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Toyota 4A-F, Repair Manual

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Toyota 4A-F Repair Manual Download Page 21

CH-ll 

2.. 

INSPECT NEGATIVE  SIDE RECTIFIER 

(el 

Connect  o

n

e 

teslet  probe  to  each  rectifier  terminal 

and 

the  oth

e

r 

10 

eech 

rectifier  negative  lerminal. 

(bl 

Reverse the 

polarity 

01 

the tester  probe

s

. 

(el 

Check  that  one  sho 

..... 

s 

continuity  a"'"  the  other 

shOWS  no continuity. 

If  not.  replace  the  rectifier holder. 

Bearings 

1. 

INSPECT  FRONT  BEARING 

Check  th81 

the bearing 

is not  rough 

or 

..... 

orn 

2. 

IF  NECESSARY. REPLACE  FRONT BEARING 

(el 

Remove  the  lour  screws  and  bearing  retainer

. 

(bl 

Using 

II 

plltU end socket ..... rench. press out the  front 

bearing. 

Summary of Contents for 4A-F

Page 1: ...4A F 4A GE ENGINE REPAIR MANUAL May 1987...

Page 2: ...UTIONS Ire given the pe rtain to till epai Ol er ltions conllined in thlt e lion RtfKI thtst pre tion bt fort Ifluting tlnr rep8 r t c TROUBLESHOOTING lables I e included lor taCh 5vstern 10 help vou...

Page 3: ...10 Ihl inlorms1ion nladed He c read the I8lk head ings end only efer 10l e detailed text when he needt i1 Impar 11Int specilicSI ons andwarnings BlwllYsstand out in bold l pI REFERENCES Refel8f CH hav...

Page 4: ...l tion Elec lron c Spark Advance EKn usl lmanifold I I E_c ept FOfITIad in Place G ket Hot Idl Compenutlon Hoi Ir Inllth Lgnitioo Int r ted ni1ion tmblv In tmanifold velvel Idle Speed Control L it han...

Page 5: ...EM DESCRIPTION A GE ENGINE ENGIN MECHANICAL Description I4 A GEI The 4A Ge engine n in line 4 cv nder 1 6 Ier OOHC 16 val engine...

Page 6: ...sin timing belt cover i made in 3 piec es A service hole is provided in the No 2 belt coyII lor adjo llng the timing belt tension Pistons are made of higilly temperature resis IlInt aluminum alloy and...

Page 7: ...HOW TO DETEAMINE BOLT STRENGTH head bolt Ho U ilOO lI n 18 bolt wnhe hex 90n bott Heugoo He agon flange boI w wuhe hex von bolt H _ M Bah 4 hl dNo 5 T 0 No maf 0 No mark 0 Two pto udino l 0 Two protru...

Page 8: ...mm ke cm Hb N m kg em II Ib N m 48 in _lb 60 52 in 1t B 1 25 0 W 0 1 25 28O 290 28 12 1 25 m 0 39 53 760 0 83 1 150 83 B 56 in lb B 1 25 0 12 W 1 25 33 J2 12 1 25 00 9JO 1 400 I 60 69 h 1t B 90 18 iI...

Page 9: ...by Ih duraTion of the electrlclIl pul COLD START INJECTOR SOLE UIU r t T l A cold stan injector m I II lln theCcnler sreH of the j ciinributlon du is provIded to nove 1bifliny when he eng i cold n in...

Page 10: ...1rOl1lc vol and flow ii ly IhrQU Jh II aIr valve to th air 18k ch hllr Thus eventho llh the 1I nrrle valve I ill ItII 1 1 1 slIlon i lake 8 volume is i llilSCd 1 idle ed will he lIhtly Ier 11I3n nom f...

Page 11: ...CHARGING SYSTEM PRECAUTIONS TROUBLESHOOTING CHARGING CIRCUIT ON VEHICLE INSPECTION ALTERNATOR ENGINE MAIN RELAY CH P ge CH 2 CH 2 CH 3 eH 4 CH 7 CH 15...

Page 12: ...ot perlOt m t ts with high voltage insulation alu nce teUer Never disconnect the b ttery whil the engine I run ning TROUBLESHOOTING Fuse blown light bumfId OUI W ng connection IoSII Ie 1191 11alor Ty...

Page 13: ...use I lC NGN f Q Switch lOA L __ 80A fusible ru s CH 3 Fusible _ L J IAn N JIII AE 4A_FI 2 30A ONA AE l l hA A L __ _ 1 6A AT T P I T Ch rge I 0 1 Ji 0 I AW Fu ibho u 1 258 T 8 t1 y I I Igni DnSwitch...

Page 14: ...roded 3 Ibt Check the fusible links for continuity INSPECT DRIVE BELT e Visually check Ihe belt for sepII etion of the IIdhesi e rubber above lind below Ihe core core sepllrlllioo Irom the belt lide...

Page 15: ...not slipped out of the groove on the bottom of the crank pulley II Afler nstelling the bell fUO the engme lor appro 5 minutes end recheck the deflection or tension 4 CHECK FUSES FOR CONTINUITY CHARGE...

Page 16: ...ing from idling to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperag8 Le thin l O A Standard voltage 13 9 Hi l Y 81 25 C 77 F 3 5 4 3 V It 115 C 1239 FI If the voltage reading...

Page 17: ...ALTERNATOR COMPONENTS DISASSEMBLY OF 1 REMOVE RE ALTERNATOR ta Remo AR END COVER b R va Ihe nul and tsr emove the Ih mlnal Insulator ree nuts and end cover...

Page 18: ...9 ft lb 39 N ml Ib Check that SST A is securad to the rotor shaft lei As shown in the figure mount SST C in a vise Ind install the alteroetor to SST C Idl To loosen the pulley nut tum SST A in 1M dire...

Page 19: ...ntinuity 3 INSPECT SLIP RINGS Check thet the slip rings are not rough or scored II rough 0 scored rlplace the rotor bl Using calipers mea lure the slip ring diameter Standard diamet r 14 2 14 4 mm 0 5...

Page 20: ...o the brush holder Ie Solder th brush wire to the bnJlh holder at ttle IIxposed length Exposed I ngth 10 6 mm 10 413 in kli Cheek lhal the brush moves smoothly in the brush holder lei Cut off the exce...

Page 21: ...bl Reverse the polarity 01 the tester probes el Check that one sho s continuity a the other shOWS no continuity If not replace the rectifier holder Bearings 1 INSPECT FRONT BEARING Check th81 the bear...

Page 22: ...bearing reUilner with the slotl of the drive end frame Ie Install the bearing retain8f with the four screws 3 INSPECT REAR BEARING Chllck that the bearing is not rough or worn 4 IF NECESSARY REPLACE...

Page 23: ...wrltlCh nd lighlln SST B c lockwise to lhe specified torqui SST 09B2 63010 Torque 400 ki em 29 lb 31 N ml 1 1 Che k IMI SST A is se ured 10 the pulley sheft Cdl A hown in Ihe figure mount SST C in e v...

Page 24: ...e horizontilly II ahOl Wn In th figure NOTE M e ure the bruah hoktI wlllf doe t sli p to one during in I II tion 1 Tighten the fille screw until there I cle r nce of at Ilist 1 mm 0 04 in l between th...

Page 25: ...continallv between terminals 1 an d 3 Ib Check that there is continultv between terminals 2 and 4 Ie Check thllt there is no continuity between terminals 4 nd 5 If conlinuitv is not as specified repla...

Page 26: ...t Replacement of Engine Cool 1l jAE end AT ReplllCllment of Engine Coolent AW WATER PUMP THERMOSTAT RADIATOR ELECTRIC COOLINQ FAN fWdietor Cooling F8n E AW Europe di to Coolin Fin lAW Europe Engl Comp...

Page 27: ...CO 2 DESCRIPTION Thisengine uli z pr urizeG WII r lon ed c ircullliion coolingsystem which include I thermostat equip ped with byp lu 1 mounted on the inlet sid 4A F 4A Of...

Page 28: ...g out coolant lire located in Ihe left sido lank The outlet for coolant and an ai drain which facilitates lhe supply of coolant to the engine are located in the right side lank The core conlie ins msn...

Page 29: ...thus permitting the engine to warm up rapidly The II I e opens when the coollnt tempe ature has riten lowing the cir culation 01 coolan Walt inside the thermottat paf1ds when heated and contracts whe...

Page 30: ...eek thefmOS 1I CO 18 Ignition liming rr rdad Set liming Elec tne cooling Iystem faully Ins pr cl elecui cooling IVSlem CO 26 AldillO hoMl plugged CIt tOtted ReplKe hose Water pump faulty Replace wll p...

Page 31: ...ement of Engine Coolant AE and AT REPLACE ENGINE COOLANT I Remove the dilltor cap Ill Or in the coollnt from the adiator and engine drain cockl lei CIoSII the dr in cocks Torquil Engine dr ln cock 130...

Page 32: ...OF ENGINE COOLANT 1 REMOVE SPARE TIRE AND FRONT LUGGAGE COMPARTMENT TRIM 2 REMOVE SERVICE HOSE 3 REMOVE NO 1 FUEL TANK PROTECTOR 4 SET HEATER CONTROL LEVER TO MAX HOT 5 REMOVE WATER FILLER CAP 8 ORAIN...

Page 33: ...wesh r lube NOTE Do not close off or p nch any of the tubes REFILL ENGINE COOLANT NOTE Use e good brand of elh llene glycol bese coo lent mixed eccordir g to Ihe manufact lr directions ta Ope Ihe wale...

Page 34: ...he radiator cap completelv to the second stop point iii Start the engine and run at fast idle for about J minutes and then turn it off If the level in the water filler hole fell add coolant as before...

Page 35: ...r Pump WATER PUMP COMPONENTS Sepl Wiler Pump Body Geske REMOVAL OF WATER PUMP 1 ORAIN COOLANT See plge CO 6 or 71 2 4A GEI REMOVE PS ANOIOR Ale DRIVE BELT 3 LOOSEN WATER PUMP PULLEY AND REMOVE ALTERNA...

Page 36: ...ight and remove the driye belt 4 14A FI REMOVE PS DRIVE BelT 5 REMOVf WATER PUMP PUllEY Remoye the fou bolts and pump puUeV 6 REMOVE WATER INLET PIPE a Di connect the waler inlet and watt bv pass hO e...

Page 37: ...pstick guide be sure 10 plug the oil pump body Ia 8 REMOVE NO 3 AND NO 2 TIMING BELT COVERS A F See pege EM 59 A GE See pliO_ EM 021 9 REMOVE WATER PUMP Remove the three bolts and wiler pump CAUTION B...

Page 38: ...ft SST 09236 00101 09237 00010 09237 000401 3 REMOVE WATER PUMP BEARINO I Using II grinding wheel grind the wllter pump rOl0r lIS 5hown CAUTION Do not grind wet r pump b erlng heft bl Heat the water p...

Page 39: ...NOTE The be ring end l ee should be flUSh with hi body top surface INSTAll SEAL I Apply 1 packing No 1 282 8 to new seal ll ld pomp body Se 1 packing Part No 08826 00 00 or eqoivalent Ibl Using SST a...

Page 40: ...aft NOTE A shown in the figure the distance from the rotor edge to the installotion surface of the pump body should be 6 0 mm 10 236 in l 5 CHECK WATER PUMP After assembly mllke surethai therotor rotl...

Page 41: ...RS 4A F S p 1 EM 94 4A GE 5 P sli EM 12l 3 INSTALL OIL DIPSTICK GUIDE AND DIPSTICK a InslaM ill new O ring on the oil dipstick guide ib Apply smell amount of engine oil to O_ring le Push in thl oil di...

Page 42: ...temporarily tighten the four bolts s I A F INSTALL PS DRIVE 8ELT 7 INSTALL ALTERNATOR DRIVE BELT Ie Pleeethe drive belt on the Nch pulley and set up the drive belL b Tighten the four bolts of the wat...

Page 43: ...opening temperature is nol within specifi liOn rllplace the thermostil k 1 Check Ihe valve lifl Velve 11ft B mm 10 31 inJ or more et IIs e 1203 F If the valve lift is IIIU Ihen specific lion repliilC...

Page 44: ...er pump the tester until the elief vllve opens Check thaI the valve opens between 0 75 kgf em 10 7 psi 74 liPs end 1 05 kg cml 14 9 psi 103 kPa Check that Ihe prnlure does not drop tepidly when pressu...

Page 45: ...ONENTS Tri 8 T PIlle D Aif ll L w T D_Ring DISASSEMBLY OF RADIATOR AE and AT 1 REMOVE TANK PLATE a Raise the clews of the umk plates with SST in hi numerical order shown in the figur SST 09230 00010 N...

Page 46: ...k p4ates o utward 2 REMOVE TANK AND O RING la Pull the tank upward b Remove the D ring 3 AfT REMOVE OIL COOLER FROM LOWIER TANK CO 21 a Remove lhe two nuts sp ing washers plate washers and Oil cooler...

Page 47: ...pect the core plate for damage If NOTE k 4 If Ihe sides Of Ihe core plate groove a e deformed reassemblv of the lank ill be impossible Therefore first correct any deformation ith pliers 01 likeobject...

Page 48: ...own in the p l te with SST in 00010 tgUIl the CAUTION If ith the SST 0 the bottom of the In Wilier I llka h guide block f pl l I tek d SST 09230 00010 PlHlf It may fesult NOTE Stake with claw The J I...

Page 49: ...ure 10 the diator Test pr sure 1 5 kg em 21 psi 147 kPa dl Inspect fot w8ler leaks NOTE On radialor wilh resin lanks Ihere is a clearance be lhe core plate end tank plate where a minute amount of air...

Page 50: ...T C INSTAllATION OF RADIATOR INSTAll RADIATOR PlaC4 l the radiator in installed position and install the two supporb with the two bolts L A NOTE Afterin allation confirm that the rubber cuahiorl A of...

Page 51: ...oling Fan AW AE AT FUM IGN 10A IAEl ELECTRIC COOLING FAN Radiator Cooling Fan Ex AW Europe SYSTEM CIRCUIT Fusible Lin FAN 30A IA RADIATOR FAN lOA All RAD FAN lOA AWl 7 5A IArT I I t l EnOi e Main Rela...

Page 52: ...ire btt ween the reley and lemperuure switch 2 DISCONNECT TEMPERATURE SWITCH CONNECTOR Cheek thai the fan rotates If itdoes nOI check the I n relay fan motor ignition relay and fuse and check for shon...

Page 53: ...G FAN RELAY LOCATION AE and AT In the engine compartment rel y box AW In the No 5 junction block of the Iront g8ge compartment A In pect relly continuity a Using an ohmmeter check Ihat there is contin...

Page 54: ...Electric Cooling Fe COol Radiator Cooling Fan AW Europe SYSTEM CIRCUIT _ CDS FAN 30A Fuse RAD rAN 30A COO I I I In Compute SwitCh r 1 1 Fute AM27 5A No Coolin l No 2 Coolin Reillv No 3 Cooiinll f o Re...

Page 55: ...eck Of II short circuil between thi I relay and temperatu e switch 3 CONNECT TEMPERATURE SWITCH CONNECTOR High Coolant Temperatufe above 90 C 1 94cFJ START ENGINE la R ise engine coolant to abo e 90 C...

Page 56: ...n block of the front luS SitSe compartment INSPECT NO 2 COOLING FAN RELAY LOCATION In the No 5 junction block of the front lug gilse compartment Inspact reiav continuity Ia Using an ohmmeter check the...

Page 57: ...relay B In pect r lay oper tlon la Apply baUery voltage across tam linol 1 lind 3 hI Using an ohmmeter check that there is contiooity betwel ln terminals 2 and 4 If operation I not 05 peeiflcd replac...

Page 58: ...fusible Link AMI SOA Fusible U 1 258 COOLIN G SYSTEM Elec tri c Cooling Fan CO 33 Engine Compartment Cooling Fan AWl SYSTEM CIRCUIT Cooling n L C O c n c m c n c omp c S O n EurOPe COMPONENTS...

Page 59: ...fan molOl engine m relay and fuse Ind check tor 0 shorl circuit belweeo hi coolil1og fan relay Gnd compartment temperature Slnsor 3 CONNECT COMPARTMENT TEMPERATURE SENSQII CONNECTOR High Temperature...

Page 60: ...not 8S specified replace the sensor 2 INSPECT COOLING FAN REtAY S procedure Cooling Fan Reley on page CO 2S LOCATION In the No 5 jum lion block of the front lug 1 8ge compartment 3 INSPECT ENGINE MAIN...

Page 61: ...it Opening Reley Solenoid Resistor and Injector Relay Cold Start Injector Time Switch Water Temperature Sensor Vacuum SenIor w o Air Flow Meted Manifold Absolute Pressure Senior Variable Re i5to w o A...

Page 62: ...FI 2 wJoAirFtow Meter EFI SYSTEM System De cription SYSTEM DESCRIPTION Iwnition Switch AIC ComP iuor Cold Start 1n ec 1Or Tm SWllch W I_T mp Swt Ch Cu Int r mp SWItch CO COI1nectOl T Ell 1 _ _ 11 Cion...

Page 63: ...Meter Ignilion Switch Fuel PressureRegut ltor SYSTEM DESCRIPTION Cont d Checkfogone We niog Light Cold SUlrt Inj clor Time SwilCh Waler Temp Sensor AlC ComPfeuor eu Check ConnllCtor T E11 Inluke Air T...

Page 64: ...Air flow meter Intake air temperature Coolant temperature Engine rpm AcceleretionJdeceleration E haust o ygen content wI TWC etc These signals are utilized by the ECU to determine Ihe injection durat...

Page 65: ...ower source for the timing light achOmetf r elC b Connect Ihe leSI probe of a lachometer to terminel IG6 of the check connector LOCATION See page FI SS Referf nce AT and AWU Connect the test probe of...

Page 66: ...e engine oil dipstick oil filler cap pev hose etc may cause the engil 8 to nm out of tune 2 DlsconrleClion looseness or cracks in the pariS of Ihe r Induction system belween the throttle body and cyli...

Page 67: ...e out the water ploofing rubber if it is 8 water ploof type connector Ibl Insert the test probe into the connector from wiring side wl1en checking the continuity amperage or voltage lei 0 0 not apply...

Page 68: ...nd Ic Tighten lhe union bolt to the specified torque Torque 300 kg cm 22 ft b 29 N m Flare Nut Type tal Apply 8 lighl coat of engine oil the lare and lighten the flare nut by hand b Using SST lighten...

Page 69: ...bl Using a service wire short te mlnals a and FP of the check connector LOCATION See page FI S9 Icl When the fuel etum hose is pinched the pressure within high pressure tine will rise to appro 4kg cm...

Page 70: ...mission control system PCV system II EGR Stem wI Ai flow meIer 191 Diner II Ignition liming Idle speed II Ite 2 The 1nO frequent CItU5e o f problem i imply I bad tacl in wiring eonnec IOI Alw y cneckI...

Page 71: ...2 Start 3 Wiring Connection SYMPTOM DIFFICULT TO START OR NO START CRANKS OK CHECK DIAGNOSIS SYSTEM Diagnosis cod 1s1 See page FI 25 or 26 CNick lor output of diagnosis code Malfunction See page fl 2...

Page 72: ...InJ NO 2 Compression pressure NOTE Check compression ptlIssure and Millimum 10 0 kg em valv8 clearance if neC6SS ry 142 pli 981 kPa at 2150 rpm 3 VGlve clearance Cold Standard IN 0 115 0 25 mm 10 006...

Page 73: ...regulator fill ISee pege FI 67 IS page FI 75 10K CHECK AIR FILTER ELEMENT Element Cleen or reolace I 10K 8AO CHECK IDLE SPEED AND IDLE CO Idle speed Adjust CONCENTRATION NO ISee page EM 39 or 42 St n...

Page 74: ...iggled I A u i iary ai aI BAD 2 Wiler hose 3 Air hOI 1 fuel pump lSI PII98 FI 55 BAD 2 Foel fil 3 Fuel pressure reg alo ISH page fl 75 BAD Injection condition Wifing conneclions BAD 2 Power to EeU 1 F...

Page 75: ...mlng Adjust See Pltge EM 37 1 Short terminalS T and E1 of the check NO connector 2 Check ignition timing St nd rd O BTOC Idle I OK CHECK T VIS INTAKE AIR CONTROL 1 VSV for air control valve VALVE NO 2...

Page 76: ...Vacuum sensor w o Air flow meter 5 Water temp sensor 6 Air temp sensor 7 Injection signal circuit II Injector wiring 2 Solenoid resistor Iwlo A r Ilow meter 3 ECU 6 Oxygen sensor Iwl TWCI Variable rui...

Page 77: ...p sensor lnjection 5191 81 circuit 11 Injector wiring 2 Solenoid resistor Iw o Air lIow meted 131 ECU SYMPTOM ENGINE BACKFIRES Lean Fuel Mixture CHECK DIAGNOSIS SYSTEM Diagnostic codels See page Fl 25...

Page 78: ...Air flow meter wI Air flow meier 4 Vecuum senaor Iw o Air Ilow meter 5 Weter temp sensor 6 Air temp sensor 7 Throttle position sensor 8 Injection sig nal circuit 111 In ector wiring 121 Fuel cut RPM...

Page 79: ...d start injector rime switch ISH page FI 95 Fuel p essure egulator Injector Leakage I 1 S rk plug 2 Compression pressure Minimum 10 0 kg em 1142 pli 981 kPal at 250 rpm 3 V lve clearance Cold Standard...

Page 80: ...BTDC ielle I OK CHECK FUEL PRESSURE I Fuet pump ISee page FI 55 ISee page FI 57 BAD 2 Fuel filter 3 Fuel pressure regulator ISee page FI 7S I OK I CHECK INJECTORS Inj ectiofl conelition See page Fl 7...

Page 81: ...FI 2S1 BAD 1 Wiring connections 2 Power to ECU 1I fusible nks 2 Fuses 3 Efl main relay 3 Air flow meter wI Air flow meterl 4 Vacuum seosor w o Air flow meter 5 Water temp 58flsor 6 Air temp sensor 7...

Page 82: ...oes out automatically wheo the mellul IC t ioll has beer cleared CHECK ENGINE WARNING LIGHT CHECK 1 The Check e 9ine wal f1irog light will come on whef l thl igf lltiof l switch is pleo ed at ON and t...

Page 83: ...tion will begin fromthesmalie value and continue in order to the larger TCeS EeU wI Air Flow Meterl 1 1 Normal System Operation no mallum lion The light will alternately blink on end OFf lor 0 25 seco...

Page 84: ...llation cen IIlso be done by removing the bantry neglltive OJ terminel but in Ihia case other memory systems clock etd will also be cancelled oul If the diagnostiC code is not cancelled out it will be...

Page 85: ...or short circuit in IhrOll1e position sensor signal Oplln or short creuir in intake eir temp n50r ignal Engine rpm is between 2 000 5 500 rpm Water lemp is 80 C 1176 f o mo e ManifoLd pt ssur B certa...

Page 86: ...U1JUL o ygen MflSOr signal 2 Ai lIowme Lean signal 3 Wlter lemp M1110r to indieste s lean condition 4 InUOke if temp enSOf 5 O Vllen senWl 1Ul JUUUUlIl Rich signat OJl f 9M sensor signal contn s 10 in...

Page 87: ...AT AW INSPECTION OF DIAGNOSIS CIRCUIT t w STOP 81n I L H j ArT f R 3 I ru FUIlbie o m C 7 m o t8ATT 5R 1 j 1 A w i qp j r 1 8111 y I F libM FUI 81 Un linl ALl AMI 80A 40A f bIoo AM w ifii j t n t...

Page 88: ...the body NO luse aod wiring between feU an ignition switch BAD Repair or replace Does check engine werning light go off when the engine is stGrled NO Is there diagnostic code output when check connect...

Page 89: ...ual Btfore beginning inspection it is bast 1 0 1i 1 make simple ch ek of the fuses fusible links and the condition of the connectors The following troubleshooting procedures are blSed on the suppositi...

Page 90: ...AW EFI SYSTEM Tl OYbi nooting with V olt O h mmeter LOCATION OF FUSES AND FUSIBLE LINKS Cont dl GAUGE Europel TURN GAG 10111_1 0 k 1 258...

Page 91: ...lhe cOnneclof connecled Verity thll the bettery voltageIs I I V 01 motewhenthe ignition switch is at ON Using e voltmeter with high impedence 10 kilN minimum measure the voltage at Nch terminlll 01 Ih...

Page 92: ...fuly open VCC E2 4 1i 5 5 IGT E l 0 7 1 0 Cr tJng Or idhng FI 37 STA 1 6 1 4 Crvnking FI 39 No 10 EO 9 1 4 ignitIOn SIW ON rI_41 No 20 E02 w El 9 _ 1 4 No trouble ChIt k eng warning light off and FI 4...

Page 93: ...le 1 258 fUlible Link O 85R Igt ilion Swileh AM2 IG2 i k ibte AM2 30A lAt AT F AM2 1 5A lAW Ballery ECU f Condition IG S W ON EFI Maon ReillY Fuso IGN lOA IAEI 1 5A IAT FI 33 STD vol lIe 0 4 V Cu RePl...

Page 94: ...oting with Volt Ohmmeter No Terminll Troubl Condition IIATT E1 No lol t 10 1 V ECU rc An Fu ibII Un Fuse AlT 80A AE SlOP SA lAD O 85R An EFt SA AT 1 2SB AWl AM2 7 SA AWl Q 1 No vohaga bootw ECU tormin...

Page 95: ...fully cloud Throttle v_lve fully open F 35 STO vol1_fe 4 5 1i 6 V 0 6 V or Ie 3 15 6 6 V VCC E 1 __ __ __ __ ___ L __ __ __ __ __ __ __ __ __ __ __ __ __ JL __ _ C C _ _i CU lhfotllePo illon SenJ lr I...

Page 96: ...0 S Ct o k th ottle PO lloon Ifl O lSee HIli fl 84 0 ehKk wring betwe n EeU lind Ihrottle posilion sensor 0 Try nother Eeu BAD 0 R IM or eplace Repai or replece These I no IIolUllg between ECU t min...

Page 97: ...fusible link AM lOA fusible Unk 1 258 EFI SYSTEM Troobleshootmg with Volt Ohmmeter TroLibl NO voltage ignitIon S itc h AM Condition STO voltae Ignkion Coil Idlil lQ 0 7 1 0 V C u TOT ehOmete L Kll L _...

Page 98: ...Idllng NO 10K 1 Check wiring bet un OAD Repair or eCU terminllEl and body r pI ce ound 10K ITry IInOlh r ECU Check luSB fu ibte tonk ignition itch Id Sllifler retpv AW OK JChick It t ibulor See 1 89 1...

Page 99: ...EM _ Trouble hOOting with Volt Ohmmeter Trouble Condition No volU C eMl 14 1 eu ignition SwilCh r M S 2 __ __ __ __ __ __ __ __ __ r __ __ __ __ __ SfA AM 40A All 80A m ITerm I lII 501 Eeu t 1 AM2 Sf2...

Page 100: ...EFI SYSTEM Troubleshooting with Volt Ohmmeter S A lTe n 501 Che k wiring between ECU lermonel ST Ind ignition Iwft 1 STl tAE IKldAT 0 ST2 tAWl...

Page 101: ...EM Troubleshooting with Volt Ohmmeter Ignition SWItch AM2 fulllblfl AM2 30A gllltion Switch AM2 1G2 AM2 7 5A Condition STO Olt tG SIW ON 14 V Eeu Injector _ _ t No 10 No 20 Inject or E 2 Eeu L _ _ _ _...

Page 102: ...FI 42 EFI SYSTEM Troubleshooting with VoitlOhmmeler 10 J Of 20 BAD Replace IIIje IOf BAD OK Try nothfl feU...

Page 103: ...hooting with VoltlOhmmflle ConditlOl No Iroubl_ he k _119 w rnlng Ught offl nd II9m rUN lln g S i c t w G UGE 7 5A 1 IAEI GAUGE 15A IAn GAUGE 7 5A lAW LI 1D EUJopoI TURN G G 7 5A lAW Olhe cc c M j FI...

Page 104: ..._ 1 vee E2 EFI SYSTEM Troubleshooting with V o lt Oh mmeter Trouble ConditiOIl No yoltage 10 S W ON r c eo Mt eoM vee vee 0 Try aoothe ECU BAD STD volt_we 3 3 3 9 V 4 5 5 5 V R pair or replace R poir...

Page 105: ...I THA E2 I EFI SYSTEM Troubleshooting with Volt Ohmmeter Trouble No voltage I IG SfW ON I Ai Temp Sensor II HA I Cot dition STO volt lle Intake Ii limP 20 6 F1 I 2 0 2 I 8 Bl HA E2 Refe to No 1 See pa...

Page 106: ...FI 10 THW U EFI SYSTEM T oubIMOOOling with VottJOhmmelM Troubl Condit ion No vo tlllle 10 S W ON feU Wa Temp Sansor 1 811 r c t T __ l I L L f temp sensor OK STD volta 0 4 0 8 V Re ir Of eplDce...

Page 107: ...STEM 1roubleshooting with Volt Ohmmeter Tr ble Conllitlon No volteg Air condllionlnU ON eu Ale Ale Compreswr OK NO D FI S10 oIU 6 14 V Rapairor replK ClMK k wiring btllween ECU rminal AlC and plitier...

Page 108: ...HROTTLE PosmON SENSOR V CHECK CONNECTOR NE DISTRIBUTOR ENGINE GROUND THW WATER TEMP SENSOR 5TH TNIS VSV VC AIR FLOW METER 1 FeU FUEL PRESSURE VSV SENSOR GROUND f V ISC T VIS VSV VS AIR FLOW METER W WA...

Page 109: ...tage at ECU Wiring Connectors TCCS ECU wI Air Flow Meterl Condition Ignition SIW ON Thfottle vltve open Throll Vltvl fully closed Ignition SIW ON ThroW valve tully open Crankillll Of idling CrlN1king...

Page 110: ...258 Bon EFI SYSTEM Troubleshooting with VolUOhmmeler Link O 8SA Qno1io 1 Switch AM2 002 i Fusible l link AM2 3010 S litE An H A M2 1 510 AWl Condition IG SfW ON AWl AE AT 3 Fuse IGN lOA IAEJ 7 510 lIt...

Page 111: ...ter FI 51 No 1 Termin l I TrOllbl I Condition I STD volt ge 2 I BATT E I No volt IiI I I 1 4 V ECU BATT Fusible UnIr ALT 80A tAEI STOP ISA tAfJ O SSR All EFI ISA tAli USB tAWI AM2 1 5A tAWI I B IIMV r...

Page 112: ...SYSTEM Troubleshooting wilh Volt Ohmmeter Tr04lbl t Condldon STO volmg Throttl v lv open 10 14 V Throttle nlv full Iose d 0 5 V or Ie No vol III SIW ON 1 T tt C 1 C C _ C v l 4 5 5 V ECU T olliePos i...

Page 113: ...er FI 53 e VTA E2 Repai or replace IRefer 10 No ISee PIIi e Fl 501 Repw IN repiac4l 10K Check Ih ol1le position sensor fSefI p8ge fl 841 OK Check ing between ECU and ttvnllie po ition tInsQr OK Try an...

Page 114: ...hooting with Volt Ohmmeter lOT El AE a nd AT No volt g IgnWoo S lch AM AW Fusible AM 30A Bentry F Fusible AM2 L 7 SA 1 258 Ignition Coi Condition STD voll Idling 0 7 1 0 11 ECU To TachOlTlflt r L 4 L...

Page 115: ...EFI SYSTEM _ Trou bleshoo ting wI t h Vol tlOh m mfltll f Cheekigni ler IS peg 1G 2JI r R i...

Page 116: ...g with Volt Ohmmeter TrOUble CondItion STDyolt 6 14 ECU Ignition Switch r AM 9 S T C __ __ __ __ __ __ __ __ __ r __ __ __ __ __ STA AMI 40A ALT 80A StattM S ITermin 1 501 To Ci u it Opuninll RellV St...

Page 117: ...EFI SYSTEM TIDublelhooting with VOlt Ohmmeter FI 57 Repe or repl ce Chllck iring be n ECU rmlr ll E1 0bodv ground OK BAD Try another ECU...

Page 118: ...Ohmmeter Trouble Condition STD voltllge 8 No 10 No 20 EO No voltlOge 10 SfW ON 8 14 V AEandAT Fusible Link AM2 JOA AW fusible Link 1 258 AM FUSB AM 1 5A Battery Ignition Switch 02 EOU Injeetor L __ __...

Page 119: ...lt Ohmmeter FI 59 10 and or No 20 and 0 Check wi ing between fCU terminel EOI andla 9Jp E02 IItId body ground 0 Try nothflr ECU Check fuse fusible lonk 0 Check wiring betwHn EeU terminal NO 10 and or...

Page 120: ...w Et T ouble No volWgoo Condition No trouble Icheck ogine we nlng IIghl off nd engine nnlog ecu r USE rW CAUGE 7 SA Check Engine tAEI Warning lig GAUGE 1SA IAn GAUGE 7 SA WI EOU T V a nothe ECU Check...

Page 121: ...TEM _ T roubl eshootitlg wi th Volt Ohmmeter Trouble No voltage Condition IG SfW DN M I III plete l ully cloMd M_u i lll plate lully open Idling cu l 2t 1 2 vs vc 4 v c ji Bll FI 61 STD volt 6 1 10 B...

Page 122: ...I SYSTEM TrouoblelhOOling wi lh V QlliOhmmeter ECU rr 4 1 J _ _ _ _ _ _ _ _ _ _ _ _ _ j 81l n A It Temp S 1iOt EI lAir F Qw MeIer STD voltllo 2 Z B V ChCk that I we vQII ge batween Eeu termmal 8or 81...

Page 123: ...EFI SYSTEM Tro u b t l hooting wit h Volt Ohmmet e r ECU W te Temp SenIOr B 81 rr C t T H iT ct t E 2 iE2 FI 3 0 4 0 7 1...

Page 124: ...ONI ECU I I 1 I checl Ir al lh ere is 01l811e Mlween ECU terminal AlC aoo I bodV lI Ol lnd 1 I Cr ock wiring belween ECUle nal Eland body I lI ound 10K JBAD L I Trv Moth ECU I I Repai d eplace I Cr ec...

Page 125: ...Reliet f SA OUTLET t t fM ET AM2 IG2 AMI STI bIe AM AM1 0 8 R 30 0 40A 80 EF SYSTEM Fuel System FUEL SYSTEM Fuel Pump EFI Main RelaY OGN 10A IAEI 1 A IAn wi AI FlOw MIIte w o Ai Flow Meter ToEeu F 56...

Page 126: ...FI S6 AW 1 SA Fusible 1 25B Battery Efl SYSTEM Fuel System EFI MDIn ReI y wI Air Flow Meterl w o Ail Flow Meled To ECU...

Page 127: ...Ih 58f 1ice wir lei Tum the ignition switch OFF If there is no pressure cheek Ihe following parts FU ible links Fuses EFI main relay Circuit opening relay Fuel pump Wiring connections 2 INSPECT fUEL P...

Page 128: ...See page fl 89 ijl Turn the ignition switch ON kl Measure the fuel prenure F uel preIJur 2 7 3 1 kg cm1 38 44 psi 266 304 kP 1 If pressure is high raplltce the fuel pressure reguLator If pressure is...

Page 129: ...147 kPa or more for 5 minutes allerthe engine is turned 011 If pressure ii not IS ipecified check the fuel pump pressure regulator andlor injector Is After checking fuel prenure disconnect the battery...

Page 130: ...orking on the fuel pump 2 REMOVE FUEL TANK 3 REMOVE FUEL PUMP BRACKET FROM FUEL TANK I Remove Ihe five boilS Ib Pull out the pump bfacket 4 REMOVE FUEL PUMP FROM FUEL PUMP 8RACKET al Remove the two nu...

Page 131: ...thlt lower ide of the fuel pump t09llther with the rubber cushion into Ihe pump bracket 3 INSTALL FUEL PUMP BRACKET tal Place thepump bracket with a nlwgasket on the fuel tank ill klstall and tOf que...

Page 132: ...etwcCfl the terminals Resistance 2 4 0 If the resistance is not as specified replilCI the Injector c Reconnect the cold start injector connector REMOVAL OF COLD START INJECTOR 1 DISCONNECT CABLE FROM...

Page 133: ...cable I Turn Ihe ignition switch ON NOTE Do not statl the engine 191 UsioQ II service wire short 18fminals 8 and FP of the check connector LOCATION See page FI S9 h Connect the test probes of Ihe SST...

Page 134: ...he injector with the two bolls Torqu 75 kg em 166 in lb 1 4 N ml 2 INSTALL COLD START INJECTOR PIPE Inlilll the injector pipe with new four gnkets Ind he two onion boilS Torqu 150 kg em 111 ft lb 1 15...

Page 135: ...CT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT VACUUM SENSING HOSE 3 DISCONNECT FUEL RETURN HOSE AE AND AT OR PIPE AW ta Put 8 suitablo conlainer or shop towel under Ihe pressure regulator b...

Page 136: ...gasoline 10 I new O ring and install it to the pressure regulator 0 1 Ill lall thl pressure regulator with the two bolts Torque 7li kSl cl I I 6li In Ib 7 4 N m 2 CONNECT FUEL RETURN HOSE IAE AND AT...

Page 137: ...an check the injec tor lrensminion operallon wilh your flogel If no sound or an unusual sound is heard checkIhe wiring connector injector resistor or injeclion Signal from ECU 2 INSPECT INJECTOR RESIS...

Page 138: ...Ove theunion bolt two gaskeh and inlet pipe 7 REMOVE DELIVERY PIPE AND INJECTORS a Remove the three boilS and delivery pipe togethef ith the fou injectors CAUTION B ear lvl not 10 dropthe injeete when...

Page 139: ...bIe viflyl hose onto the injectOf 10 pravenl 9 501ine Irom S91ashlng 0 1 II Reconnect the beu V etjy 81 cable lie Tum t ignition witch ON NOTE Do not IIan Ihe eng OJ Using a ervic wire short terminal...

Page 140: ...e SST 09268 41045 INSTALLATION OF INJECTORS 1 INSTALL INJECTORS AND DELIVERY PIPE tal Install a new grommet to the injeetor G ll Apply a light coat of gasoline to a new a ring ano install it to the in...

Page 141: ...inlet pipe end new gasket with the union end mount bolts TOfque 300 kll em 22 t Ib 29 N m 3 CONNECT FUEL RETURN HOSE 4 CONNECT INJECTOR CONNECTORS 5 CONNECT VACUUM SENSING HOSE 6 INSTALL COLD START I...

Page 142: ...eresistance betwnn each termin 1 al tweefl Resiltll lU 0 I Temp C rFI terrni fl8 i VS 2 20 3 000 ve E2 100 300 VB U 200 400 10 000 20 000 I 20 _4 4 000 7 000 0 1321 THA E2 2 000 3 000 20 i681 900 1 30...

Page 143: ...nce n Ufing pI te terminel Infintty Fully doud Fe EI 0 Other dosed pgsifion 20 _00 rully dot VS E2 20 3 000 fuly open NOTE Resistance b tween f2 nd Vs will chang In w pallern as the manuring pille slo...

Page 144: ...rottle linkage moves smoothly Ib Check the vacuum lit N port Start the engine Check the vacuum with your finger 2 INSPECT THROTTLE POSITION SENSOR a Disconnect the sensor connector Ibl Insett a feeler...

Page 145: ...ANER HOSE 15 DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 6 REMOVE THROTTLE BODY al Disconnect the following hoses I PCV hose I Water hOMS I Air hose I Emission control vacuum hoses Ib Remove the two...

Page 146: ...betwean terminals 10L arid 2 CIe_ t IW en Ioov 1Id ttop row mm in 1 0 35 1 0 0 1 4 o 9 10 0231 ContiouilV gOL E2J Conlin uity No continuity INSTALLATION OF THROTTLE BODY 1 INSTAll AIR VALVE TO THROTTL...

Page 147: ...1 00 rpm If operalion is root as specified replace the air valve wI Air Flow Met r Check the engine rpm by fully screwing in the idle speed adjusting screw At low temp Coolant temp below 80 C f1 78 F...

Page 148: ...lion System INSTALLATION OF AIR VALVE 1 INSTALL AIR VALVE TO THROTTLE BOOY Ie PllICe new gasket end O ring on the throttle body Cb Instell the eir velve with the five screws 2 INSTALL THROTTLE BODV IS...

Page 149: ...id Res tOf HO wlo A if Flow Metet l 2 kConnectOf Verillblt Re ittOf wlo Air Flow Mewl T Intake Ai Temp efl10f w o Air Flow Meted EFI Main Relay Vacuum s n or Iw o Air Flow Meted Fuel Pres ure VSV Eu O...

Page 150: ...Y a Using lin ohmmeter check that there is continuity between terminals 1 and 2 b Check that there is no continuity between terminal 3 and 4 If continuity is not specified replacethe relay 2 INSPECT R...

Page 151: ...here is continuity between terminel STA and El til CheCk thai there is continuity between terminl s B and FC Icl Chackthaithereis no cont inuity between terminals B and FP I f continuity is not as spe...

Page 152: ...terminels B and FC lel Check that there i no continUity betweeot lWIlt8 Ind FP If COntinuity i not as specified rep K the relay 2 INSPfCT RELAY OPERATION W Apply battflt y voltage aeron terminals STA...

Page 153: ...Air Flow Mlterl Ind AT w o Air Flow Meted Ignition Switch FUlibie linl AM AM2 JOA 8al1etV AW w o Air Flow Meterl Fusible U 1 258 A W wI Air Flow Meterl f AM Fusib 7 SA Link 1 258 OG Injector Injoelor...

Page 154: ...w Meter INSPECT SOLENOID RESISTOR RESISTANCE Using an ohmmeter measure the resistance between tIt minel B end other terminals No 10 No 20 Resistance 2 3 n each If th resistance is not liS specllied re...

Page 155: ...I STJ STA r I L_ _ _ _ __ Cold SbJrt Injec tor IITIIII Switch INSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT COLD START INJECTOR TIME SWITCH Using lin ohmmeter measure the resistance between ea...

Page 156: ...0 0 20 40 60 80 100 120 _4 321 68 1 04 1140 1 761121 2112481 TEMPERATURE C or INSPECTION OF WATER TEMPERATURE SENSOR INSPECT WATER TEMPERATURE SENSOR Using an ohmmeter measure the rllsistlmce between...

Page 157: ...age between ter minals vee and E2 of the vacuum sensor connector Voltlge 4 6 V INSPECT POWER OUTPUT OF VACUUM SENSOR tal Tum the ignitiOn switch ON b Disconnect the vacuum hose of Ihe intakl chambef s...

Page 158: ...STOR 1 INSPECT VOLTAGE Of VARIA8LE RESISTOR II Using a voltmeter measure the voltage between Ectl terminals vee nd E2 Voltag_ 6 V b Measore thevoltage between ECU tenninalsVAF anc E2 whilll slowly tur...

Page 159: ...9 Ib Using an ohmmetar measUl 1l the resistance between the te n3ls vee and E2 Resiltllnee 4 6 kn Ie Turn the idle midure adjusting screw lully coun tllrclockwise Idl Conncet an ohmmeter to terminals...

Page 160: ...w Meter 5 z 20 0 2 0 40 60 BOlimi20 4 32 66 I04KI40K176X212K248 TEMPERATURE C I F INSPECTION OF INTAKE AIR TEMPERATURE SENSOR INSPECT RESISTANCE OF INTAkE AIR TEMPERATURE SENSOR USil lg lin ohmmeler m...

Page 161: ...ck connector AlId maintain engine splHld 1 2 5oo pm I I Check the m ber 01 times Ihev ohm r needle lluclu es In 10 secoods ILe Ih n 8 time 8 tomes or more I w rm up th oxygen fIflSO wittl lh in 1 2 50...

Page 162: ...age between I mlnals VF end EI I I lov v I o scoonect the PCV hose I I I Meas voltage between tenn VF IIOd I JMore INn 0 V ReplI Ove rICh I Disconnect the wlte temp senSOl conne or end J coone t esisl...

Page 163: ...ol S ystem FI 103 ATandAW T 3 INSPECT HEATER COIL RESISTANCE OF OXYGEN SENSOR Using an ohmmeter mellSure the reststance between the terminals 8 lind HT Realatance 6 1 6 3 n If the resistance is not lI...

Page 164: ...ty the the battery voltage is 11 V ormore whenIhi Ignition witch is ON Voltage at ECU Wiring Connectors TCeS ECU w o Air Flow Meter ondilion ST vol aill VI Ignitioo SfW ON 1 0 _ 1 4 10 14 Th ottle val...

Page 165: ...anhlg 6 14 Ignition 5 W ON 9 14 No ttOllb e Check ngine w mln il ilht off engine running 9 14 5 1 10 8 9 ition SlW O N M awrin il plate fully clo ed 2 5 5 4 Measuring plitt fully open 6 2 6 8 Idli iI...

Page 166: ...inal of the wiring connectors e Disconnect the connectors from the ECU e Measure the res stllnce lit IISch termon Resistance of ECU Wiring Connectors TeCS ECU wlo Air Flow Meterl COndition R I unc 111...

Page 167: ...Meter Co KIltIon 1I lstano un Ttvottle va opeo Infinity TlYotll8 v t 1y dosed 2 300or Ifns TIMonle v llve tully opeo 3 300 10 000 Throttlrova t u ly c losed 200 SOO 3 000 7 000 Measuringplate fully c...

Page 168: ...ottle position sensor 101 Short terminals IOl and E2 of the wiring connectOl I Gradually raise the engine rpm and check that t is lIuctuation between the fuel cut and fuel retum points NOTE The vehicl...

Page 169: ...OF HIGH TEMPERATURE LINE PRESSURE UP SYSTEM 1 INSPECT WATER TEMPERATURE SENSOR IS plgl FI 96 2 INSPECT FUEL PRESSURE VSV A In pect VSV for open circuit Using an ohmmeter check thllt there is continuit...

Page 170: ...s em Ai I r F I f E _ 16 I I C Ine Met VSV operation oj ChICk the ail does not flow from pipe E 10 pipe F bl AppI batter voltltgtl acron the te minals Ch k that eir flows from pipe E to the filter II...

Page 171: ...h d olf Ib Using a VOllmel8l cheek that il Indicates battery foliage during crenking and for ten seconds fI r Sliming 2 INSPECT loLE UP VSV A Inspect VSV fat open circuit Using an ohmmeter check that...

Page 172: ...System C Inlpect VSV operation tal Check Ihel eir flows from pipe E to pipe F NOA E if A f L l e e b Apply beuery Yollage across the terminals Ie Check that air flows from pipe E 10 pipe F If operatio...

Page 173: ...rlOtm spark Ignition coil g niter Oistributo Spark plug 18 lty In pe t plug Higr ten ion COtd dl connected or Inlpeel cordi brok n Vacuum leaks A ir r ecH PCVline Eeft lin wI EGR yll ml Intake manilol...

Page 174: ...low compr 1on Chtc eom IKm EM 47 ENGINE HESITATES POOR ACCELERATION ProD Po ibl Cau A mldV h Engine htlsil sJ Sp k pIi Ig faulty Inlpeel plug I IC 2O 21 poD accete atoon High t_1on cord t n Inspect c...

Page 175: ...Io1correct valvl clu ance Adjust vllve cltia en r e F M 3 Engine backfnl EFF IVIlem p obLem Repair as necessary Vecuum Il3k Check hoses Ind repI al I PCV oS I Io1Uk manifold Air intake chamber I Intak...

Page 176: ...Sparl plug faully Inspect pIu 1S 1G_20 21 GR IYII m s on Chec k EGR Y5tem Low compr uion Check compression EM_41 II imCorO loertY Iklted Inflat lifH 10 proper ptelSUr Cluk h slips Troublnhool ctulch a...

Page 177: ...rom the bilek thoroughly Then blow off the I ont of the element INSPECTION OF HIGH TENSION CORDS ISee P gl 10 201 Mlximum reliltlnee 26 kn per cord INSPECTION OF SPARK PLUGS Conventional Tipped Type I...

Page 178: ...gauge mlll lHlI the clearance bel ween the valve tiller and cemsh ft Record Ihll v lve cle8rance maasurements which ara OUI of pacification They will be used 111M to determine the required rllplaceme...

Page 179: ...velve clearance N Thickness of new shim Inake N _ T IA 0 20 mm 10 008 Ex u t N T IA 0 2fi mm 10 010 in 1I Select a new shim with thickness B clo e II possible to the celculated vatues NOTE Shims are a...

Page 180: ...e tachometer termlnll to touch ground II it could ult In damag to the Igniler andlor ignition coil AI 0 tachom t Ifl not compatibll with dti ignition y m we flKommen ct thlt you confirm the compatfbil...

Page 181: ...EM 3 ENGINE MiECHANICAL Engine Tune up I4A GEI 15 UNSHORT TERMINALS T AND El Remol e the Mrvice wire f lm the check connector 6 FURTHER CHiECK IGNITION TIMING lenit ion timing 16 BTDC Of more ldle...

Page 182: ...ses for EGR SystemB etc Bhould be propllfly connected lei EFI system wiring connectors fully plugged f Ignilion liming sel correclly gl All accessories swilchitd OFF Ihl Trensmisslon in N range 2 STAR...

Page 183: ...SENSOR 5 palle F 10ll 3 CHECK VF VOLTAGE 4 5 t Conn8 t the positive l oj probe 01 a voltmeter to ter minal VF of the check cOl1neclo and neg tivI ld probe to IlIrmiOllI IEI til Hold the engine speed...

Page 184: ...2 nco eet velve clearance 3 Le ky EGR valve wi EGR yltem1 4 Leakv Intake IIfId Il hlull velvlI i LtoDky cytindet 1 Vecuum lealr Vacuum hOM EGR velve Iw EGR ystem Intake manIfold A intake ch ambet Int...

Page 185: ...2 STAAT ENGINE 3 CONNECT TACHOMETER S pege EM 371 4 CHECk AIR VALVE OPERATION ISee plge FI 87 I ADJUST IDLE SPEED Cal RBce the engine BI 2 500 rpm lor I lew seconds bl Check the idle speed Idle peed 8...

Page 186: ...l Off If th CO concentfation is 1I0t speei itd adjust the idle mixture b turning the IDlE MIXTURE ADJUSTING SCREW III thl vllrillble r si llr e If the cooc tra t klll I withirl spKificl1ioll this Idiu...

Page 187: ...he eng VTV hoi or II few eConds Ib Plug the 1M at 2 500 rpm f Tachometer 6 Ie Release he Idl Ch t throttle waive eck the OP se OP ttlng ttlog speed pe d l BOO rpm wi Cool Ing fan OFF Ie Adjust the OP...

Page 188: ...operating lemperature 2 CONNECT TACHOMETER SH plge EM 371 3 CONNECT VACUUM GAUGE Usiog 3 wav COnl eClor conoeel v Cuum gauge to the hose betwetln lhe VSV and actuator 4 INSPECT T VIS t Check that Ill...

Page 189: ...ENGINE MECHANICAL Cylinder Block CYLINDER BLOCK COMPONENTS ___ _ pO IDn Ring PO lon _ _ _ Cy r de Block EM 125 Re End PlaiD...

Page 190: ...ERNATOR AND BRACKET 7 REMOVE RH MOUNTING BRACKET 8 REMOVE TIMING BELT AND TIMI O PULLEYS 4 A f 5 peg EM 8 to 60 4 A GE ISee pege EM 57 to 69 9 REMOVE EXHAUST AND INTAKE MANifOLD STAYS 10 DISCONNECT WA...

Page 191: ...um rept c8 theconnect ing rod assembly If necessary replace the crankshaft AEMOVE CONNECTING AOo CAPS AND MEASURE OIL CLEARANCE If repLllcing the bearing replacewith one having the same number iIS mar...

Page 192: ...mag Ie Clean the Cl nk pin end be rlng fJ Check Ihe crank pin nd bearing lor pilling end IC fllches If Ihe crlnk pin or b i1 ing r damaged replau th be ing If nKess eplac the crankl hltt 191 lay Slrip...

Page 193: ...e if gr ler thIn m imum Iae the bearing If nIC IIIY rlp ec thl crankshaft k Complelely remove Ihe PllStig e 4 REMOVE PISTON AND CONNECTING ROD ASSEMBLIES tal Remove all the earbon Irom Ihl lOP of thl...

Page 194: ...the number 01 the bearing cannot 1M determined select a bNring from the table below accold ing to the numbeB imprinted on the cylinder block and crankshaft Cylinder BIoc k No C ankshaft No Be No Exemp...

Page 195: ...in correct order Ie lifl out the crankshilft NOTE Keep th upper bearing Ind upper thruSI washers No 3 cap only in lned In Ihe cylinder block iii C eln tlch jou 1 and be ing e Check IlCh oumal nd beari...

Page 196: ...NOTE If replecing the cylinder block subassembly the bearing standard clt rence wilt be 0 015 0 045 mm 0 0008 0 0018 in 1 II the 011 cleerence Is greater thIn maximum replace the bHri I 1f Ilecessary...

Page 197: ...eater than mallimum repl ce the cylinder block 4 INSPECT CYLINDERS FOR VERTICAL SCRATCHES Visually check the cylindar for vertical scretches s If deep scratches are present rebor all four cy nders or...

Page 198: ...rllpl ee th pl lon nd pin II HL 2 REMOVE PISTON RINGS tel U ing piston ring IIlpOrldet remon the eomprn ring Ibl Remo the two sidll r il tnd oil ring upendOf b NOTE Arr nge the ring in eort et order 3...

Page 199: ...move the snap rings b Gradulllly heat th pistOl to 70 BO C tl58 176 F1 Ie Using II plastic faced hammer and brll5S t 9htlv lip 001 the piston pin end remove the connecting 00 NOTE The piston and pin a...

Page 200: ...o not damege the piston 2 INSPECT PISTON DIAMETER AND OIL CLEARANCE 4A f 3B mm 4A GE 42 0 mm 1 Using e micromeler and with the piS10fl l lpside down measl I e the piSlon diameter 9t right angles to th...

Page 201: ...clearaf ICe i not within specification replace the piston 4 INSPECT PISTON RING END GAP tal InMrt the pislon ring into the cy nder bore fJl Us ng a piston push the poston nng a little beyond the bott...

Page 202: ...e the connecting rod assembly fbI Check for IwisL Maximum twitt 0 06 mm 10 0020 In per 100 mm 13 94 In If twist is greator than maximum eplace the connecting rod 55l1mbly NOTE II repillcing the connec...

Page 203: ...on afld piston pin assembly 8 A GE IF NECESSARY REPLACE CONNECTING ROD SUSHINGS a Using SST and a press push out the bushing SST 09222 30010 Ib Aligfl the oil holesof the bushing and connecting rod 1...

Page 204: ...nd witll the piston upsidedown meBSure the piston diamatlll at B l ight engl to the pistOrl pin hole Cente lirlll thll indicated di tenes from slr ir1 bollom edge 4A F 38 5 mm Ui76 In J 4A QE 42 0 mm...

Page 205: ...E 41 188 42 000 mm 6628 8635 inJ If the diameter is not within lpeclfiution check the oil clearance fbi Chllck each main journal and crank pin fortaper and out ol round as shown MaKimum t8per and out...

Page 206: ...I retainer eOgoe SST 09223 41020 NOTE Be carelul not to Install the oil seal shmtwi Ic Apply MP o ean to the oil seal lip IF REAR OIL SEAL RETAINER IS INSTALLED ON CYLINDER BLOCK tal Using a kl life c...

Page 207: ...Align the Iront mark of the piston and connecting od fbI Coat the piston pin with engine oil Ie Using SST ptess in the piston pin SST 09221 25022 109221 00050 09221 00130 09221 001401 Id Check that th...

Page 208: ...g piston ring e pender inllall the two com preulon rings with the code mark fllCil lg upw rd lei Posilion the piston ril lgS so th t the ring ends I H shown CAUTtoN Do n ol elign the end g P 3 INSTALL...

Page 209: ...bearing in the cylinder block and bearing caps cl lubricate the faces of the bearings with clean engine oil CAUTION Install the bearing with the 011 hole In lhe block 2 INSTALL UPPER THRUST WASHERS In...

Page 210: ...wilh I short piece of hose 10 protect the crankshalt from damage k 1 Using II piston ring comprenor push the correctly numbered piston and connecting rod Issembly nlo each cylinder with the froot mark...

Page 211: ...IMING PUllEYS AND TIMING SELT 4A_F S e plges EM 53 to 66 4A GE See plgel EM 62 to 6SJ B INSTALL RH MOUNTING BRACKET Torqu 600 kg em 136ft Ib 49 N mJ 9 INSTALL BRACKET AND ALTERNATOA Torque Brecket 500...

Page 212: ...Had lOA GEl Cylinder II MECHANICAL ENGINE EAD CYLINDER H COMPONENTS A C 1i Slav g Mounl ing _ No 2 I COVIrI EM ill...

Page 213: ...71 2_ REMOVE DISTRIBUTOR 3 REMOVE EXHAUST MANIFOLD 181 Remove the four boilS two null end upper heet IniWl tor b AE nd ATI R move the three bolli nut RH end LH menifold tllY Ie AWl Remove the bolt nul...

Page 214: ...tepa 3 to 7 on INIg FI 7S 7 REMOVE VACUUM PIPE I wi EGR SYSTEM AND CYLINDER HEAO REAR COVER al Iwl EGR System Discoooect the v tCuum hoses from the throttle body hI Iw o EGR System Remov Ihe two boill...

Page 215: ...NO 2 TIMING BELT COVERS Remove the seven bolts No 3 No 2 belt covers end geskets t4 REMOVE CYLINOER HEAO COliER II Remove the four bolts center COVM and gnket b Remove the eight cap nuts seal washers...

Page 216: ..._ c Remove the timing belt from the camsh ft liming pulleys NOTE Support the belt so the rn8 hing of the crankshllft tim ing pulley aod timing beltdoes not shift Be carelul not to drop anything inside...

Page 217: ...and remove the ten cylinder head bolts in several paSSl ll in the seqLHInee shown SST 09205 18010 CAUTION He d w p ge or clicking could Ieluh from r moving bolta in incorrect older fbI Uftthe cylinde...

Page 218: ...FTERS ANO SHIMS NOTE Arrange the valve lifter ar d him in correct oroer 2 REMOVE VALVES III Using SST compreu the valve spring a d remove the twtI keepoet SST 09202 70010 b Remove the spring retail lt...

Page 219: ...oil from hi bolt holes WARNING Protect your eVaI when u ing hlgll pIIU Ule lir 2 REMOVE GASKET MATERIAL U51ng a gaskel scraper remove IU Ih gaskll malerial flam Ih manifold and cylinder h ad 1ur1I1CI...

Page 220: ...waorpag ia greater than mlltimum replace the c tindet 7 INSPECT CYLINDER HI AD FOR CRACKS Using a dVe penetBn check the combustion chamber intake and uhaust PO 1s head suriace and the lOP 01 m heed 10...

Page 221: ...0010 0 0024 in hhauS1 0 030 0 065 mm 0 0012 0 0026 In 1 Maximum oil clearance Intaka 0 08 mm 0 0031 in 1 Exhaust 0 10 mm 0 0039 In If the clearance is greater than maximum replace Ihe valve and guide...

Page 222: ...mension 1 1 050 1 1 077 mm 0 4350 0 4361 In l the bushi 9 borediameter of Ihecytiflder head is greater lhan 1 1 077 mm 0 4361 in repl ce the cylinder he d II Gnldually heBI thecylinder head to eo 1OO...

Page 223: ...e I e stem lip is worn resurface IhfI tip wi lh II grind r or replace the alv CAUTION Do not lI ind off more than the minimum oY ali Ien8th 12 INSPECT AND CLEAN VALVE SEATS 1 1 Using a 45 cltfbidecult...

Page 224: ...fTIlCt the se I lei Hand lap the vlllve and vlllve seat with n abrasive compound leI After IwInd lapping cleen the valve and vllive ell 13 INSPECT VALVE SPRINGS lal Uaing a steel square mellsure the s...

Page 225: ...um ci cle runOul 0 04 mm 10 0016 in 1 II the circle tunout is greater th n maximum replace lhe c mehaft In peel cern lobe U ing a micrometer me sure the cam lobe heighl Stendard urn e height 36 410 35...

Page 226: ...slall thl c mshaftl ISle step 2 on pages EM IIS and 1 191 IbJ Using a dial indicator measure Iha thrust clearllnce while moving thl camshaft back and forih Stlndard thrult clearance 0 080 0 100 mm 0 0...

Page 227: ...m repl c the m fIIlold INSPECTION OF TOYOTA VARIABLE INDUCTION SYSTEM T VIS 1 INSPECT AIR CONTROL VALVE oj With 300 rnmHg 111 81 In Hg 40 0 kpaJ 01 lI cuum pptied 10 the Clu lor check th t the control...

Page 228: ...n If there I no continuity replace the VSV B In pect VSV for ground U ing on Ohmmeter check that there is no continuity bet ween 88ch terminal and the VSV body If there is continuity replace the VSV...

Page 229: ...Inllllil thl following pans 111 New oil seal 121 VaivI 131 Spring Ial 141 Valve spring 151 SpriIlg relaiMf CAUTION Confirm the corr ctdirection of the alv sprint lbl Using SST compress 11 11 vlllvI p...

Page 230: ...position on the cylinder head gasket S Tighten cylinder h d bolts NOTE Th cy nder head boIlS re tighten in three progressive steps If Imy 01 bolts break or defrorn replace them lal Apply a ghl coat of...

Page 231: ...shafts in position on the cylinder head u shown in the figure NOTE The e thaust camshaft hos a distributor drive gear b Apply seal packing to the cylirlder head as shown In the figu e Seal pecking Per...

Page 232: ...N ml 4 INSTALL RH MOUNTING BRACKET Install the mounting braeket with the three bolts Torque 250 kg em 18 ft lb 25 N ml 5 INSTALL CAMSHAFT TIMING PULLEYS S uep 1 on peg EM 621 Torque 476 kg em 34 h Ib...

Page 233: ...n the crankshal clockwise Ic Check that each pulley aligns with the timiotg markJ as shown in the ligure If the marks do no align shift meshing 01 the timing bell and timing pulley and readjust accord...

Page 234: ...Torque 130 kg em 9 Ib 13 N m Idl Install Ina gasket to Iha cenler COllet lei InilaM the center COlier with Iha four bolts 10 INSTALL NO 2 AND NO 3 TIMINO BELT COVERS a Install the gnkel to the bell c...

Page 235: ...M TANK a Install the liS ll and Vlleuum lank IIs IImbty wittl ths two bolls b Connaet the lIacuum hosas 6 INSTALL THROTTLE BODY See teps 2 lind 3 page FI 8S 16 INSTALL CYLINDER HEAO REAR COVER AND VAC...

Page 236: ...cuum modulator with the bolt Icl Install the vacuum hoses 20 INSTALL EXHAUST MANIFOLO al Install Ihe lower heat insulator to the manifold with the three bolls bl Install II new gasket and the manifold...

Page 237: ...12 4 11tets 13 1 US qu 10 9 Imp qts 23 START ENGINE AND CHECK FOR LEAKS 24 PERFORM ENGINE ADJUSTMENT la Adjust thevalve cleaterlce See pege EM 37 Valve elnrlnee Cold InUike 0 15 0 25 mm 0 Oa6 O alO I...

Page 238: ...NG BELT t 1 REMOVE WATER PUMP PULLEY AND DRIVE BELT 2 REMOVE SPARK PLUGS See lIe IG 20 3 SET NO 1 CYLINDER TO TOe COMPRESSION Ie Tum the crankshol1 pulley end Iign ils groove wilh lhoe liming mark 0 O...

Page 239: ...NG 8ELT COVERS Remove the ten bolt the No 3 No 2 No 1 belt COVi and ge ket 6 REMOVE TIMING SElT GUIDE 7 REMOVE TIMING BELT NOTE If reusing the timing belt draw a direction ow on the timing belt Gn d K...

Page 240: ...thl bolt plJlley end Insion sPfing I REMOVE CRANKSHAFT TIMING PUlllY 10 REMOVE CYLINDER HEAD COVERS See etlp 14 on peg EM lOll 11 REMOVE CAMSHAFT TIMING PULLEYS SICU the tIe 3gonal wrench nead portion...

Page 241: ...iming pulley II Ihere lire defeel lIS shown in the figures cheek the following points Ie remat e parting Check tor proper installation Check Ihe timing cover gaskel lor damlliJll and proper instIllati...

Page 242: ...ing belt 2 INSPECT IDLER PULLEY Check the turning smoothness of the er pulley If necessery repj ce the idler pulley 3 INSPECT TENSION SPFIINQ Referencel lal Measure the fr length 01 the tension spring...

Page 243: ...b 47 N m 2 INSTAll CVlINDEA HEAO COVERS ISee step 9 on page EM 1211 3 INSTAll CRANKSHAFT TIMING PUllEY Align the pUlley set keywith the key g ooll 01 the pulley and slide the pulley 4 TEMPORARilY INST...

Page 244: ...t insuring the teflsion between lhe inta e camshaft and craflkshaH timiflg pulleys 7 CHECK VALVE TIMING AND TIMING BELT DEFLECTION Ie Slowly loosen the idler pullev bolt bl Temporarily inSlall the cra...

Page 245: ...g e O f etio 4 mm 0 16 in at 2 kg 14 4 b 20 NI If he deflec ion is not 1 specified adjust with the idler puNllv f Remove the tllmpaflfilv installed crankshaft pullev 8 INSTALL TlMINQ BELT GUIDE Instel...

Page 246: ...e key groove of he pulle 54ide the pulle b Using SST ins ll and torqlle the the bo lt SST 09213 70010 and 09330 00021 Torque 1 400 kg em 01 ft Ib 137 N m INSTALL SPAAK PLUGS ISee plge 10 2 1 To que 18...

Page 247: ...a through Icl for each cylinder CAUTION Thi m urem nt mu t b done in ort tim ponible Compr ion pr ssure 12 6 kg cmf 179 Pit 1 236 kPe Minimum p nu l 10 0 kg cmi 142 p l 981 kP Olffl nc b twlen ch cyl...

Page 248: ...AT nd AWl With II lachometer connected to the Iystem exln nect the tett probe 01 the tachometer to negativa 19I termlnll of the ignition coil 3 A lome tachomete Ira not compltlbla with thl igni tion I...

Page 249: ...problems Ignition coil Ign ler Drst i bulor High tension cords Spark oIug f ly Ignir on wiring faultv IncOf e 1 Ignition riming InCOIIIICI iJnirion IlITIIng Incor ect gnltion lom ng Ir c orrect ignit...

Page 250: ...UIT Oi tnbutor Ignitioo Coil Signal Rolor IGT IGf Spark Plug Ign hor Coil Firing OrOOr 1 3 4 2 IGF IGT ELECTRONIC SPARK ADVANCE ESA The ECU is programmed with data IOf optimum ignition timl 9 under en...

Page 251: ...K CHECK RESISTANCE OF SIGNAL GENERATOR IPICKUP COIL See page 10 23 R i UlnCI 140 180 n OK CHECK AIR GAP OF DISTRIBUTOR Itl Disconnect the high tension cord from the distribu to Ibl Hold the end ebout...

Page 252: ...butor CIP Mnimum rl tlnCI 2 6 11 0 plr cord II the r btlnea is g ter thin mulmum check 1M t mine lt neeeswry replace thl h h IIMion cord tnd Of distnbutor eap INSPECTION OF SPARK PLUGS Conventional Ti...

Page 253: ...h for cleenlnll Never ettempl to ediutt tha elect oda lIep on u ed sp k plug Spark plug should bl replacld Ivety 100 000 km 60 000 mill l INSPECT ELECTRODE A If using e ml lr in uletion tl i tenci met...

Page 254: ...t base of the ground electrOde 00 r IOt touch the tip 6 CLEAN SPARK PLUGS If the electrode has traces of wet carbon allow it to dl and Ihen clean with a spark plug cleaner Air pressure Below 6 kg cm 8...

Page 255: ...IBUTOR 1 INSPECT AIR GAP Using a feeler gauge menure the gap between the signal rotor and pickup coil proj9Ctlon Air glP 0 2 0 4 mm 0 008 0 016 in 1 If the air gap is not as specified repl ce the dist...

Page 256: ...10 24 Non r IIHbie IJiIrt A T end AW IGNITION SYSTEM 4A GE Distributor DISTRIBUTOR COMPONENTS O Ri 0 O R Driven Gelll Streight Pin Distributor Cap ion Cordi wilh High lens COld Clamp Dust Cover l...

Page 257: ...n Idl Remove the driven gear 2 INSTAll NEW DRIVEN GEAR ta Remove the two bolts distributor c ap and O nl l l Q Slide the driven gear onto the governor shaft wI Align the drilled mark of the driven 1lf...

Page 258: ...to Iha hOUSing bl Apply lighl coat of engine oil on the O ring c Align the drilled mllrk of thll driven gear wilh the groove AEI or cllvity IAT lind AWl 01 the housing Id Insertthedistributor aligning...

Page 259: ...LU BRICATION SYSTEM Plge DESCRIPTION LU 2 TROUBLESHOOTING LU OIL PRESSURE CHECK LU S REPLACEMENT OF ENGINE OIL AND OIL FILTER lU 6 Oil PUMP OIL COOLER AND PRESSURE REGULATOR lU 7 LU 17 II...

Page 260: ...DESCRIPTION A fully pressurized fuliV filtered lubriCEltion system has been adopted fOf this engine 4A F 4A GE Fun r i lIIIVE r i t t i c ws1Wf 011 VEN G NI IN _n_ c_St1 rr C Yr flOfA HEAD OI F IlUR...

Page 261: ...he oil pump ilse11 is an inler nal gear pump which USIS a dri e ge r and dri en gear inside the pump body When the dri gear rotates the dri lflll gear rotates in the same dir tion When both gears rot8...

Page 262: ...12 EM 142 Gasket fauly Replace gasket low oil pressu Oil le kBge Rep i IS necen ry Relief VII _ f uI y Rep Ioe valve LU l0 13 Oil pump ully Repair oil pump LU Poor quality engine oil RepllICe engine o...

Page 263: ...CHECK ENGINE OIL LEVEL Ttle oiI level hould be between ttle L and f marks on the d ptUck If low check for le kltge and add oil up to the F mark 3 REMOVE OIL PRESSURE SWITCH ORSENDER GAUGE NOTE wI Send...

Page 264: ...9228 06500 3 REFILL WITH ENGINE OIL 8 Clean and install the oil drllin plug with a new gasket TOrque the drain plug Torque 360 kg cm 125 ft lb 34 N m b Fililhe engine with new 011 API grade SC SD SE S...

Page 265: ...LUBRICATION SYSTEM Oil Pump OIL PUMP COMPONENTS Ooven Rotor 4A_F 4A_GEI Guket Relief v Spring _ Retaine D Snap finQ 0 1 Pan _ _ _ _ _ Gasket O n Plug LU 7...

Page 266: ...sert the blade 01 SST between the oil pan and baf fie plMe cui oft appHed sealer and then remove ttlt 011 pen SST 09032 00100 CAUTION Do not u e SSTfor the 011pumpbody lide Ifn c IIry UII Icrewdrivlr...

Page 267: ...LT IDLER PULLEY ANO CRANKSHAFT TIMING PULLEY 4A F ISee p g EM 4 to 50 4A GE IS p EM 57 to 591 6_ REMOVE OIL OIPSTICK GUIDE AND DIPSTICK 7 REMOVE OIL PUMP 1 1 Remove the liven bolt LU I Ibl U ing p tie...

Page 268: ...ner DISASSEMBLY OF OIL PUMP 5 pIIge LU 7 _ REMOVE DRIVE AND DRIVEN ROTORS GEARS Ia Remove the five boilS lind oil pump body COVII b Remove lhe drive and driven 101015 gearsl 2 REMOVE RELIEF VALVE a Us...

Page 269: ...SURE TIP CLEARANCE Using fe ler gauge meilsure the etelranee betwe n both rotor tips SunG ld el r ne 0 116 0 156 mm 0 0046 0 0061 in 1 M o irnum et ne 0 315 mm 0 01 38 In l It th eleanme is g 8ale the...

Page 270: ...eplace the lie set end or body MEASURE SIDE CLEARANCE Using a feeler gauge and flat block n18a If the side clearance as sho n St nd d cl nc 0 025 0 075 mm 0 0010 0 0030 in 1 Maximum clearance 0 10 mm...

Page 271: ...lal Insert Ihe relief lal le spring and relainer inlo the pump body 1 Using snap ring pliers inslall Ihe snap Ing 2 INSTAll DRIVE AND DRIVEN ROTORS GEARS II Insert the dri le and driven rOlon gea s in...

Page 272: ...O ring coated with a small amount of engine 011 b Install a new O ring 10 tl e oil dipstick guide Id Install the rnoul lling bolt Id Insert the oil dipstick 3 INSTALL CRANKSHAFT TIMINO PULLEY IDLER PU...

Page 273: ...m tube and reinstall Up Ie Inslall the bailie plate 5 INSTALL OIL STRAINER Pillee a IlfIW oil llraioe glP et and inslall the oil rajrMt with two bolts and 110 0 nuts TOfq the bolts and nuts TOfque 96...

Page 274: ...e INIterial must be removed and reapplied e Immediatelyremovenozzle from tube and rein cap el Install the oil pen overthe studs on tha bto withth nineteen bolts and two nuts Torque the bolts and nulS...

Page 275: ...TEM Oil Cooler nd Pressure R 01 egulalOoI RE AND PRESSURE COMPONENTS _ 1 LU 1 7 U J Ga lce r c li9 Iu j lt J o o c h l f U Go L v mOon PIpe e pr na Ji G LL Relief Va Plug 1 Oil Coole Hose Gukel Oil Co...

Page 276: ...T r _ _ _ _ _ _ _ _ _ _ _ RegUI tor COMPONENTS f ICon d LUBRICATION SVSTEM O Cooler nd P 0 1 Cooler _ _ Oil Cooler III...

Page 277: ...Aw LU8RICATION SYSTEM Oil Cooler lind Pressore Regull1lOf COMPONENTS Cont d No I O fill r B itCk No 2 Oil OK Union SoIl OW f Ier Oil Cool r Hos _ _ O Cooler_ _ _ _ _ _ LU 10...

Page 278: ...0 lBI 1 REMOVE UNION PIPE Remove the union boll two gaskets and union pipe 2 REMOVE OIL fiLTER Using SST remove the oil filler SST 09228 05500 3 REMOVE OIL fiLTER BRACKET lOlL PRESSURE REGULATOR Remo...

Page 279: ...o nuts lilter bracket and O ring 4 REMOVE NO 1 OIL FILTER BRACKET Oil PRESSURE REGULATOR Remove the union boll g3sket filter brackEu and O r in g 5 DISASSEM8lE NO 1 OIL FILTER 8RACKET OIL PRESSURE REG...

Page 280: ...Jliel valve pll lg TOrQl e the plug Torql l 375 kg em 127 ft Ib 37 N m 2 INSTALL OIL FILTER BRACKET Insert a new O fing and the tilter bra cket with the l lnion boiL Torque the union bolt TOI ql le 46...

Page 281: ...d th filler bracket with I new gasket and he unlOO bolt TorqUI Ihe union bolt Torque 4150 kg em 133 fI lb 4 N m 3 INSTALL NO 2 OIL FILTER BRACKET Install e n4 W O ring and the liller brecket wi h the...

Page 282: ...I Ai llow mller Inlllke idle pe t moni oId ComprGlI ion It t50 1 l 500 pressure limil Oitfe lIn t o t p es ure between eachcylinde 4 5 mm 0 16 0 20 In 6 7 mm 0 24 028 in 10 80 kg 30 15 kg 6 0 tCl l 6...

Page 283: ...mm 0 2350 0 2356 in hhaull 5 965 5 980 mm 0 2348 0 2354 in St 011 clearance STD IIItake 0 025 0 060 mm 0 0010 0 o24 in Eohaust 0 030 0 065 mm 0 0012 0 0026 In limot In 3h 0 08 mm 0 0031 no bhlU51 0 1...

Page 284: ...m 81 00 81 03 mm 81 50 81 53 mm 81 23 mm 81 73 mm 80 89 80 92 mm 81 39 81 42 INn 0 10 0 1 2 mm 0 04 0 08 mm 0 03 0 07 mm 0 25 0 47 mm 0 20 0 42 mm 0 15 0 52 mm 1 07 mm 1 02 mm 1 1 2 mm 0 15 0 25 mm 0...

Page 285: ...pin tape and OUt Of found limit Torque Specifications PI tightened Camshaft liming pulley x Cam halt Idler pulley Cylinder block CrankShaft pulley Crankthaft Cyfonder head Cylinder block Camshaft bea...

Page 286: ...0 59 mm 0 023 in lOt E2 Intinrty Throtlle valve tully ITA E2 3 300 10 000 n opened position ICC E2 3 000 7 000 II Solenoid Rtsoslance 8 No 0 2 3 n e er 8 No 20 2 3 0 Cold 5Iart Resistance STA STJ belo...

Page 287: ...trOUble ICheckenginewaminglightoW 9 14 and enginerunning 1M E2 33 3 9 IG SIW ON VCC E2 4 5 5 5 THA E2 IntBkea rtempereture 20 C 68 F 2 0 2 B THW E2 Coolanttempe ature BO C 117soFI 0 4 O B AlC E1 tG SI...

Page 288: ...THA 2 I nlilke ir lemperal 20 C 15 8 F 2 2 8 2 Coolant lemper tureeo c 11S F 0 4 0 1 Ale A ir eonditiorfonll ON 5 14 IG SfW ON Che k engine eonneetor T El nol shott 10 1 4 T 1 Chec k engine conne dor...

Page 289: ...i AI flow mllRr 1 200 pm Torque Specifications f c PI ighl ed kg em Ib N m F r e Union bolt IVPR 00 F nul IVPR Fuel pump _ Fuel Ulnk 30 ir Ib C I IIln injll lor _ 1n18k m fold 65 In III C ld lIart Inj...

Page 290: ...ninll trltvel 8 mm or mo e O ll in or mo wl LUBRICATION SYSTEM Oil prnsure no m 1 oper ting tempe llure II Idle speed More I n 0 3 kg em 4 3 psi 29 kP II 3 000 rpm 2 6 5 0 kglem 35 8 71 1 1 1 245 490...

Page 291: ...uoction 1 2 11 1 0 kw Mo e than 3 000 Pm 1 3 5 mm 0631 in 8 5 mm 0 335 lit 1 785 kll 2 41 5 kll 139 S 3 1b 1 8 24N 1 2 kll 12 6 lb 1 2 N 30 mm 1 18 in 2 9 mm 1 14 in 0 05 mm o ocno in Alternator Ratad...

Page 292: ...21 5 11010 I 092 14010 09213_111121 0821 71 610 NOTE Classitication A SST requited for vehicle spectio _ nd minor rep irs and multipurpose SST B SST reQ lired for major repairs involving di 8ssemblv o...

Page 293: ...Name 8 Note u Pan No illustration OI2IH11G2D rs T _ G 0121 Io_C oI TF I s i a e 1ll U1 2i022 B IISZ2I 1O O 18 0h0 ISIT1 4A_F IOU11 GQUO IG G e m tO 4OI IG O I oem lOO10 B 4A GE O I2ZJ 41OZD B I nuJ 4I...

Page 294: ...1 tfjjj blZJl 1S1 OI IIINt ongSIWi W ZJJ ooalDi fIoe mm l10211 IIu l s 09131 00lI40 1ShatI Dt24G OCIOI jU II 11124C1 1OO2G IW Geutt hi 092 HIO lZi 11 114USO 6 J r t ot2 1 410l5 I 092 4601 OIIUS nOID 0...

Page 295: ...str tion a ____ AC I C 0 0 0 JfoJ q _11 301111 1 12 51 M5IO OOIIl 111 20011 000 OIIJl mn 2 3010 OIMl 30051 lIMZ lOD1D 11 11 c O 3 S No U u on Cflnkihlit pu ey s C Shlfll onl011 Hlal r s INo l 4A r 101...

Page 296: ...t bflaring UP No Halt cifcle plug for lA F Seal packIng or lIquovalenl 08826 00080 U O pan 0 1 pan balllo plale IFor 4A GEI Ignition coil M Wale inlet haUling Seal ing No 1282 8 or 08826 00100 WII OII...

Page 297: ...STARTING SYSTEM TROUBLESHOOTING STARTING SYSTEM CIRCUIT CONVENTIONAL TYPE STARTER REDUCTION TYPE STARTER STARTER RELAY AW ST 5T 2 5T 3 ST 4 5T 14 ST 23...

Page 298: ...repl ce witch Replace tusibte link Rep atarte ST 4 or I Replace ignition switch Engine cranks lowly Botterv charge low Chock batte y Pf cilic gravity CH 4 BauelV cable Ioo e cor oded or worn Stortlt...

Page 299: ...RCUIT AM1 40A tAE AT AM2 1 iA WI ALT eOA Fvsl Link AM eOA T 1 Igrjtion SwilCh AM ST AM1 1AE STI STl IAE An AM2 lAWl 5T2 lAW Ignition SWilch Fusible U k i T Fusible Link WI Termi el 3 0 T r Starter m l...

Page 300: ...emove the nul and disconnect the lelld wire from the magnetic switch terminal Ib loosen the two nulS holding the meogoelie witch 10 the drive housing lift the magnetic witch up and out to unhook the p...

Page 301: ...ush r holder h Pull the brush holderoff the armature 4 REMOVE flELO FRAME FROM DRIVE HOUSING Pull apart bV hand 5 REMOVE ARMATURE 6 lal Remove tM drive lever from Ihe drive housing lbl Pull the armatu...

Page 302: ...r continuity betweeo tf1 e segments of the comml ltator Ifthere no continuity between any segment replace the armalure Commutator 1 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If surface is dirty...

Page 303: ...OPEN CIRCUIT Using In Ohmmeter check lor continuity between the field coil brush leads If there is no continuity replace the field frame 2 CHECKTHAT fiELD COIL IS NOT GROUNDED Using Ir I Ohmmeter Che...

Page 304: ...K CLUTCH Rotate the pinion clockwise and check thBt it tums freely Try 10 roille the pinion counterclockwise and check thatit loch Brushes MEASURE BRUSH LENGTH Sund rd length 16 mm 0 63 In Minimum len...

Page 305: ...ional Type SllIrter 5T 9 Brush Holder CHECK INSULATION OF BRUSH HOLDER Using an ohmmetar cheek for 1 10 continuity betwel51l the positive IMld negative brush holders If there is continuity repair Of r...

Page 306: ...ure Ibl Drive in the snap ring with 14 mm 0 55 inJ soekel wrench Ihen fil it into the shah groove lei Using a vise compress the snap ring Meke sure that thesnap ring fits correctly kli Using a screwdr...

Page 307: ...e sheft 6 INSTALL FIELD FRAME WITH ARMATURE AND END FRAME IN DRIVE HOUSING a Match the protrusion of the drive lever Wilh field frame tbl Inslall and tighlen the two Ihrough boha 6 INSTALL BEARING COV...

Page 308: ...lS outward II the pinion do es not move replace the magnetic witch 2 PERFORM HOLD IN TEST With the battery connected as above and with the pinion out disconnect the negll ye lead from terminal C Check...

Page 309: ...clearance 0 1 0 4 mm 10 004 0 016 in S PERFORM NO LOAD PERFORMANCE TEST Cal connect the field coit lead to terminal C Make lure the lead is not grounded Ib Connect the battery and 8 tllf to the storte...

Page 310: ...TYPE STARTER DISASSEM STARTER BLY OF REDUCTION TYPE REMOVE FIELD tG R NEliC SWI ME WITH ARMATURE FROM emove the nut 0 1 magnetic wilCh t nect the INd nal wife from thI lbl Remove the frame with tht t...

Page 311: ...NO tOLER GEAR FROM STARTER HOUSING REMOVE STEEL BAll AND SPRING Using a magnetic finger remove the spring and steel ball from the clutch shaft hole REMOVE BRUSHES AND BRUSH HOLDER la Removethetwo scre...

Page 312: ...ty between tt e segments 01 the commutator If there is no continuity between any segment replace lhe illTTliiture Commutator 1 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surfece is dirty o...

Page 313: ...frame INSPECT THAT FIELD COlL IS NOT GROUNDED Using an ohmmeter check for no continuity betwlHln the field coil end and filld frame If Ihere il continuity repeir or replece the r Jeld frame Brushes ME...

Page 314: ...we r or damage Ifdamaged repillce lind 150 check the llywheel ring geSf for wllar or dllmllge 2 INSPECT CLUTCH Rotate the pinion clockwise and check Ihllt lt tums Ireely Try to rotille Ihe pinion cou...

Page 315: ...onto the s alt Magnetic Switch 1 PERfORM PULL IN COIL OPEN CIRCUIT TEST Using an o mmeter c f1ck lorcont inuily between terminal 50 and tarminal C If t _ is no continuity replace t e magnetic switch...

Page 316: ...armature bearings and insert the ermature into the field frame 2 INSTALL BRUSH HOLDER AND BRUSHES 3 8 Using a screwdriver hold the brush spring back ond itlstall the brush into the brush holder Instal...

Page 317: ...er gear and beanng in the starter housing 6 INSTALL STARTER HOUSINO Place the starter housing on Ihe magneti4 switch and in lall the two screws 6 INSTALL FIELD FRAME WITH ARMATURE IN MAGNETIC SWITCH I...

Page 318: ...d 15 above wilh lhe plunger out di connecl the negative lead from lelminal C b Check Ihal Ihe plunger remains out tt the plunger relurns inward repl ce lilt magnetic SWilch J INSPECT PLUNGER RETURN Di...

Page 319: ...ter check that there is continUity IMotween termiNlS 1 and 3 Ibl Ch Ck that there is no contln uity IMotween terminals 2 and 4 If continuity is not as specified replace the relay 2 INSPECT RfLAY OPERA...

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