six nuts exhaust manifold and gasket 3 REMOVE VALVES a Using SST compress the valve spring and remove the two keepers SST 09202 43013 HINT Arrange the valve lifters and shims in correct order 2 REMOVE VALVE LIFTERS AND SHIMS Pull out the valve lifter and shim by hand ENGINE ENGINE MECHANICAL EG2 61 ...

Page 339: ...arts 1 Spring retainer 2 Valve spring 3 Valve 4 Spring seat HINT Arrange the valves valve springs spring seats and spring retainers incorrect order c Using needle nose pliers remove the oil seal ENGINE ENGINE MECHANICAL EG2 62 ...

Page 340: ... NOTICE Be careful not to scratch the cylinder block contact surface b Using a gasket scraper remove all the gasket material from the cylinder block surface c Using compressed air blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high com pressed air B Clean combustion chambers Using a wire brush remove all the carbon from the combustion chambers NOTICE Be careful not to...

Page 341: ...eplace the cyl inder head B Inspect for cracks Using a dye penetrant check the combustion cham ber intake ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head 4 CLEAN VALVES a Using a gasket scraper chip off any carbon from the valve head b Using a wire brush thoroughly clean the valve D Clean cylinder head Using a soft brush and solvent thoroughly clean t...

Page 342: ...lve stem diameter Intake 7 970 7 985 mm 0 3138 0 3144 in Exhaust 7 965 7 980 mm 0 3136 0 3142 in 6 IF NECESSARY REPLACE VALVE GUIDE BUSHINGS a Insert an old valve wrapped with tape into the valve guide bushing and break off the valve guide bushing by hitting it with a hammer Remove the snap ring HINT Wrap the tape approx 12 mm 0 47 in from the valve stem end NOTICE Be careful not to damage the val...

Page 343: ...r than 13 077 mm 0 5148 in replace the cylinder head b Gradually heat the cylinder head to 80 100 C 176 2 12 F d Using a caliper gauge measure the bushing bore di ameter of the cylinder head f Gradually heat the cylinder head to 80 100 C 176 212 F c Using SST and a hammer tap out the guide bushing SST 09201 60011 13 050 13 077 0 5138 0 5148 13 000 13 027 0 5118 0 5129 Both intake and exhaust Bushi...

Page 344: ...rall length is less than minimum replace the valve 7 INSPECT AND GRIND VALVES a Grind the valve enough to remove pits and carbon b Check that the valve is ground to the correct valve face angle Valve face angle 44 5 g Using SST and a hammer tap in a new guide bushing until the snap ring makes contact with the cylinder head SST 09201 60011 h Using a sharp 8 mm reamer ream the guide bushing to the o...

Page 345: ... the seat Check that the seat contact is in the middle of the valve face with the following width 1 2 1 6 mm 0 047 0 063 in 8 INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats If not correct the valve seats as follows 1 If the seating is too high on the valve face use 3a and 45 cutters to correct the seat e Check the sur...

Page 346: ...ted mark If the free length is not as specified replace the valve spring c Using a spring tester measure the tension of the valve spring at the specified installed length Installed tension 242 268 N 24 7 27 3 kgf 54 5 60 2 lbf at 40 0 mm 1 575 in If the installed tension is not as specified replace the valve spring d Hand lap the valve and valve seat with an abrasive compound a After hand lapping ...

Page 347: ... in If the cam lobe height is less than minimum replace the camshaft C Inspect camshaft journals Using a micrometer measure the journal diameter Journal diameter 33 959 33 975 mm 1 3370 1 3376 in If the journal diameter is not as specified check the oil clearance E Inspect camshaft journal oil clearance a Clean the bearing caps and camshaft journals b Place the camshafts on the cylinder head c Lay...

Page 348: ...learance while moving the camshaft back and forth Standard thrust clearance 0 080 0 190 mm 0 0031 0 0075 in Maximum thrust clearance 0 25 mm 0 0098 in If the thrust clearance is greater than maximum re place the camshaft If necessary replace the bearing caps and cylinder head as a set c Remove the camshafts 11 INSPECT VALVE LIFTERS AND LIFTER BORES a Using a caliper gauge measure the lifter bore d...

Page 349: ... 053 mm 0 0011 0 0021 in Maximum oil clearance 0 10 mm 0 0039 in If the oil clearance is greater than maximum replace the lifter If necessary replace the cylinder head 13 INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge measure the surface contacting the cylinder head and air intake chamber for warpage Maximum warpage 0 10 mm 0 0039 in If warpage is greater than maximum rep...

Page 350: ...sing a precision straight edge and feeler gauge measure the surface contacting the cylinder head for warpage Maximum warpage 0 70 mm 0 0276 in If warpage is greater than maximum replace the manifold ENGINE ENGINE MECHANICAL EG2 73 ...

Page 351: ... and oil seals with new ones c Using SST compress the valve spring and place the two keepers around the valve stem SST 09202 43013 HINT The intake valve oil seal is gray and the exhaust valve oil seal is brown b Install the following parts 1 Valve 2 Spring seat 3 Valve spring 4 Spring retainer 1 INSTALL VALVES a Using SST push in a new oil seal SST 09201 41020 ENGINE ENGINE MECHANICAL EG2 74 ...

Page 352: ...nd 3 INSTALL CAMSHAFT HOUSING PLUGS a Place a new housing plug in position on the cylinder head facing the cup side inward b Install the housing rear plate with the two bolts Torque 4 9 N m 50 kgf cm 43 in lbf d Using a plastic faced hammer lightly tap the valve stem tip to assure proper fit ENGINE ENGINE MECHANICAL EG2 75 ...

Page 353: ...and the exhaust manifold with the six nuts Torque 39 N m 400 kgf cm 29 ft lbf b Install the exhaust manifold heat insulator with the three bolts 4 INSTALL CYLINDER HEADS A Place cylinder head on cylinder block a Place two new cylinder head gaskets in position on the cylinder block NOTICE Be careful of the installation direction b Place the two cylinder heads in position on the cyl inder head gaske...

Page 354: ...l and uniformly tighten the eight cylinder head bolts on one side of the cylinder head in several passes in the sequence shown then do the other side as shown Torque 44 N m 450 kgf cm 33 ft Ibf If any one of the bolts does not meet the torque specification replace the bolt d Mark the front of the cylinder head bolt head with paint f Retighten cylinder head bolts by an additional 90 g Check that th...

Page 355: ...No 08826 00080 or equivalent C Install cylinder head 6 pointed head bolts a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b Install the cylinder head bolt to each cylinder head Torque 41 N m 420 kgf cm 30 ft lbf c Install the bearing caps in their proper locations ENGINE ENGINE MECHANICAL EG2 78 ...

Page 356: ...0 22 0 32 mm 0 009 0 013 in d Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts e Install and uniformly tighten the twelve bearing cap bolts on one side in several passes in the sequence shown then do the other side as shown Torque 16 N m 160 kgf cm 12 ft lbf g Using SST tap in the two camshaft oil seals SST 09214 60010 f Apply MP grease to a new oil seal...

Page 357: ...the other side as shown Install the two cylinder head covers Torque 5 4 N m 55 kgf cm 48 in lbf 7 INSTALL CYLINDER HEAD COVERS a Remove the old packing FIPG material b Apply seal packing to the cylinder head as shown in the illustration Seal packing Part No 08826 00080 or equivalent 8 INSTALL WATER BY PASS PIPE TO RH CYLINDER HEAD Install the water by pass pipe with the bolt ENGINE ENGINE MECHANIC...

Page 358: ...olt Torque 37 N m 380 kgf cm 27 ft lbf c Install the oil dipstick 11 INSTALL GENERATOR 12 INSTALL EXHAUST CROSSOVER PIPE Install two new gaskets and the crossover pipe with the six nuts Torque 39 N m 400 kgf cm 29 ft Ibf 13 INSTALL KNOCK SENSOR WIRE 14 INSTALL INTAKE MANIFOLD install two new gaskets and the intake manifold with the twelve bolts and four nuts Torque 18 N m 185 kgf cm 13 ft lbf 9 IN...

Page 359: ... intake manifold Torque 13 N m 130 kgf cm 9 ft lbf m Install the No 1 fuel pipe to the No 3 bearing cap with the bolt c While turning the injector clockwise and counter clockwise push it to the delivery pipe Install the eight injectors d Position the injector connector outward e Install a O ring to the spacer f Place the six spacers and insulators into the injector holes g Place the four spacers o...

Page 360: ...zzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap c Install the idler pulley with the four bolts Uniformly tighten the bolts in several passes Torque 18 N m 185 kgf cm 13 ft Ibf 17 INSTALL PAIR REED VALVE AND NO 1 INJECTION MA...

Page 361: ...on bolts Torque 34 N m 350 kgf cm 25 ft lbf b Install the No 3 fuel pipe with four new gaskets and two union bolts Torque 34 N m 350 kgf cm 25 ft lbf 24 INSTALL AIR INTAKE CHAMBER a Install a new gasket and the intake chamber with the six bolts and two nuts Torque 18 N m 185 kgf cm 13 ft lbf 23 INSTALL ENGINE WIRE a Install the engine wire with the two bolts 21 INSTALL NO 4 TIMING BELT COVER Insta...

Page 362: ... the EGR valve pipes as sembly air intake chamber stay and throttle cable bracket with the six nuts and two bolts Torque 29 N m 300 kgf cm 22 ft Ibf for A 18 N m 185 kgf cm 13 ft lbf for B b Install the accelerator cable bracket with the two bolts c Connect the four vacuum hoses to the air pipes i Install the PS pump bracket with the bolt and nut d Connect the No 1 air hose to the reed valve ENGIN...

Page 363: ...m hose to the gas filter m Connect the cold start injector connector n Install the No 5 water by pass hose to the water by pass pipe o Connect the No 4 water by pass hose to the union of intake manifold j Install No 1 engine hanger Torque 40 N m 410 kgf cm 30 ft lbf p Connect the PCV hose to the union ENGINE ENGINE MECHANICAL EG2 86 ...

Page 364: ... exhaust pipe to the catalytic converter with new gasket and the two bolts Torque 39 N m 400 kgf cm 29 ft Ibf c Install the pipe bracket to the transmission with the two bolts d Install the pipe bracket to the exhaust pipe with the pipe clamp e Connect the oxygen sensor connector q Connect the vacuum and fuel hoses to the pressure regulator r Connect the charcoal canister vacuum hose to the thrott...

Page 365: ...trap wires and connectors Ground strap to LH fender apron Generator connector and wire Igniter connector Oil pressure sender gauge connector Ground strap to engine rear side ECM connectors VSV connectors A C compressor connector M T only Starter relay connector Solenoid resister connector Data link connector 1 w ADD ADD switch connector 32 INSTALL GENERATOR DRIVE BELT 33 INSTALL COOLING FAN Instal...

Page 366: ...oise shock slipage correct shift points and smooth operation 45 RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL 38 INSTALL RADIATOR a Install the radiator with the four bolts b Install the No fan shroud with the four bolts c Install the No 2 fan shroud with the two clips d Install the radiator hoses e A T only Connect the oil cooler hoses f Connect the reservoir tank hose 37 M T only CONNECT CLUTCH REL...

Page 367: ...CYLINDER BLOCK COMPONENTS ENGINE ENGINE MECHANICAL EG2 90 ...

Page 368: ...ATOR a Disconnect the reservoir hose b A T only Disconnect the oil cooler hoses c Remove the radiator hoses 10 REMOVE PS DRIVE BELT AND PUMP PULLEY 11 DISCONNECT PS PUMP FROM ENGINE 12 REMOVE A C DRIVE BELT d Remove the two clips and No 2 fan shroud e Remove the four bolts and No 1 fan shroud f Remove the four bolts and radiator 9 M T only DISCONNECT CLUTCH RELEASE CYLINDER HOSE ENGINE ENGINE MECH...

Page 369: ...onnector 1 w ADD ADD switch connector b Disconnect the following hoses PS air hoses from gas filter and air pipe Brake booster hose w Cruise Control System Cruise control vacuum hose Charcoal canister hose from canister VSV vacuum hoses c Disconnect the following cables Accelerator cable A T only Throttle cable w Cruise Control System Cruise control cable 16 DISCONNECT HEATER HOSES 17 DISCONNECT F...

Page 370: ...MEMBER 28 REMOVE N0 1 FRONT FLOOR HEAT INSULATOR AND BRAKE TUBE HEAT INSULATOR 4WD 19 REMOVE FRONT EXHAUST PIPE a Disconnect the heated oxygen sensor connector b Loosen the pipe clamp bolt c Remove the two bolts and pipe bracket d Remove the three nuts and disconnect the exhaust pipe from the exhaust manifold Remove the gasket 29 2WD REMOVE ENGINE REAR MOUNTING BRACKET a Remove the four bolts hold...

Page 371: ...engine and transmission assembly onto the stand 32 REMOVE TRANSMISSION FROM ENGINE 33 M T only REMOVE CLUTCH COVER AND DISC 30 4WD REMOVE NO 2 FRAME CROSSMEMBER a Remove the four bolts holding the engine rear mou nting insulator to the frame crossmember b Raise the transmission slightly with a jack c Remove the eight bolts holding the frame crossme mber to the side frame Remove the frame crossme m...

Page 372: ...acer 4 REMOVE RH AND LH ENGINE MOUNTING BRACKETS Remove the four bolts and mounting bracket Remove the two mounting brackets 2 REMOVE REAR END PLATE Remove the bolt and rear end plate 3 INSTALL ENGINE STAND FOR DISASSEMBLY 6 REMOVE TIMING BELT See pages EG2 33 to 38 7 REMOVE CYLINDER HEADS See pages EG2 53 to60 5 REMOVE ENGINE COOLANT DRAIN PLUGS ENGINE ENGINE MECHANICAL EG2 95 ...

Page 373: ...ve the oil pressure sender gauge SST 09816 30010 13 REMOVE OIL FILTER 15 2WD REMOVE OIL COOLER AND BRACKET ASSEMBLY a Remove the No 1 and No 2 oil cooler hoses 10 REMOVE WATER PUMP Remove the seven bolts and water pump 11 REMOVE GENERATOR ADJUSTING BAR 14 REMOVE KNOCK SENSOR Using SST remove the knock sensor SST 09817 16011 ENGINE ENGINE MECHANICAL EG2 96 ...

Page 374: ... the bracket to the cylinder block c Remove the relief valve seal washer oil cooler and seal washer d Remove the O ring and gasket from the oil cooler b Remove the two bolts holding the bracket to the cylinder block c Remove the union bolt gasket 0 ring the oil cooler bracket assembly and 0 ring 17 REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench remove the oil filter union 16 4WD REMOVE OIL C...

Page 375: ...ICE Do not use SST for the oil pump and rear oil seal retainer Be careful not to damage the baffle plate flange 21 REMOVE OIL PUMP a Remove the seven bolts b Using a plastic faced hammer carefully tap oft the oil pump c Remove the O ring from the cylinder block 19 REMOVE OIL STRAINER Remove the two bolts two nuts oil strainer and gasket ENGINE ENGINE MECHANICAL EG2 98 ...

Page 376: ...ecessary re place the crankshaft 3 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Using a punch or numbering stamp mark the conne cting rod and cap to ensure correct reassembly c Using a plastic faced hammer lightly tap the con necting rod bolts and lift off the connecting rod cap HINT Keep the lower bearing inserted with the con necting rod cap See Components 1 REMOVE REAR OIL SEAL RETAINER...

Page 377: ...ck the crank pin and bearing for pitting and scr atches If the crank pin or bearing is damaged replace the bearings If necessary grind or replace the crankshaft d Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage i Remove the two nuts and connecting rod cap See procedure b and c above g Lay a strip of Plastigage across the crank pin ENGINE ENGINE MECHA...

Page 378: ... sizes of standard bearings marked 1 2 and 3 accordingly Reference Standard sized bearing center wall thickness Mark 1 1 484 1 488 mm 0 0584 0 0586 in Mark 2 1 488 1 492 mm 0 0586 0 0587 in Mark 3 1 492 1 496 mm 0 0587 0 0589 in Connecting rod big end inside diameter Mark 1 58 000 58 008 mm 2 2835 2 2838 in Mark 2 58 008 58 016 mm 2 2838 2 2841 in Mark 3 58 016 58 024 mm 2 2841 2 2844 in Crank pin...

Page 379: ...asher thickness 2 440 2 490 mm 0 0961 0 0980 in HINT Keep the bearings connecting rod and cap to gether Arrange the piston and connecting rod assembl ies in correct order 6 REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE a Uniformly loosen and remove the main bearing cap bolts in several passes in the sequence shown b Cover the connecting rod bolts with a short piece of hose to protect the cranksh...

Page 380: ...block h Install the main bearing cap with the eight bolts See step 4 on page EG2 118 Torque 61 N m 625 kgf cm 45 ft lbf for 1 at Turn 90 for 2nd NOTICE Do not turn the crankshaft d Clean each main journal and bearing e Check each main journal and bearing for pitting and scratches If the journal or bearing is damaged replace the bearings If necessary grind or replace the crankshaft f Place the cran...

Page 381: ... 0012 0 0026 in If the oil clearance is greater than maximum replace the bearings If necessary grind or replace the cra nkshaft HINT If using a standard bearing replace with one having the same number If the number of the bearing cannot be determined select the correct bearing by adding together the numbers imprinted on the cylin der block and crankshaft then selecting the bearing with the same nu...

Page 382: ...Mark 5 2 001 2 004 mm 0 0788 0 0789 in Cylinder block main journal bore diameter Mark 1 68 010 68 016 mm 2 6776 2 6778 in Mark 2 68 016 68 022 mm 2 6778 2 6780 in Mark 3 68 022 68 028 mm 2 6780 2 6783 in Crankshaft main journal diameter Mark 0 63 996 64 000 mm 2 5195 2 5197 in Mark 1 63 990 63 996 mm 2 5193 2 5195 in Mark 2 63 985 63 990 mm 2 5191 2 5193 in k Completely remove the Plastigage 7 REM...

Page 383: ...move all the gasket material from the top surface of the cylinder block B Clean cylinder block Using a soft brush and solvent thoroughly clean the cylinder block I 3 INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches If deep scratches are present rebore all the six cyl inders If necessary replace the cylinder block 4 INSPECT CYLINDER BORE DIAMETER HINT There...

Page 384: ...he diameter is greater than maximum rebore all the six cylinders If necessary replace the cylinder block PISTON AND CONNECTING ROD DISASSEMBLY 1 CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin If any movement is felt replace the piston and pin as a set 5 REMOVE CYLINDER RIDGE If the wear is less than 0 2 mm 0 008 in using a ridge reamer grind the top...

Page 385: ...e the connecting rod SST 09221 25024 09221 00020 09221 00030 09221 00181 09221 00190 09221 00200 HINT The piston and pin are a matched set Arrange the pistons pins rings connecting rods and bearings in correct order b Remove the two side rails and oil ring by hand HINT Arrange the piston rings in correct order only b Using a groove cleaning tool or broken ring clean the piston ring grooves ENGINE ...

Page 386: ...tract the piston diameter measurement from the cylinder bore diameter measurement Standard oil clearance 0 130 0 150 mm 0 0051 0 0059 in Maximum oil clearance 0 17 mm 0 0067 in If the oil clearance is greater than maximum replace all the six pistons If necessary rebore all the six cylinders or replace the cylinder block 2 INSPECT PISTON A Inspect piston oil clearance HINT There are three sizes of ...

Page 387: ... is greater than maximum replace the piston HINT Use new cylinder block Use a piston with the same number mark as the cylinder diameter marked on the cylinder block The shape of the piston varies for the RH and LH banks The RH piston is marked with R the LH piston with L C Inspect piston ring end gap a Insert the piston ring into the cylinder bore b Using a piston push the piston ring a little bey...

Page 388: ...ix cylin ders or replace the cylinder block 3 INSPECT CONNECTING ROD A Inspect connecting rod alignment Using a rod aligner and feeler gauge check the con necting rod alignment Check for bend Maximum bend 0 05 mm 0 0020 in per 100 mm 3 94 in If bend is greater than maximum replace the conne cting rod assembly Check for twist Maximum twist 0 15 mm 0 0059 in per 100 mm 3 94 in If twist is greater th...

Page 389: ...er C Piston oil clearance 0 130 0 150 mm 0 0051 0 0059 in H Allowance for honing 0 02 mm 0 0008 in or less 3 BORE AND HONE CYLINDER TO CALCULATED DIMENSIONS Maximum honing 0 02 mm 0 0008 in NOTICE Excess honing will destroy the finished round ness b If the cap nut cannot be turned easily measure the outer diameter of the compressed thread with a ver nier caliper Standard outer diameter 7 860 8 000...

Page 390: ...3 505 mm 2 4998 2 5002 in Crank pin diameter STD 54 987 55 000 mm 2 1648 2 1654 in U S 0 25 54 745 54 755 mm 2 1553 2 1557 in U S 0 50 54 495 54 505 mm 2 1455 2 1459 in If the diameter is not as specified check the oil cle arance See 3 or 6 page EG2 99 or 102 b Check each main journal and crank pin for taper and out of round as shown Maximum taper and out of round 0 02 mm 0 0008 in If the taper or...

Page 391: ...pump body edge SST 09309 37010 c Apply MP grease to the oil seal lip CRANKSHAFT OIL SEALS REPLACEMENT HINT There are two methods A and B to replace the oil seal which are as follows c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its surface is flush with the oil pump body edge SST 09306 37010 1 REPLACE CRANKSHAFT FRONT OIL SEAL A If oil pump is removed f...

Page 392: ...until its surface is flush with the rear oil seal retainer edge SST 09223 56010 c Apply MP grease to the oil seal lip 2 REPLACE CRANKSHAFT REAR OIL SEAL A If rear oil seal retainer is removed from cylinder block a Using a screwdriver and hammer tap out the oil seal c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its surface is flush with the rear oil seal...

Page 393: ...ng SST press in the piston pin SST 09221 25024 09221 00020 09221 00030 09221 00181 09221 00190 09221 00200 b Using a piston ring expander install the two com pression rings with the code marks facing upward Code mark No 1 1 Ror T No 2 2R or T2 c Position the piston rings so that the ring ends are as shown NOTICE Do not align the ring ends 2 INSTALL PISTON RINGS a Install the oil expander and two s...

Page 394: ...20 mm 0 79 in bearings in the other positions Upper bearings have an oil holes lower bearings do not 3 INSTALL BEARINGS a Align the bearing claw with the groove of the con necting rod or connecting cap b Install the bearings in the connecting rod and conne cting rod cap 2 INSTALL UPPER THRUST WASHERS Install the thrust washers under the No 2 journal po sition of the cylinder block with the oil gro...

Page 395: ...ain bearing cap bolts HINT The main bearing cap bolts are tightened in two progressive steps steps b and d If any main bearing cap bolt is broken or de formed replace it 4 INSTALL MAIN BEARING CAP AND LOWER THRUST WASHERS A Place main bearing cap and lower thrust washers on cylinder block a Install the thrust washers on the No 2 journal position of the bearing cap with the grooves facing outward b...

Page 396: ...ONNECTING ROD ASSEMBLIES a Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage b Using a piston ring compressor push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward NOTICE The shape of the piston varies for the RH and LH banks The RH piston is marked with R The LH piston with...

Page 397: ...ts are tightened in two progressive steps steps b and d If any connecting rod bolt is broken or deformed replace it 7 INSTALL CONNECTING ROD CAPS A Place connecting rod cap on connecting rod a Match the numbered connecting rod cap with the connecting rod b Install the connecting rod cap with the front mark facing forward d Retighten the connecting rod cap nuts 90 as shown e Check that the painted ...

Page 398: ...lock Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the oil seal retainer as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has be...

Page 399: ...g a non residue solvent clean both sealing surfaces b Apply seal packing to the oil pump as shown in the illustration Seal packing Part No 08826 00080 or equivalent NOTICE Avoid applying en excessive amount to the surface Be particularly careful near oil passage Install a nozzle that has been cut to a 2 3 mm 0 08 4 12 in opening Parts must be assembled within 5 minutes of application Otherwise the...

Page 400: ...te as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 3 4 mm 0 12 0 16 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap c Attach the baffle plate to the cylinder block d Engage the spline teeth of the oil ...

Page 401: ...acking Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 3 4 mm 0 12 0 16 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap c Install the oil pan with the two nuts and seventeen bolts Torque 5 9 N m 60 kgf cm 52 in lbf 3 INSTALL OIL STRAINER Insta...

Page 402: ...b Install new gasket and O ring to the union bolt c Apply a light coat of engine oil on the O ring d Apply a light coat of engine oil on the threads of the union bolt 7 2WD INSTALL OIL COOLER AND BRACKET ASSEMBLY a Install a new 0 ring to the oil cooler bracket 6 INSTALL KNOCK SENSOR Using SST install the knock sensor SST 09817 16011 h install the No 1 and No 2 oil cooler hoses ENGINE ENGINE MECHA...

Page 403: ...ING BRACKETS Install the mounting bracket with the four bolts Install the two mounting brackets Torque 39 N m 400 kgf cm 29 ft Ibf 11 INSTALL OIL FILTER 8 4WD INSTALL OIL COOLER a Install new 0 ring and gasket to the oil cooler b Apply a light coat of engine oil on the threads of the relief valve 9 INSTALL ENGINE COOLANT DRAIN PLUGS Torque 29 N m 300 kgf cm 22 ft Ibf f Install the No 1 and No 2 oi...

Page 404: ...seal packing to the sealing groove of the water pump as shown in the illustration Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap 12 INSTALL OIL PRESSURE SENDER GAUG...

Page 405: ...seal packing to the sealing groove of the water by pass pipe as shown in the illustration Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap c Install the water by pass...

Page 406: ...or M T 83 N m 850 kgf cm 61 ft lbf for A T 21 INSTALL FLYWHEEL OR DRIVE PLATE a Apply adhesive to two or three threads of the mou nting bolt end Adhesive Pert No 08833 00070 THREE BOND 1324 or equivalent 17 INSTALL CYLINDER HEADS See pages EG2 76 to 87 18 INSTALL TIMING BELT See pages EG2 41 to 48 19 REMOVE ENGINE STAND 20 INSTALL REAR END PLATE Install the rear end plate with the bolt Torque 7 4 ...

Page 407: ...NSTALL NO 2 FRAME CROSSMEMBER a Raise the transmission slightly with a jack b Install the frame crossmember to the side frame with the eight bolts Torque 95 N m 970 kgf cm 70 ft lbf c Lower the transmission and transfer d Install the frame crossmember to the engine rear mou nting insulator Torque 13 N m 130 kgf cm 9 ft lbf 4 2WD INSTALL ENGINE REAR MOUNTING BRACKET a Raise the transmission slightl...

Page 408: ...HAFT See page PR 16 14 INSTALL REAR PROPELLER SHAFT See page PR 15 15 M T only INSTALL SHIFT LEVERS 16 INSTALL FRONT EXHAUST PIPE a Connect the exhaust pipe to the LH exhaust manifold with new gasket and three new nuts Torque 62 N m 630 kgf cm 46 ft lbf b Connect the exhaust pipe to the catalytic converter with new gasket and the two bolts Torque 39 N m 400 kgf cm 29 ft lbf c Install the pipe brac...

Page 409: ...p wires and connectors Ground strap to LH fender apron Generator connector and wire Igniter connector Oil pressure sender gauge connector Ground strap to engine rear side ECM connectors VSV connectors A C compressor connector M T only Starter relay connector Solenoid resister connector Data link connector 1 w ADD ADD switch connector 22 INSTALL GENERATOR DRIVE BELT 23 INSTALL COOLING FAN Install t...

Page 410: ... 37 PERFORM ROAD TEST Check for abnormal noise shock slippage correct shift points and smooth operation 38 RECHECK ENGINE COOLANT AND OIL LEVELS 27 INSTALL RADIATOR a Install the radiator with the four bolts b Install the No 1 fan shroud with the four bolts c Install the No 2 fan shroud with the two clips d Install the radiator hoses e A T Connect the oil cooler hoses f Connect the reservoir tank ...

Page 411: ...EXHAUST SYSTEM ENGINE ENGINE MECHANICAL EG2 134 ...

Page 412: ...battery 55D 23R type 80D 26R type High tension cord resistance Limit at 250 rpm STD Limit Difference of pressure between each cylinder SERVICE SPECIFICATIONS SERVICE DATA High tension cord resistance Spark plug Recommended spark plug Protrusion from housing end Compression pressure Timing belt tensioner Ignition timing Idle speed ND NGK Tune up ENGINE ENGINE MECHANICAL EG2 135 ...

Page 413: ...ance Journal diameter Circle runout Cam lobe height Inside diameter Outside diameter Valve face angle Stem diameter STD Limit STD Limit Valve guide bushing Journal oil clearance Valve overall length STD O S 0 05 Air intake chamber Stern oil clearance Limit STD Limit Intake Manifold Margin thickness Exhaust Manifold Thrust clearance Cylinder head Valve spring STD Limit STD Limit Valve lifter Warpag...

Page 414: ...erence Connecting rod bearing center wall thickness Reference Cylinder head surface warpage Cylinder bore diameter Piston ring groove clearance Connecting rod oil clearance Main journal bore diameter Connecting rod Piston and piston ring Piston ring end gap Piston oil clearance Piston diameter Cylinder block ENGINE ENGINE MECHANICAL EG2 137 ...

Page 415: ...er x Fan bracket Camshaft timing pulley x Camshaft Main journal diameter Reference Generator bracket x Cylinder head No 1 idler pulley x Cylinder head Exhaust manifold x Cylinder head Water outlet x No 2 idler pulley Crankshaft pulley x Crankshaft Cylinder head x Cylinder block Cooling fan x Fluid coupling Fan bracket x Cylinder block Spark plug x Cylinder head Main journal diameter Crank pin diam...

Page 416: ...f valve Rear oil seal retainer x Cylinder block Cylinder head cover x Cylinder head Air intake chamber x Intake manifold No 2 idler pulley x Intake manifold Oil dipstick guide x Cylinder head Main bearing cap x Cylinder block EGR pipe x Air intake chamber Oil pan x Rear ail seal retainer PAIR reed valve x Cylinder head Rear end plate x Cylinder block Intake manifold x Cylinder head Engine hanger x...

Page 417: ... engine mounting bracket x Support member 2W0 Front exhaust pipe x Three way catalytic converter No 2 frame crossmember x Side frame 4WD Tailpipe x Three way catalytic converter Front exhaust pipe x Exhaust manifold RH engine mounting insulator x Body LH engine mounting insulator x Body ENGINE ENGINE MECHANICAL EG2 140 ...

Page 418: ...this manual Positive crankcase ventilation Evaporative emission control Exhaust gas recirculation Pulsed secondary air injection Three way catalytic converter Multiport fuel injection EMISSION CONTROL SYSTEMS PREPARATION RECOMMENDED TOOLS SYSTEM PURPOSE PCV EVAP EGR PAIR TWC MFI 09082 00015 TOYOTA Electrical Tester 09258 00030 Hose Plug Set EQUIPMENT Torque wrench Vacuum gauge Abbreviation Purpose...

Page 419: ...LAYOUT AND SCHEMATIC DRAWING ENGINE EMISSION CONTROL SYSTEMS EG2 142 ...

Page 420: ...through the PCV valve to the intake manifold for combustion in the cylinders POSITIVE CRANKCASE VENTILATION PCV SYSTEM Engine not Running or Backfiring Acceleration or Heavy Load Idling or Decelerating Normal Operation ENGINE EMISSION CONTROL SYSTEMS EG2 143 ...

Page 421: ...ough the valve Petroleum substances inside the valve are harmful PCV HOSES AND CONNECTIONS INSPECTION VISUALLY INSPECT HOSES CONNECTIONS AND GASKETS Check for cracks leaks or damage 4 BLOW AIR FROM INTAKE MANIFOLD SIDE Check that air passes through with difficulty If the PCV valve fails either check replace it 5 REINSTALL PCV VALVE ENGINE EMISSION CONTROL SYSTEMS EG2 144 ...

Page 422: ...tank is absorbed in the canister HC from tank is absorbed in the canister Check Valve is Charcoal Canister Air is led into the fuel tank Positioned below purge port Positioned above purge port Throttle Valve Opening Evaporated Fuel HC Above 54 C 129 F High pressure in tank Engine Coolant Temp Check Valve in Cap High vacuum in tank Below 35 C 95 F CLOSED CLOSED CLOSED CLOSED CLOSED OPEN OPEN OPEN O...

Page 423: ...hile holding the purge pipe closed HINT Do not attempt to wash the canister No activated carbon should come out 5 INSTALL CHARCOAL CANISTER FUEL VAPOR LINES FUEL TANK AND TANK CAP INSPECTION 1 VISUALLY INSPECT LINES AND CONNECTIONS Look for loose connections sharp bends or damage 2 VISUALLY INSPECT FUEL TANK Look for deformation cracks or fuel leakage CHARCOAL CANISTER INSPECTION 1 REMOVE CHARCOAL...

Page 424: ...k that the TVV is closed e Heat the TVV to above 54 C 129 F with hot water f Blow air into a pipe and check that the TVV is open If a problem is found replace the TVV g Apply adhesive to two or three threads of the TVV and reinstall it Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent Torque 25 N m 250 kgf cm 18 ft lbf h Fill the radiator with engine coolant TVV INSPECTION ENGINE EMISSION...

Page 425: ... combustion temperature EXHAUST GAS RECIRCULATION EGR SYSTEM Pressure constantly alternating between low and high Positioned between EGR port and R port Pressure in the EGR Valve Pressure Chamber CLOSES passage to atmosphere CLOSES passage to atmosphere OPENS passage to atmosphere Throttle Valve Opening Angle Positioned below EGR port Positioned above R port Engine Coolant Temp EGR Vacuum Modulato...

Page 426: ...ect a vacuum gauge to it 3 CHECK SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle 5 CHECK VSV AND EGR VACUUM MODULATOR WITH WARM ENGINE a Warm up the engine b Check that the vacuum gauge indicates zero at idle c Check that the vacuum gauge indicates low vacuum at 3 500 rpm EGR SYSTEM INSPECTION 1 CHECK AND CLEAN FILTER N EGR VACUUM MODULATOR a Check the filte...

Page 427: ...EGR VALVE a Apply vacuum directly to the EGR valve with the engine idling b Check that the engine runs rough or dies c Reconnect the vacuum hoses to the proper locations If no problem is found with this inspection the system is okay otherwise inspect each part EGR VALVE INSPECTION 1 REMOVE EGR VALVE Check the valve for sticking and heavy carbon de posits If a problem is found replace it 2 INSTALL ...

Page 428: ...SV c Disconnect the battery d Blow air into a pipe E and check that air comes out of pipe G If a problem is found replace the VSV 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between the terminals and the VSV body If there is continuity replace the VSV ENGINE COOLANT TEMP SENSOR INSPECTION See page EG2 348 ecIFe 01 ENGINE EMISSION CONTROL SYSTEMS EG2 151 ...

Page 429: ... by the exhaust pulsation in the exhaust manifold PULSED SECONDARY AIR INJECTION PAIR SYSTEM Engine Coolant Temp Throttle Valve Position Between 1 200 3 200 rpm Above 35 C 95 F Below 25 C 77 F Below 1 000 rpm Normal driving Engine RPM Deceleration Condition Idling PAIR VSV OFF OFF ENGINE EMISSION CONTROL SYSTEMS EG2 152 ...

Page 430: ... REED VALVE BY BLOWING AIR INTO PIPE a Apply vacuum to the reed valve diaphragm b Blow air into a pipe and check that the reed valve is open c Release the vacuum and check that the reed valve is closed 3 CHECK PAIR SYSTEM WITH WARM ENGINE a Warm up the engine b With the engine idling check that a bubbling noise is not heard from the air pipe c Race the engine above 2 000 rpm and quickly close the ...

Page 431: ...not flow fron the black pipe to the orange pipe 3 CHECK FOR OPEN CIRCUIT Using an ohmmeter measure the resistance between the terminals Specified resistance 30 50 at 20 C 68 F If the resistance is not within specification replace the VSV 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between the terminals and the VSV body If there is continuity replace the VSV c Disc...

Page 432: ...he protector is damaged or dented to the extent that it contacts the catalyst repair or re place it To reduce HC CO and NOx emissions they are oxidized reduced and converted to nitrogen N2 carbon dioxide CO2 and water H2 by the catalyst THREE WAY CATALYTIC CONVERTER TWC SYSTEM Oxidation and reduction HC CO and NOx Exhaust Port Exhaust Gas CO2 H20 N2 TW C ENGINE EMISSION CONTROL SYSTEMS EG2 155 ...

Page 433: ...2 INSTALL CONVERTER a Place new gaskets on the converter front and rear pipes and connect the converter to the exhaust pipes b Torque the bolts Torque 39 N m 400 kgf cm 29 ft lbf c Reinstall the bracket bolts and tighten them HEAT INSULATOR INSPECTION 1 CHECK HEAT INSULATOR FOR DAMAGE 2 CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR ENGINE EMISSION CONTROL SYSTEMS EG2 ...

Page 434: ...SERVICE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS EGR valve x Air intake chamber TWC x Exhaust pipe Part tightened VSV for PAIR VSV for EG R ENGINE EMISSION CONTROL SYSTEMS EG2 157 ...

Page 435: ...MFI SYSTEM SYSTEM CIRCUIT DESCRIPTION ENGINE MFI SYSTEM EG2 158 ...

Page 436: ...nt temperature etc the microcomputer ECM triggers the spark at precisely the right instant 3 Diagnosis Function When the ECM detects malfunction or abnormalities in the sensor network it lights the mal function indicator lamp in the combination meter At the same time the trouble is identified and a diagnostic trouble code is recorded by the ECM The diagnostic trouble code can be read by the number...

Page 437: ...the fuel tank through the return pipe When the engine is hot the fuel pressure is increased to control percolation in the fuel system and improve restartability and idling stability The pulsation damper absorbs the slight fluctuations in fuel pressure caused by fuel injector from the injector The injectors operate on input of injection signals from the ECM and inject fuel into the intake manifold ...

Page 438: ...e valve opening is distributed from the air intake chamber to the manifold of each cylinder and is drawn into the combustion chamber At low temperatures the air valve opens and the air flows through the air valve and the throttle body into the air intake chamber During engine warning up even if the throttle valve is completely closed air flows to the air intake chamber thereby increasing the idle ...

Page 439: ...rature and atmospheric pressure etc and convert the information into an electrical signal which is sent to the ECM Based on these signals the ECM calculates the optimum ignition timing for the current conditions and operates the injectors The ECM not only controls the fuel injection timing but also the self diagnostic function which records the occurrence of a malfunction ignition timing control i...

Page 440: ...n Measuring Tool Set 09842 30070 Wiring F EFI Inspection 09082 00015 TOYOTA Electrical Tester 09268 45012 EFi Fuel Pressure Gauge 09842 30050 Wire A EFI Inspection Plug for the vacuum hose fuel hose etc 09843 18020 Diagnosis Check Wire 09200 00010 Engine Adjust Kit 09240 00020 Wire Gauge set 09258 00030 Hose Plug Set Fuel line flare nut Throttle body ENGINE MFI SYSTEM EG2 163 ...

Page 441: ...EQUIPMENT Graduated cylinder Carburetor cleaner Tachometer Throttle body Throttle body Soft brush Injector ENGINE MFI SYSTEM EG2 164 ...

Page 442: ...the tachometer positive terminal to the IG E terminal of the DLC1 b Use the battery as the power source for the timing light tachometer etc 3 IN EVENT OF ENGINE MISFIRE THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN a Check proper connection of battery terminals etc b Handle high tension cords carefully c After repair work check that the ignition coil termi nals and all other ignition system lines are ...

Page 443: ...ecially do not wind them together c Check that the feeder and antenna are properly adj usted d Do not equip your vehicle with a powerful mobile radio system e Do not open the cover or the case of the ECM unless absolutely necessary If the IC terminals are touched the IC may be destroyed by static electricity ELECTRONIC CONTROL SYSTEM 1 Before removing MFI wiring connectors terminals etc first disc...

Page 444: ...take care to prevent entry of water Also when washing the engine compartment prevent water from getting on the MFI parts and wiring connectors 7 Parts should be replaced as an assembly b Fully insert the connector and check that it is locked 8 Care is required when pulling out the inserting wiring connectors a To pull the connector out release the lock and pull on the connector 9 When inspecting a...

Page 445: ...ed torque Torque 15 N m 150 kgf cm 11 ft lbf Flare nut type a Apply a light coat of engine oil to the flare and tighten the flare nut by hand b Then using SST tighten the flare nut to the specified torque SST 09631 22020 Torque 27 N m 280 kgf cm 20 ft lbf HINT Use a torque wrench with a fulcrum length of 30 cm 11 81 in b Insert the tester probe into the connector from the wiring side when checking...

Page 446: ... approx 392 kPa 4 kgf cm2 57 psi In this state check to see that there are no leaks from any part of the fuel system NOTICE Always pinch the hose Avoid bending the hose as it may cause the hose to crack 5 Confirm that there are no fuel leaks after performing any maintenance on the fuel system a With engine stopped turn the ignition switch ON b Using SST connect terminals FP and B of the DLC 1 SST ...

Page 447: ...tor lamp when TE1 and E1 terminals on the DLC1 are connected When 2 or more codes are indicated the lowest number code will appear first If a malfunction is detected when in the test mode the ECM lights up the malfunction indicator lamp to inform the technician of the occurrence of a malfunction except for code Nos 42 43 and 51 In this case TE2 and E1 terminals on the DLC1 should be connected as s...

Page 448: ... temperature 2 Turn the ignition switch ON Do not start the engine MALFUNCTION INDICATOR LAMP CHECK 1 The malfunction indicator lamp will come on when the ignition switch is placed at ON and the engine is not running 2 When the engine is started the malfunction indicator lamp should go off If the light remains on the diagnosis system has detected a malfunction or abnormality in the system 3 Using ...

Page 449: ...ill be repeated as long as the DLC1 terminals TE1 and E1 are connect ed HINT In the event of a number of trouble codes indication will begin from the smallest value and continue to the largest in order 4 Read the diagnostic trouble code as indicated by the number of flashes of the malfunction indicator lamp Diagnostic trouble code See pages EG2 176 and 177 a Normal System Operation no malfunction ...

Page 450: ...t normal operating temperature c 2 trip detection logic The diagnostic trouble codes 21 25 26 and 71 are used 2 trip detection logic is used With this logic when a logic malfunction is first detected the mal function is temporarily stored in the ECM memory If the same case is detected again during the second drive test this second detection causes the malfunc tion indicator lamp to light up The 2 ...

Page 451: ... the operation in step 3 is not performed When the automatic transmission shift lever is in the D 2 L or R shift position or when the air conditioning is on or when the accelerator pedal is depressed code 51 Switch condition signal is output but this is not abnormal HINT To confirm that the test mode is operating check that the malfunction indicator lamp flashes when the ignition switch is turned ...

Page 452: ...ngine components requiring removal of the battery terminal a check must first be made to see if a diagnostic trouble code has been recorded 2 After cancellation perform road test of the vehicle to check that a normal code is now read on the mal function indicator lamp If the same diagnostic trouble code appears it indi cates that the trouble area has not been repaired thoroughly DIAGNOSIS INDICATI...

Page 453: ...litude of heated oxygen sensor signal OX is reduced to between 0 35 0 70 V continuously for 60 secs or more 6 2 trip detection logic 2 Open or short in engine coolant temp sensor circuit for 0 5 sec or more THW Open or short in intake air temp circuit Intake air temp sensor ECM Open or short in heated oxygen sensor circuit Heated oxygen sensor ECM Open or short in heater circuit of heated oxygen s...

Page 454: ...ort detected continuously for 0 5 sec or more in volume air flow meter circuit Open E2 short VS VC DIAGNOSTIC TROUBLE CODES Cont d Open or short detected in throttle position sensor signal VTA for 0 5 sec or more IDL contact is ON and VTA output exceeds 1 45 V SPD signal is not input to the ECM for at least 8 seconds during high load driving with engine speed between 2 750 rpm and 4 000 rpm Open o...

Page 455: ... steady speed to avoid engine braking 6 Maintain the vehicle speed at 40 50 mph Keep the vehicle running for 1 2 min after starting acceleration HINT If a malfunction is detected the malfunction indication lamp will light up during step 6 NOTICE If the conditions in this test are not strictly followed detection of the malfunction will not be possible DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTE...

Page 456: ...on is detected the malfunction indication lamp will light up during step 6 NOTICE If the conditions in this test are not strictly followed detection of the malfunction will not be possible DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the mal...

Page 457: ...n indicator lamp will light up during step 4 NOTICE If the conditions in this test are not strictly followed detection of the malfunction will not be possible DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the malfunction is corrected when the...

Page 458: ...alfunction indication lamp will light up during step 4 NOTICE If the conditions in this test are not strictly followed detection of the malfunction will not be possible DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Cont d Purpose of the driving pattern a To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded b To check that the malfunction is correcte...

Page 459: ... when ECM terminal W is grounded to the body Check bulb fuse and wiring between ECM and ignition switch Is there diagnostic trouble code output when DLC1 and terminals TE1 and E1 are connected Check wiring between ECM and malfunction Indicator lamp DIAGNOSIS CIRCUIT INSPECTION Check wiring between ECM terminal E1 and body ground Cancel out diagnostic trouble code Further repair required Repair or ...

Page 460: ...le check of the fuses fusible links and connecting condition of the connectors before making your inspection according to the procedures listed The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component outside the computer or a short circuit within the computer If engine trouble occurs even though proper operating v...

Page 461: ...TLE POSITION SENSOR VOLUME AIR FLOW METER INTAKE AIR TEMP SENSOR VOLUME AIR FLOW METER HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR PATTERN SELECT SWITCH T F FLUID TEMP SENSOR 4WD OIL TEMP SENSOR HEATED OXYGEN SENSOR VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR EGR GAS TEMP SENSOR COLD START INJECTOR CRUISE CONTROL ECU A C MAGNET SWITCH STOP LIGHT SWITCH ENGINE GROUND O D MAIN SWITCH SENSOR GROUND START...

Page 462: ...t temperature 80 C 176 F Intake air temperature 20 C 68 F Measuring plate fully closed Measuring plate fully open Stop light switch ON Throttle valve fully open Throttle valve open Ignition SW ON Ignition SW ON Ignition SW ON Ignition SW ON Ignition SW O N Ignition SW ON STD voltage EG2 194 Terminals 3 000 rpm Condition See page Cranking Cranking EG2 190 EG2 188 EG2 196 EG2 186 EG2 193 EG2 198 EG2...

Page 463: ... and body ground 1 There is no voltage between ECM terminals BATT and E1 Check wiring between fuse and ECM Check fuse and fusible link Ignition switch 4N Repair or replace Repair or replace Try another ECM BATT El STD Voltage No voltage Terminals Condition Replace Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG2 186 ...

Page 464: ...between ECM terminal El and body ground Check wiring between EFI main relay and ECM terminal B B1 Check wiring between E F I main relay and battery Check fuse fusible link and ignition switch Check EF 1 main relay B B1 E1 Repair or replace Repair or replace Repair or replace Repair or replace Try another ECM BAD Replace BAD SAD BAD BAD ENGINE MFI SYSTEM EG2 187 ...

Page 465: ...tle valve fully closed Throttle opener must be cancelled first Check wiring between ECM and throttle position sensor Replace or repair throttle position sensor 3 Check throttle position sensor Throttle valve fully open Throttle valve open IDL E2 E21 Ignition switch O N Replace or repair Replace or repair Try another ECM Refer to No 1 STD Voltage No voltage Condition Terminals Trouble BAD BAD BAD B...

Page 466: ...ge between ECM terminals VC and E2 E21 IG SW ON 3 Check throttle position sensor Check wiring between ECM and throttle position sensor Check wiring between ECM and throttle position 2 Check throttle position sensor Perform inspection of VC E2 E21 Repair or replace wiring Try another ECM VTA E2 E21 VC E2 E21 Repair or replace Repair or replace Repair or replace Try another ECM Refer to No 1 BAD BAD...

Page 467: ... ECM and volume air flow meter Replace or repair volume air flow meter Intake air temperature 20 C 68 F 3 Check volume air flow meter Measuring plate fully dosed Measuring plate fully open Replace or repair wiring Try another ECM VC E2 E21 Refer to No 1 Ignition SW ON STD Voltage No voltage Terminals IG SW ON Condition Trouble Idling BAD BAD No ENGINE MFI SYSTEM EG2 190 ...

Page 468: ...tween ECM terminals THA and E2 E21 IG SW ON Check wiring between ECM and volume air flow meter Check wiring between ECM and volume air flow meter 2 Check intake air temp sensor b Check volume air flow meter Replace volume air flow meter Repair or replace wiring Refer to VC E2 E21 THA E2 E21 VS E2 E21 Repair or replace Try another ECM Repair or replace Repair or replace Try another ECM Refer to No ...

Page 469: ...ECM and engine coolant temp sensor Check wiring between ECM terminal E1 and body ground Engine coolant temperature 80 C 176 F 3 Check engine coolant temp sensor Replace engine coolant temp sensor Ignition switch ON Repair or replace Repair or replace Try another ECM Refer to No 1 STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG2 192 ...

Page 470: ...nd body ground Check wiring between ignition switch ST1 terminal and starter terminal 50 Check wiring between ECM terminal STA and starter terminal 50 Check fusible link battery wiring and ignition switch Check starter operation Repair or replace Repair or replace Repair or replace STD Voltage Check starter No voltage Cranking Terminals Condition Trouble BAD BAD BAD BAD No ENGINE MFI SYSTEM EG2 19...

Page 471: ...n each injector STD resistance 13 4 14 2 Ω Check wiring between ECM terminal E01 and or E02 and body ground Check wiring between ECM terminal 10 and or 20 and battery Check fusible link and ignition switch Ignition switch ON Repair or replace Repair or replace Repair or replace Try another ECM Replace injector STD Voltage No voltage Terminals Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG2 ...

Page 472: ... E1 and body ground Check wiring between ECM and igniter Check wiring between igniter and distributor Repair or replace Repair or replace Repair or replace Repair or replace Pulse generation Try another ECM Check distributor Refer to No 1 Check igniter STD Voltage No voltage Terminals Condition GT E1 Replace Trouble Idling BAD BAD BAD BAD BAD BAD No ENGINE MFI SYSTEM EG2 195 ...

Page 473: ...minal E1 and body ground Check GAUGE fuse 10A and malfunction indicator lamp No trouble malfunction indicator lamp off and engine running Fuse blows again Check wiring between ECM terminal W and fuse Repair or replace Repair or replace Try another ECM Repair or replace STD Voltage No voltage Terminals Condition Trouble BAD BAD No BAD ENGINE MFI SYSTEM EG2 196 ...

Page 474: ...RT Check wiring between ECM terminal E1 and body ground Check wiring between ECM and cold start injector Engine coolant temperature 80 176 F 3 Check cold start injector Replace cold start injector Repair or replace wiring Try another ECM Refer to No 1 STD Voltage No voltage Cranking Terminals Condition Trouble BAD BAD No ENGINE MFI SYSTEM EG2 197 ...

Page 475: ... and body ground 1 There is no voltage between ECM terminals STP and E1 Check wiring between ECM terminal STP and battery Check STOP fuse 15A and stop light switch Stop light switch ON Repair or replace Repair or replace Repair or replace Terminals Try another ECM STD Voltage No voltage Condition Trouble BAD BAD BAD No ENGINE MFI SYSTEM EG2 198 ...

Page 476: ... ENGINE MFI SYSTEM EG2 199 ...

Page 477: ...r leaking into air induction system Check distributor and ignition system Replace heated oxygen sensor Check volume air flow meter Check cold start injector Rich malfunction only Check fuel pressure Try another ECM Check spark plugs Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Check injector System normal Repair air l...

Page 478: ... E2 E21 Engine running at 2 000 rpm Check wiring between ECM terminal E1 and body ground Check wiring between ECM and EG R gas temp sensor Check EGR gas temp sensor Replace EGR gas temp sensor Check EGR system Try another ECM Repair or replace Repair or replace Repair or replace Refer to No 1 BAD BAD BAD BAD ENGINE MFI SYSTEM EG2 201 ...

Page 479: ...ngine b Using SST connect terminals FP and B of the DLC 1 SST 09843 18020 HINT The DLC1 is located near the No 2 relay block c Check that there is pressure in the fuel inlet hose HINT At this time you will hear fuel return noise from the fuel return hose FUEL PUMP SYSTEM CIRCUIT ENGINE MFI SYSTEM EG2 202 ...

Page 480: ...ressure gauge to the LH delivery pipe with three new gaskets and SST union bolt as shown in the illustration SST 09268 45012 Torque 34 N m 350 kgf cm 25 ft lbf g Wipe off any splattered gasoline h Reconnect the battery negative terminal c Place a suitable container or shop towel under the LH delivery pipe d Slowly loosen the union bolt of the No 3 fuel pipe and remove the union bolt and two gasket...

Page 481: ... not within specification check the fuel pump fuel pressure regulator and or injectors s After checking fuel pressure disconnect the battery negative terminal and carefully remove the SST to prevent gasoline from splashing p Reconnect the vacuum hose to the fuel pressure regulator q Measure the fuel pressure at idling Fuel pressure 226 255 kPa 2 3 2 6 kgf cm2 33 37 psi If not within the specified ...

Page 482: ... ft lbf u Reconnect the battery negative terminal v Start the engine and check for fuel leakage FUEL PUMP REMOVAL 1 DRAIN FUEL FROM FUEL TANK CAUTION Do not smoke or work near an open flame when working on the fuel pump 2 REMOVE FUEL TANK COMPONENTS FOR REMOVAL AND INSTALLATION ENGINE MFI SYSTEM EG2 205 ...

Page 483: ...fuel pump b Connect the fuel hose to the outlet port of the fuel pump c Install the fuel pump connector d Install the fuel pump by pushing the lower side of the fuel pump FUEL PUMP INSTALLATION See Components for Removal and Installation 1 INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip 5 REMOVE FUEL PUMP FILTER FROM FUEL PUMP a Using a small screwdriver remove the cl...

Page 484: ...the spe cified position and install the clip to the specified location If reusing the hose reinstall the clip at the original location 5 REFILL WITH FUEL 3 INSTALL FUEL PUMP BRACKET a Place the bracket with a new gasket on the fuel tank b Install and tighten the seven bolts Torque 3 9 N m 40 kgf cm 34 in lbf ENGINE MFI SYSTEM EG2 207 ...

Page 485: ...nnect the cold start injector connector b Using an ohmmeter check the resistance of the in jector Resistance 2 4 If the resistance is not as specified replace the cold start injector c Connect the cold start injector connector COMPONENTS FOR REMOVAL AND INSTALLATION ENGINE MFI SYSTEM EG2 208 ...

Page 486: ...ON HINT Do not start the engine e Using SST connect terminals FP and B of the DLC 1 SST 09843 18020 COLD START INJECTOR REMOVAL See Components for Removal and Installation 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT COLD START INJECTOR CONNEC TOR 3 REMOVE COLD START INJECTOR a Put a suitable container or shop towel under the cold start injector tube b Remove the union bolt an...

Page 487: ...all the cold start injector with the two nuts Torque 7 8 N m 80 kgf cm 69 in lbf 2 INSPECT LEAKAGE a Disconnect the test probes of SST from the battery and check fuel leakage from the injector SST 09842 30050 Fuel drop One drop or less per minute b After checking remove SST and restore the following parts to their original positions DLC1 Ignition switch OFF Cold start injector Injector connector f...

Page 488: ...18020 b Check for fuel leakage c Remove SST from the DLC1 2 INSTALL COLD START INJECTOR TUBE Using new gaskets connect the cold start injector tube with the union bolts Torque 15 N m 150 kgf cm 11 ft lbf 3 CONNECT COLD START INJECTOR CONNECTOR 4 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY ENGINE MFI SYSTEM EG2 211 ...

Page 489: ...1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DRAIN ENGINE COOLANT FUEL PRESSURE REGULATOR ON VEHICLE INSPECTION CHECK FUEL PRESSURE See step 2 on page EG2 203 COMPONENTS FOR REMOVAL AND INSTALLATION ENGINE MFI SYSTEM EG2 212 ...

Page 490: ...FOLLOWING CABLES a w Cruise control Actuator cable with bracket b Accelerator cable c A T Throttle cable 4 DISCONNECT AIR CLEANER HOSE 7 REMOVE AIR INTAKE CHAMBER a Disconnect the throttle position sensor connector b Disconnect the canister vacuum hose from the throttle body d Disconnect the No 4 water by pass hose from the union of the intake manifold c Disconnect the PCV hose from the union ENGI...

Page 491: ...C Disconnect the EGR gas temp sensor connector j Disconnect the EGR vacuum hoses from the air pipe and EGR vacuum modulator f Disconnect the cold start injector connector g Remove the union bolt two gaskets and cold start injector tube e Disconnect the No 5 water by pass hose from the water by pass pipe k Remove the nut two bolts intake chamber stay and throttle cable bracket ENGINE MFI SYSTEM EG2...

Page 492: ...fuel pressure regulator q Remove the six bolts two nuts intake chamber and gasket o Disconnect the four vacuum hoses from the air pipes p Remove the two bolts and accelerator cable bracket n Disconnect the No 1 air hose from the PAIR reed valve ENGINE MFI SYSTEM EG2 215 ...

Page 493: ...gulator c Thrust the fuel pressure regulator completely into the delivery pipe by hand 2 INSTALL AIR INTAKE CHAMBER a Position a new gasket on the intake manifold b Install the intake chamber with the six bolts and two nuts Torque 18 N m 185 kgf cm 13 ft lbf d Turn the fuel pressure regulator counterclockwise until the outlet faces in the direction indicated in the illustration e Torque the lock n...

Page 494: ...the pipes to the intake chamber and RH exhaust manifold h C C only Connect the two water by pass hoses to the EGR valve i Install the air intake chamber stay and throttle cable bracket Install and torque the six nuts and two bolts Torque A 29 N m 300 kgf cm 22 ft lbf B 18 N m 185 kgf cm 13 ft lbf c Install the accelerator cable bracket with the two bolts d Connect the four vacuum hoses to the air ...

Page 495: ...d start injector connector r Connect the canister vacuum hose to the throttle body s Connect the throttle position sensor connector o install the No 5 Water by pass hose to the water by pass pipe p Connect the No 4 water by pass hose to the union of the intake manifold q Connect the PCV hose to the union ENGINE MFI SYSTEM EG2 218 ...

Page 496: ...l leakage c Remove SST from the DLC1 6 CONNECT FOLLOWING CABLES a A T Throttle cable b Accelerator cable c w Cruise control Actuator cable with bracket 7 REFILL WITH ENGINE COOLANT 8 CONNECT CABLE TO NEGATIVE TERMINAL CF BATTERY 3 CONNECT FUEL RETURN HOSE 4 CONNECT VACUUM SENSING HOSE 5 CONNECT AIR CLEANER HOSE ENGINE MFI SYSTEM EG2 219 ...

Page 497: ...INJECTOR COMPONENTS FOR REMOVAL AND INSTALLATION ENGINE MFI SYSTEM EG2 220 ...

Page 498: ...ontrol Actuator cable with bracket b Accelerator cable c A T Throttle cable 4 DISCONNECT AIR CLEANER HOSE See Components for Removal and Installation 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DRAIN ENGINE COOLANT 7 REMOVE AIR INTAKE CHAMBER a Disconnect the throttle position sensor connector b Disconnect the canister vacuum hose from the throttle body c Disconnect the PCV hose from th...

Page 499: ...and C C Disconnect the EGR gas temp sensor connector j Disconnect the EGR vacuum hoses from the air pipe and EGR vacuum modulator e Disconnect the No 5 water by pass hose from the water by pass pipe k Remove the nut two bolts intake chamber stay and throttle cable bracket d Disconnect the No 4 water by pass hose from the union of the intake manifold ENGINE MFI SYSTEM EG2 222 ...

Page 500: ...om No 3 camshaft bearing cap Injector connectors I C C only Disconnect the two water by pass hoses from the EGR valve m Remove the five nuts EGR valve with the pipes and two gaskets q Remove the six bolts two nuts intake chamber and gasket o Disconnect the four vacuum hoses from air pipes p Remove the two bolts and accelerator cable bracket n Disconnect the No 1 air hose from the PAIR reed valve E...

Page 501: ... four insulators ten spacers and four O rings from the cylinder head d Pull out the six injectors from the delivery pipes e Remove the O ring and grommet from each injector INJECTORS INSPECTION 1 MEASURE RESISTANCE OF INJECTOR Using an ohmmeter check the resistance of both terminals Resistance 13 4 14 2 Ω 9 REMOVE NO 2 AND NO 3 FUEL PIPES Remove the four union bolts No 2 No 3 fuel pipes and eight ...

Page 502: ...hold the injector and union with SST clamp SST 09268 41045 f Put the injector into the graduated cylinder HINT Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out i Using SST connect terminals FP and B of the DLC1 SST 09843 18020 HINT Fuel pump will operate g Connect the battery negative cable h Turn the ignition switch ON HINT Do not start the engine 2 TEST INJE...

Page 503: ...d check for fuel leakage from the injector nozzle SST 09842 30070 Fuel drop One drop or less per minute See Components for Removal and Installation 1 INSTALL INJECTORS AND DELIVERY PIPES a Install a new grommet to the injector b Apply a light coat of gasoline to a new O ring and install it to the injector c While turning the injector clockwise and counter clockwise push it to the delivery pipe Ins...

Page 504: ...othly the probable cause is incorrect installation of 0 rings Replace the O rings k Position the injector connector upward 2 INSTALL NO 2 AND NO 3 FUEL PIPES a Install the No 2 fuel pipe with four new gaskets and two union bolts Torque 34 N m 350 kgf cm 25 ft Ibf b Install the No 3 fuel pipe with four new gaskets and two union bolts Torque 34 N m 350 kgf cm 25 ft lbf I Tighten the four nuts holdin...

Page 505: ...ble bracket Install and torque the six nuts and two bolts Torque A 29 N m 300 kgf cm 22 ft lbf B 18 N m 185 kgf cm 13 ft lbf 4 INSTALL AIR INTAKE CHAMBER a Position a new gasket on the intake manifold b Install the intake chamber with the six bolts and two nuts Torque 18 N m 185 kgf cm 13 ft lbf c Install the accelerator cable bracket with the two bolts d Connect the four vacuum hoses to the air p...

Page 506: ...as filter m Connect the cold start injector tube with a new gasket and the union bolt Torque 15 N m 150 kgf cm 13 ft lbf n Connect the cold start injector connector o Install the No 5 water by pass hose to the water by pass pipe p Connect the No 4 water by pass hose to the union of the intake manifold q Connect the PCV hose to the union ENGINE MFI SYSTEM EG2 229 ...

Page 507: ...ING CABLES a A T Throttle cable b Accelerator cable c w Cruise control Actuator cable with bracket r Connect the canister vacuum hose to the throttle body s Connect the throttle position sensor connector 9 REFILL WITH ENGINE COOLANT 10 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 5 CONNECT FUEL RETURN HOSE 6 CONNECT VACUUM SENSING HOSE 7 CONNECT AIR CLEANER HOSE ENGINE MFI SYSTEM EG2 230 ...

Page 508: ...FUEL TANK AND LINE COMPONENTS ENGINE MFI SYSTEM EG2 231 ...

Page 509: ...r damage c Inspect the fuel tank for deformations cracks or fuel leakage d Inspect the filler neck for damage or fuel leakage e Hose and tube connections are as shown in the il lustration If a problem is found repair or replace the parts as necessary 1 Always use new gaskets when replacing the fuel tank or component part 2 Apply the proper torque to all parts to be tightened PRECAUTIONS ENGINE MFI...

Page 510: ...en each terminal If not within specification replace the volume air flow meter c Reconnect the volume air flow meter connector COMPONENTS FOR REMOVAL AND INSTALLATION Between terminals 46 C 104 F 60 C 140 F 20 C 4 F 200 400C 0 4 0 7k 200 600C 0 9 1 3 k 20 C 68 F Temperature 10 20k O C 32 F Resistance THA E2 THA E2 THA E2 THA E2 THA E2 4 7k 2 3k FC E1 VS e2 VC e2 Infinity ENGINE MFI SYSTEM EG2 233 ...

Page 511: ...OR BRACKET a Disconnect the air hose b Remove the two bolts and resonator bracket 3 DISCONNECT VOLUME AIR FLOW METER CON NECTOR 4 DISCONNECT AIR CLEANER HOSE VOLUME AIR FLOW METER REMOVAL See Components for Removal Installation 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY HINT Resistance between terminals E2 and VS will change in a wave pattern as the measuring plate slowly opens If not wi...

Page 512: ... and four nuts Pry the lock plate on the nut b Install the bracket with the bolt and two screws 2 INSTALL AIR CLEANER CAP AND VOLUME AIR FLOW METER ASSEMBLY 3 INSTALL AIR CLEANER HOSE 4 CONNECT VOLUME AIR FLOW METER CONNEC TOR 5 INSTALL RESONATOR BRACKET a Install the resonator bracket with the two bolts b Connect the air hose 6 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY ENGINE MFI SYSTEM EG2 2...

Page 513: ...vacuum at each port Start the engine Check the vacuum with your finger d Using an ohmmeter measure the resistance between each terminal e Reconnect the sensor connector Clearance between lever and stop screw Throttle valve fully open 0 50 mm 0 020 in 0 80 mm 0 031 in Between terminals Resistance 0 47 6 1 k 0 3 1 12 1 k 2 3 k or less At 3 500 rpm 3 9 9 0 k 0 mm 0 in No vacuum No vacuum Port name No...

Page 514: ...G2 27 Idle speed 800 50 rpm e If not as specified adjust with the DP adjusting screw D Check and adjust DP setting speed a Maintain engine speed at 2 500 rpm or more b Plug the VTV hole with your finger c Release the throttle valve d Check the DP is set DP setting speed 2 000 200 rpm C Remove cap filter and separator from DP ENGINE MFI SYSTEM EG2 237 ...

Page 515: ...e returns to idle speed in approx 1 second c Release the throttle valve d Check that the throttle opener is set Throttle opener setting speed 900 1 800 rpm if not as specified replace the throttle body assembly C Check throttle opener setting speed a Disconnect the vacuum hose from the throttle opener and plug the hose end b Maintain the engine at 2 500 rpm F Reinstall DP separator filter and cap ...

Page 516: ... coolant temp below 80 C 176 F When the idle speed adjusting screw is in the engine speed should drop After warm up When the idle speed adjusting screw is in the engine speed should drop below idle speed stop COMPONENTS FOR REMOVAL AND INSTALLATION e Reconnect the vacuum hose to the throttle opener ENGINE MFI SYSTEM EG2 239 ...

Page 517: ...CONNECT VACUUM HOSES 6 REMOVE ACCELERATOR CABLE BRACKET 7 DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 3 DISCONNECT FOLLOWING CABLES a w Cruise control Actuator cable with bracket b Accelerator cable c A T Throttle cable 8 REMOVE THROTTLE BODY a Remove the four bolts throttle body and the gasket b Disconnect the No 4 and No 5 water by pass hoses from the throttle body ENGINE MFI SYSTEM EG2 240 ...

Page 518: ...earance between the throttle stop screw and throttle lever when the throttle valve is fully closed 3 INSPECT THROTTLE POSITION SENSOR a Apply vacuum to the throttle opener b Insert a thickness gauge between the throttle stop screw and stop lever c Using an ohmmeter measure the resistance between each terminal d Reconnect the sensor connector Clearance between lever and stop screw Throttle valve fu...

Page 519: ...JUST THROTTLE POSITION SENSOR a Loosen the two screws of the sensor d Gradually turn the sensor clockwise until the ohm meter deflects and secure the sensor with the two screws e Using a thickness gauge recheck the continuity be tween terminals IDL and E2 Clearance between lever and stop screw Continuity IDL E2 0 50 mm 0 020 in 0 80 mm 0 031 in No continuity Continuity ENGINE MFI SYSTEM EG2 242 ...

Page 520: ...ody with the four bolts Torque 18 N m 185 kgf cm 13 ft lbf 2 CONNECT THROTTLE POSITION SENSOR CON NECTOR 7 REFILL WITH ENGINE COOLANT 8 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 6 CONNECT FOLLOWING CABLES a A T Throttle cable b Accelerator cable c w Cruise control Actuator cable with bracket 3 INSTALL ACCELERATOR CABLE BRACKET 4 CONNECT VACUUM HOSES 5 CONNECT AIR CLEANER HOSE ENGINE MFI SYSTEM...

Page 521: ...ELECTRONIC PARTS LOCATION ENGINE MFI SYSTEM EG2 244 ...

Page 522: ...that there is no continuity between terminals 2 and 5 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Using an ohmmeter check that there is continuity between terminals 3 and 5 If operation is not as specified replace the relay EFI MAIN RELAY INSPECTION EFI MAIN RELAY ENGINE MFI SYSTEM EG2 245 ...

Page 523: ...ween terminals B and FP If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals STA and E1 b Using an ohmmeter check that there is continuity between terminals B and FP c Apply battery voltage across terminals B and FC d Check that there is continuity between terminals 13 and FP If operation is not as specified replace the relay CIRCUI...

Page 524: ...ing an ohmmeter measure the resistance between terminals If the resistance is not as specified replace the switch c Reconnect the connector COLD START INJECTOR TIME SWITCH Engine coolant temperature Above 25 C 77 F Below 10 C 50 F Between terminals Resistance STA Ground STA STJ STA STJ 30 50 30 90 70 90 ENGINE MFI SYSTEM EG2 247 ...

Page 525: ...P SENSOR a Disconnect the connector b Using an ohmmeter measure the resistance between terminals Resistance Refer to the chart above If the resistance is not as specified replace the sensor c Reconnect the connector ENGINE COOLANT TEMPERATURE ECT SENSOR ENGINE MFI SYSTEM EG2 248 ...

Page 526: ...the battery terminals as illustrated b Blow into pipe E and check that air comes out of air filter c Disconnect the battery d Blow into pipe E and check that air comes out of pipe G If a problem is found repair or replace the VSV FUEL PRESSURE CONTROL SYSTEM ENGINE MFI SYSTEM EG2 249 ...

Page 527: ...ce between both terminals as illustrated Specified resistance 30 50 Ω at 20 C 68 F 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between each terminal and the VSV body If there is continuity replace the VSV ENGINE MFI SYSTEM EG2 250 ...

Page 528: ...SENSOR Using an ohmmeter measure the resistance between both terminals Resistance 69 89 k 50 C 122 F 11 15 k 100 C 212 F 2 4 k 150 C 302 F If the resistance is not as specified replace the sensor EGR GAS TEMPERATURE SENSOR California and C C ENGINE MFI SYSTEM EG2 251 ...

Page 529: ...een terminals TE1 and E1 of the DLC1 SST 09843 18020 Warm up the heated oxygen sensor with the engine at 2 500 rpm for approx 90 seconds And maintain engine speed at 2 500 rpm Warm up the heated oxygen sensor with the engine at 2 500 rpm for approx 90 seconds Less than 8 times CONTINUED ON PAGE EG2 253 Connect terminals TE1 and E1 of the DLC1 And maintain engine speed at 2 500 rpm Check that the n...

Page 530: ... engine speed at 2 500 rpm Read and record diagnostic trouble codes See page EG2 176 Malfunction code s ex code 21 code 25 and code 26 Connect terminals TE1 and El of the DLC1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VF1 and E1 Measure voltage between terminals VF1 and E1 Repair the relevent diagnostic trouble code ...

Page 531: ...nal HINT Perform all voltage measurements with the con nectors connected Verify that the battery voltage is 11 V or more when the ignition switch is ON ENGINE CONTROL MODULE ECM ENGINE CONTROL MODULE ECM INSPECTION HINT The MFI circuit can be checked by measuring the voltage and resistance at the wiring connectors of the engine control module ECM ENGINE MFI SYSTEM EG2 254 ...

Page 532: ...e coolant temperature 80 C 176 F Engine coolant temperature 80 C 176 F Intake air temperature 20 C 68 F Measuring plate fully closed Measuring plate fully open Throttle valve fully open Stop light switch ON Throttle valve open Ignition SW ON Ignition SW ON Ignition SW ON Ignition SW ON Ignition SW ON Ignition SW ON STD voltage 3 000 rpm Condition Terminals Cranking Cranking Idling Idling V0224 3 E...

Page 533: ...ctors Resistance Throttle valve fully closed Throttle opener must be cancelled first Throttle valve fully closed Throttle opener must be cancelled first Engine Control Module ECM Terminals Throttle position sensor connector disconnected Volume air flow meter connector disconnected Engine coolant temperature 80 C 176 F Intake air temperature 20 C 68 F Hot 50 100 C 122 212 F Cold 10 50 C 14 122 F Ho...

Page 534: ...ility of yours before use 3 INSPECT FUEL CUT OPERATION a Increase the engine speed to at least 2 500 rpm b Check for injector operating sound c Check that when the throttle lever is released injector operation sound stops momentarily and then res umes HINT The vehicle should be stopped Accessories switched OFF Fuel return rpm M T 1 300 rpm A T 1 500 rpm 4 DISCONNECT TACHOMETER FUEL CUT RPM FUEL CU...

Page 535: ... between stop screw and lever Terminals EGR gas temp sensor Calif and C C California 2WD only Others Cold start injector time switch VSV Fuel pressure control Engine coolant temp sensor Heated oxygen sensor Fuel pressure regulator Resistance Fuel leakage Throttle position sensor Volume air flow meter Heater coil resistance Cold start injector Fuel pressure Throttle body at no vacuum Resistance Res...

Page 536: ...ttle valve open IG SW ON Throttle valve fully closed Throttle opener must be cancelled first Idling 3 000 rpm IG SW ON IG SW ON IG SW ON Intake air temp 20 C 68 F IG SW ON IG SW ON Measuring plate fully closed IG SW ON Engine coolant temp 80 C 176 F IG SW ON Measuring plate fully open IG SW ON Throttle valve fully open Terminals Condition ECM ENGINE MFI SYSTEM EG2 259 ...

Page 537: ... Throttle opener must be cancelled first TORQUE SPECIFICATIONS Cold start injector x Air intake chamber Delivery pipe x Cold start injector tube Delivery pipe x Fuel pressure regulator Delivery pipe x Pulsation damper Delivery pipe x Intake manifold Delivery pipe x No 3 fuel pipe Delivery pipe x No 2 fuel pipe Fuel return rpm Fuel drain plug Part tightened Fuel cut rpm Fuel pump M T A T Terminals ...

Page 538: ... is a network of channels in the outer area of the cylinder block and cylinder head It is designed so that the engine coolant flowing through it can provide adequate cooling to the areas subjected to the highest thermal stresses in particular the cylinders and combustion chambers during engine operation RADIATOR The radiator mounted at the front of vehicle consists of an upper and lower tank and a...

Page 539: ... as a result of volumetric expansion when the engine coolant is heated When the engine coolant temper ature drops engine coolant in the reservoir tank returns to the radiator thus keeping the radiator full at all times and avoiding needless engine coolant loss To find out if the engine coolant needs to be replenished check the reservoir tank level WATER PUMP The water pump is used for forced circu...

Page 540: ... or equivalent SSM SPECIAL SERVICE MATERIALS 10 0 liters 10 6 US qts 8 8 Imp qts 9 8 liters 10 4 US qts 8 6 Imp qts PREPARATION EQUIPMENT 2WD M T A T 4WD M T A T ENGINE COOLANT Radiator cap tester Ethylene glycol base Classification Torque wrench Thermometer Water pump Capacity Heater Item ENGINE COOLING SYSTEM EG2 263 ...

Page 541: ...ner 2WD M T 9 9 liters 10 5 US qts 8 7 Imp qts A T 9 7 liters 10 3 US qts 8 5 Imp qts 4WD M T 10 0 liters 10 6 US qts 8 8 Imp qts A T 9 8 liters 10 4 US qts 8 6 Imp qts e Install the radiator cap f Start the engine and check for leaks g Recheck the engine coolant level and refill as neces sary COOLANT CHECK AND REPLACEMENT 1 CHECK ENGINE COOLANT LEVEL IN RESERVOIR TANK The engine coolant level sho...

Page 542: ...L 1 REMOVE TIMING BELT See page EG2 32 2 REMOVE THERMOSTAT 3 DISCONNECT NO 2 OIL COOLER HOSE FROM WATER PUMP 4 REMOVE WATER PUMP Remove the seven bolts and water pump WATER PUMP COMPONENTS ENGINE COOLING SYSTEM EG2 265 ...

Page 543: ...ove Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the surface Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove nozzle from the tube and reinstall cap 2 INSPECT FLUID COUPLING Check the fluid coupling for dama...

Page 544: ...pump with the seven bolts Torque Bolt A 18 N m 185 kgf cm 13 ft lbf Bolt B 20 N m 200 kgf cm 14 ft lbf 2 CONNECT NO 2 OIL COOLER HOSE 3 INSTALL THERMOSTAT 4 INSTALL TIMING BELT See page EG2 41 ENGINE COOLING SYSTEM EG2 267 ...

Page 545: ...g temperature 80 84 C 176 183 F Valve lift 8 mm 0 31 in or more at 95 C 203 F If the valve opening temperature and valve lift are not within specifications replace the thermostat c Check that the valve spring is tight when the ther mostat is fully closed If not tight replace the thermostat THERMOSTAT INSTALLATION 1 INSTALL THERMOSTAT a Place a new gasket to the thermostat b Install the thermostat ...

Page 546: ...ICE If using a high pressure type cleaner be car eful not to deform the fins of the radiator core For example keep a distance of more than 40 50 cm 15 75 19 69 in between the radiator core and cleaner nozzle when the cleaner nozzle pressure is 2 942 3 432 kPa 30 35 kgf cm2 427 498 psi 2 CHECK COOLING SYSTEM FOR LEAKS a Fill the radiator with engine coolant and attach a radiator cap tester b Warm u...

Page 547: ...NSTALL RADIATOR a Install the radiator with the four bolts b Connect the oil cooler hoses c Install the No 1 fan shroud d Install the No 2 fan shroud RADIATOR REMOVAL 1 DRAIN ENGINE COOLANT 2 REMOVE ENGINE UNDER COVER 3 REMOVE RADIATOR a Disconnect the reservoir hose b Remove the radiator hoses 2 INSTALL ENGINE UNDER COVER 3 FILL WITH ENGINE COOLANT 4 START ENGINE AND CHECK FOR LEAKS e Install the...

Page 548: ...r block Short bolt Water pump x Cylinder block Long bolt Relief valve opening pressure Cylinder block x Drain plug Valve opening temperature Water inlet x Water pump Start to open Fully open Part tightened Radiator cap STD Limit Thermostat Valve lift ENGINE COOLING SYSTEM EG2 271 ...

Page 549: ...DESCRIPTION A fully pressurized fully filtered lubrication system is used in this engine OPERATION LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM EG2 272 ...

Page 550: ...ns and is discharged when the space becomes narrow OIL PRESSURE REGULATOR RELIEF VALVE At high engine speeds the oil pump supplies more oil to each part than it is necessary For this reason an oil pressure regulator which works to prevent an oversupply of oil is installed on the oil pump During normal oil supply a coil spring and valve keep the by pass closed but when too much oil is being supplie...

Page 551: ...ers 4 5 US qts 3 8 Imp qts 4 5 liters 4 8 US qts 4 0 Imp qts 5 3 liters 5 6 US qts 4 7 Imp qts 5 4 liters 5 7 US qts 4 8 Imp qts 09309 37010 Transmission Bearing Replacer RECOMMENDED TOOLS 09816 30010 Oil Pressure Switch Socket 09228 07500 Oil Filter Wrench 09200 00010 Engine Adjust Kit 09032 00100 Oil Pan Seal Cutter Precision straight edge EQUIPMENT LUBRICANT Oil pressure gauge Camshaft front oi...

Page 552: ...sive 1344 THREE BOND 1344 LOCTITE 242 or equivalent SSM SPECIAL SERVICE MATERIALS Oil pump Oil pan baffle plate Oil pan 08826 00080 Seal packing or equivalent Oil pressure sender gauge ENGINE LUBRICATION SYSTEM EG2 275 ...

Page 553: ...the L and F marks on the level gauge If low check for leakage and add oil up to the F mark 4 INSTALL OIL PRESSURE GAUGE 5 START ENGINE Start the engine and warm it up to normal operating temperature 6 MEASURE OIL PRESSURE Oil pressure At idle speed 29 kPa 0 3 kgf cm2 4 3 psi or more At 3 000 rpm 245 520 kPa 2 5 5 3 kgf cm2 36 75 psi 3 REMOVE OIL PRESSURE SENDER GAUGE Using SST remove the oil press...

Page 554: ...o or three threads Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent b Using SST install the oil pressure sender gauge SST 09818 30010 Torque 15 N m 150 kgf cm 11 ft lbf 9 START ENGINE AND CHECK FOR LEAKS ENGINE LUBRICATION SYSTEM EG2 277 ...

Page 555: ...e gasoline thinners or solvents In order to preserve the environment used oil and used oil filters must be disposed of only at desig nated disposal sites 1 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil dipstick c Remove the oil drain plug and drain the oil into a container d Tighten the filter by hand until the gasket contacts the seat of the filter mounting Then using SST give it ...

Page 556: ...iters 5 6 US qts 4 7 Imp qts Oil capacity 4WD Drain and refill w o Oil filter change 4 2 liters 4 4 US qts 3 7 Imp qts w Oil filter change 4 5 liters 4 8 US qts 4 0 Imp qts Dry fill 5 4 liters 5 7 US qts 4 8 Imp qts 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE LEVEL Recheck the engine oil level and refill as necessary ENGINE LUBRICATION SYSTEM EG2 279 ...

Page 557: ...ss bar separate the oil pan from the baffle plate SST 09032 00100 HINT When removing the oil pan be careful not to damage the oil pan flange OIL PUMP REMOVAL 1 REMOVE ENGINE UNDER COVER 2 4WD REMOVE FRONT DIFFERENTIAL See page SA 57 3 DRAIN ENGINE OIL 4 REMOVE TIMING BELT See page EG2 32 OIL PUMP COMPONENTS ENGINE LUBRICATION SYSTEM EG2 280 ...

Page 558: ... REMOVE DRIVEN AND DRIVE ROTORS a Remove the seven screws and pump body cover b Remove the drive and driven rotors 9 REMOVE OIL PUMP a Remove the seven bolts and oil pump b Using a plastic faced hammer carefully tap the oil pump body c Remove the O ring from the cylinder block 7 REMOVE OIL STRAINER Remove the two bolts two nuts oil strainer and gasket 2 REMOVE RELIEF VALVE a Unscrew the relief val...

Page 559: ...othly replace the valve and or oil pump assembly OIL PUMP INSPECTION 1 INSPECT BODY CLEARANCE Using a thickness gauge measure the clearance be tween the driven rotor and pump body Standard clearance 0 10 0 13 mm 0 0039 0 0051 in Maximum clearance 0 30 mm 0 0118 in If the clearance is greater than maximum replace the oil pump rotor set and or pump body 2 INSPECT TIP CLEARANCE Using a thickness gaug...

Page 560: ...il seal which are as follows b Using SST and a hammer tap in a new oil seal until its surface is flush with the oil pump body edge SST 09309 37010 c Apply MP grease to the oil seal lip c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its surface is flush with the oil pump body edge SST 09306 37010 REPLACE CRANKSHAFT FRONT OIL SEAL A If oil pump is removed ...

Page 561: ...ng a non residue solvent clean both sealing surfaces b Apply seal packing to the oil pump as shown in the illustration Seal packing Part No 08826 00080 or equivalent OIL PUMP ASSEMBLY See components 1 INSTALL DRIVE AND DRIVEN ROTORS Put the drive and driven rotors in the pump body 3 INSTALL RELIEF VALVE Install relief valve and the spring in the body and screw on the relief valve plug with a new g...

Page 562: ...e teeth of the crankshaft 2 CLEAN OIL PAN BAFFLE PLATE AND OIL PAN Remove any old packing FIPG material and be car eful not to drop any oil on the contacting surfaces of the oil pan baffle plate oil pan cylinder block and sealing grooves Using a razor blade and gasket scraper remove all the remaining seal packing FIPG material from the gasket surfaces Thoroughly clean all components to remove all ...

Page 563: ...and seventeen bolts Torque 5 9 N m 60 kgf cm 52 in M 3 INSTALL OIL PAN BAFFLE PLATE Apply seal packing to the baffle plate as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 3 4 m m A 12 0 16 in opening HINT Avoid applying an excess amount to the sur face If parts are not assembled within 5 minutes of applying the seal packing the ef...

Page 564: ...6 on page EG2 42 7 INSTALL TIMING BELT See page EG2 41 8 4WD INSTALL FRONT DIFFERENTIAL See page SA 106 9 ENGINE UNDER COVER 10 FILL WITH ENGINE OIL 11 START ENGINE AND CHECK FOR LEAKS 12 RECHECK ENGINE OIL LEVEL ENGINE LUBRICATION SYSTEM EG2 287 ...

Page 565: ...OIL COOLER REMOVAL 1 DRAIN ENGINE COOLANT 2 DISCONNECT OIL COOLER HOSES Disconnect the No 1 and No 2 oil cooler hoses OIL COOLER COMPONENTS ENGINE LUBRICATION SYSTEM EG2 288 ...

Page 566: ...t lbf 4WD Install the oil cooler with the relief valve and two new gaskets Torque 59 N m 600 kgf cm 43 ft lbf Install and torque the two bolts Torque 39 N m 400 kgf cm 29 ft lbf 3 REMOVE OIL COOLER 2WD Remove the two bolts union bolt relief valve gaskets and oil cooler 4W D Remove the bolt relief valve gaskets and oil cooler OIL COOLER INSPECTION INSPECT OIL COOLER Check the oil cooler for damage ...

Page 567: ...3 FILL WITH ENGINE COOLANT 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE OIL LEVEL 2 CONNECT OIL COOLER HOSES Connect the No 1 and No 2 oil cooler hoses ENGINE LUBRICATION SYSTEM EG2 290 ...

Page 568: ...nder block STD Limit STD Limit STD Limit Oil pump x Oil pump body cover Relief valve operating pressure Oil strainer x Cylinder block Oil pump x Cylinder block Oil cooler x Cylinder block Oil pan x Cylinder block Oil pump x Relief valve Oil cooler x Relief valve Body clearance Part tightened Tip clearance Side clearance Oil pressure Oil pump ENGINE LUBRICATION SYSTEM EG2 291 ...

Page 569: ...IGNITION SYSTEM IGNITION SYSTEM IG 1 ...

Page 570: ...mpatibility of your unit before use 4 Never allow the ignition coil terminals to touch ground as it could result in damage to the igniter and or ignition coil 5 Do not disconnect the battery when the engine is running 6 Make sure that the igniter properly grounded to the body PRECAUTIONS 1 Do not allow the ignition switch to be ON for more than 10 minutes if the engine will not start 22R E IGNITIO...

Page 571: ...tion timing under any and all operating conditions Using data provided by sensors which monitor various engine functions rpm intake air volume engine temperature etc the microcomputer ECM triggers the spark at precisely the right instant SYSTEM CIRCUIT IGNITION SYSTEM 22R E IG 3 ...

Page 572: ...Tester RECOMMENDED TOOLS 08826 00080 Seal packing or equivalent Megger insulation resistancenneter 09843 18020 Diagnosis Check Wire 09200 00010 Engine Adjust Kit EQUIPMENT Insulation resistance meter Spark plug cleaner Ignition timing Timing light Tachometer Ignition coil IGNITION SYSTEM 22R E IG 4 ...

Page 573: ... there is battery voltage at ignition coil positive terminal CHECK RESISTANCE OF SIGNAL GENERATOR PICKUP COIL See page IG 8 Resistance Cold 185 275 Hot 240 325 CHECK AIR GAP OF DISTRIBUTOR See page IG 7 Air gap 0 2 0 4 mm 10 008 0 016 in CHECK RESISTANCE OF HIGH TENSION CORD See page IG 6 Maximum resistance 25 k per cord CHECK CONNECTION OF IGNITION COIL IGNITER AND DISTRIBUTOR CONNECTOR Check wir...

Page 574: ...d If the resistance exceeds maximum check the termi nals If any defect has been found replace the high tension cord and or distributor cap SPARK PLUGS INSPECTION 1 REMOVE SPARK PLUGS 2 CLEAN AND INSPECT SPARK PLUGS a Clean the spark plugs with a spark plug cleaner or wire brush b Inspect the spark plugs for electrode wear thread damage and insulator damage If a problem is found replace the plugs S...

Page 575: ...1 INSPECT AIR GAP Using a thickness gauge measure the gap between the signal rotor and the signal generator pickup coil projection Air gap 0 2 0 4mm 0 008 0 015in 4 MEASURE SECONDARY COIL RESISTANCE Using an ohmmeter measure the resistance between the positive terminal and high tension terminal Secondary coil resistance Cold 9 0 15 4k Secondary coil resistance Hot 11 4 18 1 k 5 CONNECT HIGH TENSIO...

Page 576: ...he signal generator pickup coil Generator resistance Cold 185 2750 Generator resistance Hot 240 325 If the resistance is not as specified replace the dis tributor housing assembly If the air gap is not as specified replace the housing distributor assembly IGNITION SYSTEM 22R E IG 8 ...

Page 577: ... AND PULL OFF DISTRIB UTOR CAP 3 REMOVE HOLD DOWN BOLT AND PULL OUT DISTRIBUTOR DISTRIBUTOR INSTALLATION 1 INSTALL DISTRIBUTOR AND SET TIMING a Install a new O ring to the distributor HINT Always use a new 0 ring when installing the distributor DISTRIBUTOR COMPONENTS IGNITION SYSTEM 22R E IG 9 ...

Page 578: ...T connect terminals TE1 and E1 of the DLC 1 SST 09843 18020 b Check the idle speed Idle speed 750 rpm c Temporarily install the rotor d Begin insertion of the distributor with the rotor poi nting upward and the distributor mounting hole ap proximately at center position of the bolt hole When fully installed the rotor will rotate to the posi tion shown b Turn the crankshaft pulley until No 1 cylind...

Page 579: ...ust by turning the distributor e Tighten the hold down bolt and recheck the ignition timing Torque 19 N m 195 kgf cm 14 ft lbf f Remove the SST SST 09843 18020 6 FURTHER CHECK IGNITION TIMING Check that the ignition timing advances Ignition timing 10 14 BTDC idle 7 DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE IGNITION SYSTEM 22R E IG 11 ...

Page 580: ...istance Cold Secondary coil resistance Hot Air gap Pickup coil resistance Cold Pickup coil resistance Hot TORQUE SPECIFICATIONS Spark plug x Cylinder head Distributor x Cylinder head High tension cord Part tightened Ignition coil Spark plug Distributor Resistance ND NGK Type Limit Gap IGNITION SYSTEM 22R E IG 12 ...

Page 581: ...timing under ail operating conditions Using data provided by sensors which monitor various engine functions RPM intake air volume engine coolant temperature etc the microcomputer ECM triggers the spark at precisely the right instant 3VZ E IGNITION SYSTEM 3VZ E IG 13 ...

Page 582: ... of a high voltage sufficient to cause a spark to jump across the spark plug gap The ECM monitors the engine condition by signals from each sensor calculates the ignition timing and sends an ignition signal to the igniter High voltage from the ignition is distributed to each spark plug in the appropriate order to generate a spark between the electrodes which ignites the air fuel mixture PICKUP COI...

Page 583: ... ignition switch on for more than 10 minutes if the engine does not start 2 With a tachometer is connected to the system connect the tachometer positive terminal to the IG terminal of the DLC1 3 As some tachometers are not compatible with this ignition system we recommend that you confirm the compatibility of your unit before use 6 Make sure that the igniter is properly grounded to the body IGNITI...

Page 584: ...o maintain the most appropriate ignition timing the ECM sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark SYSTEM CIRCUIT IGNITION SYSTEM 3VZ E IG 16 ...

Page 585: ...TA Electrical Tester RECOMMENDED TOOLS 09843 18020 Diagnosis Check Wire 09200 00010 Engine Adjust Kit 09240 00020 Wire Gauge Set Air gaps of G 1 and G2 pickups EQUIPMENT Spark plug cleaner Timing light Ignition timing Tachometer IGNITION SYSTEM 3VZ E IG 17 ...

Page 586: ... to ON 2 Check that there is battery voltage at ignition coil positive terminal CHECK RESISTANCE OF IGNITION COIL See page IG 22 Resistance Cold Hot Primary 0 36 0 55 0 45 0 65 Secondary 9 0 15 4 11 4 18 1 k CHECK RESISTANCE OF HIGH TENSION CORD See page IG 19 Maximum resistance 25 k per cord CHECK AIR GAP OF DISTRIBUTOR See page IG 23 Air gap 0 2 0 4 mm 0 008 0 016 in Check wiring between ignitio...

Page 587: ... the terminals If necessary replace the high tension cord 1 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS Disconnect the high tension cords at the rubber boot DO NOT pull on the cords NOTICE Pulling on or bending the cords may damage the conductor inside 2 DISCONNECT HIGH TENSION CORDS FROM DISTRIBUTOR CAP AND IGNITION COIL a Using a screwdriver lift up the lock claw and dis connect the holder fr...

Page 588: ...tributor ignition coil with the spline of the holder and push in the cord SPARK PLUGS INSPECTION 1 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS NOTICE Check that the holder is correctly installed to the grommet and distributor cap as shown in the illus tration 2 REMOVE SPARK PLUGS Using a 16 mm plug wrench remove the spark plug IGNITION SYSTEM 3VZ E IG 20 ...

Page 589: ...ELECTRODE GAP Carefully bend the outer electrode to obtain the cor rect electrode gap Correct electrode gap 0 8 mm 0 031 in 6 INSTALL SPARK PLUGS Using a 16 mm plug wrench install and torque the spark plug Torque 18 N m 180 kgf cm 13 ft lbf 3 CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush clean the spark plug 7 RECONNECT HIGH TENSION CORDS TO SPARK PLUGS IGNITION SYSTEM 3VZ E IG 21 ...

Page 590: ...55 Primary coil resistance Hot 0 45 0 660 If the resistance is not as specified replace the igni tion coil 1 DISCONNECT IGNITION COIL CONNECTOR 2 DISCONNECT HIGH TENSION CORD 3 CLEAN COIL AND CHECK FOLLOWING a Check for cracks or damage b Check the terminals far carbon tracks c Check the high tension cord hole for carbon deposits and corrosion IGNITION COIL INSPECTION NOTICE Cold and Hot in the fo...

Page 591: ...sembly 5 INSPECT SIGNAL GENERATOR PICKUP COIL RESISTANCE Using an ohmmeter check resistance of the pickup coil DISTRIBUTOR INSPECTION NOTICE Cold and Hot in the following sentences express the temperature of the coils themselves Cold is from 10 C 14 F to 50 C 122 F and Hot is from 50 C 122 F to 100 C 212 F If the resistance is not as specified replace the dis tributor housing assembly 6 REINSTALL ...

Page 592: ...de Do not wipe any of the oil from the grommet after the high tension cord is disconnected 2 DISCONNECT DISTRIBUTOR CONNECTOR DISTRIBUTOR REMOVAL 1 DISCONNECT HIGH TENSION CORDS FROM DISTRIBUTOR CAP a Using a screwdriver lift up the lock claw and dis connect the holder from the distributor cap DISTRIBUTOR COMPONENTS IGNITION SYSTEM 3VZ E IG 24 ...

Page 593: ...C COMPRESSION a Turn the crankshaft pulley until the timing mark is aligned with the 0 mark on the No 1 timing belt cover 5 REMOVE DISTRIBUTOR a Remove the hold down bolt b Pull out the distributor from the cylinder head 6 REMOVE O RING b Check that the distributor rotor direction is as shown If not turn the crankshaft pulley one complete revo lution b Align the protrusion on the driven gear with ...

Page 594: ... groove of the dis tributor housing with the groove on the No 4 cam shaft bearing cap b Check that the lock claw of the holder is engaged by lightly pulling the holder 5 CONNECT DISTRIBUTOR CONNECTOR NOTICE Check that the holder is correctly installed to the grommet and distributor cap as shown in the illus tration d Lightly tighten the hold down bolt 3 INSTALL DUST PROOF PACKING AND DISTRIBUTOR C...

Page 595: ... lbf f Remove the SST from the DLC1 SST 09843 18020 9 FURTHER CHECK IGNITION TIMING Check that the ignition timing advances Ignition timing 8 BTDC idle 10 DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE 8 ADJUST IGNITION TIMING a Using SST connect terminals TE1 and E1 of the DLC 1 SST 09843 18020 b Check the idle speed Idle speed 800 50 rpm 6 WARM UP ENGINE TO NORMAL OPERATING TEMPERATURE 7 CON...

Page 596: ...STARTING SYSTEM STARTING SYSTEM ST 1 ...

Page 597: ...STARTER COMPONENTS STARTING SYSTEM Starter ST 2 ...

Page 598: ... flywheel bellhousing 3VZ E Engine Remove the two mounting bolts and remove the starter motor from flywheel bellhousing DISASSEMBLY OF STARTER See page ST 2 1 REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY a Remove the nut and disconnect the lead wire from the magnetic switch terminal b Remove the two through bolts Pullout the field frame with the armature from the magnetic switch ...

Page 599: ...brush holder Disconnect the four brushes and remove the brush holder 6 REMOVE ARMATURE FROM FIELD FRAME 3 REMOVE CLUTCH ASSEMBLY AND GEARS FROM STARTER HOUSING 4 REMOVE STEEL BALL AND SPRING Using a magnetic finger remove the spring and steel ball from the clutch shaft hole b Remove the starter housing with the pinion gear 1 4 1 6 kW idler gear bearing and clutch assembly STARTING SYSTEM Starter S...

Page 600: ...ater than maximum correct it on a lathe 2 INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the segments of the comrnutator If there is no continuity between any segment replace the armature Commutator 1 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt correct it with sandpaper No 400 or on a lathe 3 INSPECT COMMUTATOR DIAM...

Page 601: ...eign material Smooth out the edge Standard undercut depth 0 6 mm 0 024 in Minimum undercut depth 0 2 mm 0 008 in If the undercut depth is less than minimum correct it with a hacksaw blade Field Frame Field Coil 1 INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the lead wire and field coil brush lead If there is no continuity replace the field frame 2 IN...

Page 602: ...nd negative brush holders If there is continuity repair or replace the brush holder Clutch and Gears 1 INSPECT GEAR TEETH Check the gear teeth on the pinion gear idler gear and clutch assembly for wear or damage If damaged replace the gear or clutch assembly If damaged also check the flywheel ring gear for wear or damage Bearings 1 INSPECT BEARINGS Turn each bearing by hand while applying inward f...

Page 603: ...ly 2 PERFORM HOLD IN COIL CIRCUIT TEST Using an ohmmeter check that there is continuity between terminal 50 and the switch body If there is no continuity replace the magnetic switch as sembly b Using SST and a press press in a new bearing SST 1 0 kW 09285 76010 1 4 kW 1 6 kW 09201 41020 2 IF NECESSARY REPLACE BEARINGS a Using SST remove the bearing SST 09286 46011 STARTING SYSTEM Starter ST 8 ...

Page 604: ...ect the brush into the brush holder Connect the four brushes HINT Check that the positive lead wires are not grounded c 1 4 kW 1 6 kW Place the 0 ring on the field frame d Install the end cover to the field frame with the two screws 4 INSTALL GEARS AND CLUTCH ASSEMBLY a Apply grease to the gears and clutch assembly b Place the clutch assembly idler gear bearing and pin ion gear 11 4 1 6 kW in the ...

Page 605: ...e cutout of the magnetic switch 5 INSTALL STARTER HOUSING a Apply grease to the return spring b Insert the return spring into the magnetic hole e Place the starter housing on the magnetic switch and install the two screws c Install the two through bolts d Connect the lead wire to the magnetic switch ter mi na1 C and install the nut STARTING SYSTEM Starter ST 10 ...

Page 606: ...t the negative lead from terminal C Check that the pinion gear remains out If the clutch pinion gear returns inward replace the mag netic switch assembly 4 PERFORM NO LOAD PERFORMANCE TEST a Connect the battery and ammeter to the starter as shown b Check that the starter rotates smoothly and steadily with the pinion gear moving out Check that the am meter reads the specified current Specified curr...

Page 607: ... in the flywheel bellhousing and in stall and torque the starter mounting bolts Torque 39 N m 400 kgf cm 29 ft lbf 2 CONNECT TWO WIRES TO STARTER Connect the connector to the terminal on the magnetic switch Connect the cable from the battery to the termi nal on the switch and install the nut 3 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY Check that the engine starts STARTING SYSTEM Starter ST 12 ...

Page 608: ...he relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Check that there is continuity between terminals 3 and 5 If operation is not as described replace the relay STARTER RELAY INSPECTION OF STARTER RELAY LOCATION The relay is located in the No 1 junction block on the driver s side CLUTCH START SWITCH M T only See page CL 4 STARTING SYSTEM Starter Relay Clutch Start ...

Page 609: ...CHARGING SYSTEM CHARGING SYSTEM CH 1 ...

Page 610: ...links for continuity 3 INSPECT DRIVE BELT a Visually check the belt for excessive wear frayed cords etc HINT 22R E Check that the belt does not touch the bottom of the pulley groove If any defect has been found replace the drive belt 3VZ E Cracks on the ribbed side of the belt are consi dered acceptable If the belt has chunks missing from the ribs it should be replaced PRECAUTIONS 1 Check that the...

Page 611: ...ck with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley After installing a new belt run the engine for approx 5 minutes and then recheck the tension 4 INSPECT FUSES FOR CONTINUITY ENGINE 10A CHARGE 7 5A IGN 7 5A 6 INSPECT DISCHARGE WARNING LIGHT CIRCUIT a Turn the ignition switch ON Check that the discharge warning light is lit b Start the eng...

Page 612: ...r 8 INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the heater fan control switch at Hl b Check the reading on the ammeter Standard amperage 30 A or more If the ammeter reading is less than 30 A repair the gener ator See page CH 5 HINT If the battery is fully charged the indication will sometimes be less than 30 A If the voltage ...

Page 613: ...GENERATOR COMPONENTS CHARGING SYSTEM Generator CH 5 ...

Page 614: ...Remove the drive belt 4 w PS REMOVE WATER INLET HOSE a Remove the engine under cover b Remove the water inlet hose c with A C Remove the No 2 fan shroud 3 DISCONNECT WIRING FROM GENERATOR a Disconnect the connector from the generator b Remove the nut and wire from the generator 6 REMOVE GENERATOR a Hold the generator and remove the pivot b Remove the generator CHARGING SYSTEM Generator CH 6 ...

Page 615: ...nnector from the generator b Remove the nut and disconnect the wire from the generator 3 REMOVE GENERATOR DRIVE BELT Loosen the generator pivot bolts adjusting nut and lock bolt and remove the generator drive belt 4 REMOVE GENERATOR a Remove the pivot bolt and adjusting lock bolts b Remove the generator CHARGING SYSTEM Generator CH 7 ...

Page 616: ...ASSEMBLY OF GENERATOR See page CH 5 1 REMOVE REAR END COVER a Remove the nut and terminal insulator b Remove the three nuts and end cover 4 REMOVE RECTIFIER HOLDER a Remove the four screws and rectifier holder b Remove the four rubber insulators 2 REMOVE BRUSH HOLDER Remove the two screws brush holder and cover 3 REMOVE IC REGULATOR Remove the three screws and IC regulator CHARGING SYSTEM Generato...

Page 617: ...TICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a turn e Remove the generator with SST A and B from SST C f Turn SST B and remove SSTs A and B g Remove the pulley nut and pulley 6 REMOVE REAR END FRAME a Remove the four nuts b Using SST remove the rear end frame SST 09286 46011 7 REMOVE ROTOR FROM DRIVE END FRAME CHARGING SYSTEM Generator CH 9 ...

Page 618: ...Minimum diameter 12 8 mm 0 504 in If the diameter is less than minimum replace the rotor Stator 1 INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the coil leads If there is no continuity replace the drive end frame as sembly 2 INSPECT ROTOR FOR GROUND Using an ohmmeter check that there is no continuity be tween the slip ring and the rotor If there is contin...

Page 619: ...t off the excess wire f Apply insulation paint to the soldered point 2 IF NECESSARY REPLACE BRUSHES a Unsolder and remove the brush and spring b Run the wire of the brush through the hole in the brush holder and insert the spring and brush into the brush holder Rectifier 1 INSPECT POSITIVE SIDE RECTIFIER a Using an ohmmeter connect one tester probe to the positive stud and the other to each rectif...

Page 620: ...IDE RECTIFIER a Connect one tester probe to each rectifier terminal and the other to each rectifier negative terminal Bearings 1 INSPECT FRONT BEARING Check that the bearing is not rough or worn 2 IF NECESSARY REPLACE FRONT BEARING a Remove the four screws and bearing retainer b Using a press and socket wrench press out the front bearing CHARGING SYSTEM Generator CH 12 ...

Page 621: ...aring retainer with the four screws 4 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing cover and bearing SST 09820 00021 b Using SST and a press press in a new bearing and the bearing cover SST 09285 76010 3 INSPECT REAR BEARING Check that the bearing is not rough or worn CHARGING SYSTEM Generator CH 13 ...

Page 622: ...END FRAME a Using a plastic faced hammer lightly tap in the rear end frame b Install the four nuts d As shown in the illustration mount SST C in a vise and install the generator with SST A and B to SST C e To torque the pulley nut turn SST A in the direction shown in the illustration Torque 110 N m 1 125 kgf cm 81 ft lbf f Remove the generator with SST A and B from SST C g Turn SST B and remove SS...

Page 623: ...tion HINT Check that the brush holder s cover doesn t slip to one side during installation c Tighten the five screws until there is a clearance of at least 1 mm 0 04 in between the brush holder cover and connector 6 INSTALL REAR END COVER a Install the end cover with the three nuts b Install the terminal insulator with the nut 7 MAKE SURE ROTOR ROTATES SMOOTHLY CHARGING SYSTEM Generator CH 15 ...

Page 624: ...or drain cock and fill with coolant 6 CONNECT NEGATIVE CABLE TO BATTERY 7 PERFORM ON VEHICLE INSPECTION See page CH 2 3 INSTALL WATER INLET HOSE a Install the water inlet hose b Install the engine under cover c with A C Install the No 2 fan shroud 4 CONNECT WIRING TO GENERATOR a Connect the wire to the generator and install the nut b Connect the connector to the generator CHARGING SYSTEM Generator...

Page 625: ... b Connect the connector to the generator 4 CONNECT NEGATIVE CABLE TO BATTERY 5 PERFORM ON VEHICLE INSPECTION See pages CH 2 to 3 INSTALLATION OF GENERATOR 3VZ E 1 INSTALL GENERATOR Mount the generator on the generator bracket with pivot bolt and adjusting lock bolts Do not tighten the bolts CHARGING SYSTEM Generator CH 17 ...

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