Toyota 4A-FE Repair Manual Download Page 1

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Compression Check

Timing Belt

Summary of Contents for 4A-FE

Page 1: ...thout the written permission of Toyota Motor Corporation INTRODUCTION _ ENGINE MECHANICAL om EFI SYSTEM COOLING SYSTEM m LUBRICATION SYSTEM m IGNITION SYSTEM STARTING SYSTEM Eli CHARGING SYSTEM m SERV...

Page 2: ...DUCTION Page HOW TO USE THIS MANUAL IN 2 IDENTIFICATION INFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 4 PRECAUTIONS FOR VEHICLES EQUIPPED WtTH A CATALYTIC CONVERTER IN 7 ABBREVIATIONS USED IN THIS M...

Page 3: ...TIONS are given that pertain to all repair operations contained in that section Read these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you d...

Page 4: ...ACK to the information needed He can read the task head ings and only refer to the detailed text when he needs it Impor tant specifications and warnings always stand out in bold type REFERENCES Refere...

Page 5: ...he cable from the negative terminal which is grounded to the vehi cle body c To prevent damage to the battery terminal post loosen the terminal nut and raise the cable straight up without twisting or...

Page 6: ...SSM where specified and follow the proper work procedure A list of SST and SSM can be found at the back of this manual 10 When replacing fuses be sure the new fuse is the correct amperage DO NOT excee...

Page 7: ...insert the tester probe carefully to prevent terminals from bending g When using a vacuum gauge never force the hose onto a connector that is too large Use a step down adapter instead Once the hose ha...

Page 8: ...ast idle speed for more than 10 minutes and at idle speed for more than 20 minutes 3 Avoid spark jump test a Perform spark jump test only when absolutely necessary and as quickly as possible b While t...

Page 9: ...ntrolled Unit Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Exhaust manifold valve Except Formed in Place Gasket Fusible Link Ignition Integrated Ignition Assembly Intak...

Page 10: ...EM 2 DESCRIPTION 4A FE ENGINE ENGINE MECHANICAL Description 4A FE The 4A FE engine is an in line 4 cylinder 1 6 liter DOHC 16 valve engine EM7830 EM7831...

Page 11: ...oval of the camshafts The resin timing belt cover is made of 3 pieces A service hole is provided in the No 1 belt cover for adjusting the timing belt tension Pistons are made of highly temperature res...

Page 12: ...M 30 31 Spark plug faulty Inspect plugs IG 11 12 I EGR system always on w EGR system Check EGR system Low compression Check compression EM 38 Tires improperly inflated Inflate tires to proper pressure...

Page 13: ...s not excessively dirty damaged or oily 2 CLEAN AIR FILTER Clean the element with compressed air First blow from the back thoroughly Then blow off the front of the element INSPECTION OF HIGH TENSION C...

Page 14: ...a Check only those valves indicated in the illustration Using a thickness gauge measure the clearance between the valve lifter and camshaft Record the valve clearance measurements which are out of sp...

Page 15: ...s of shim used A Valve clearance measured N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 25 mm 0 010 in Select a shim with a thickness as close as possible to the calculated val...

Page 16: ...30 30 301 32 32 32 32 34 34 34 34 0 391 0 400 1010 1212 14 14H18j16 1616 1618 18 18 20120 20 20 20122 22 22 24 2 4 2424 2426 28 28i28 2S 28 2828 30 t03032 32 3232 3234 3434 0401 0420 1012 1214 1418 16...

Page 17: ...mple A 2 800 mm shim is installed and the measured clearance is 0 450 mm Replace the 2 800 mm shim with shim No 22 3 000 mmL Shim No 02 04 06 08 10 12 14 16 18 Thickness Shim No Thickness 2 500 0 0984...

Page 18: ...ult in damage to the igniter and or ignition coil As some tachometers are not compatible with this ignition system we recommend that you confirm the compatibility of your unit before use 3 INSPECT AND...

Page 19: ...HECK IGNITION TIMING a Remove SST from the check connector SST 09843 18020 b Check the ignition timing Ignition timing 5 15 BTDC idle Transmission in neutral range HINT The timing mark move in a range...

Page 20: ...um hoses for EGR systems etc should be properly connected e All accessories switched off f EFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral range 2...

Page 21: ...HOMETER See page EM 20 4 CHECK AIR VALVE OPERATION See page Fl 131 5 INSPECT AND ADJUST IDLE SPEED 6 Idle speed 800 rpm w Cooling fan OFF If not as specified adjust the idle speed by turning the IDLE...

Page 22: ...1 Faulty ignition Incorrect timing Fouled shorted or improperly gapped plugs Open or crossed ignition wires Cracked llA cap 2 Incorrect valve clearance 3 Leaky EGA valve w EGR system 4 Leakt intake an...

Page 23: ...Ignition timing set correctly h Transmission in neutral range i Tachometer and HC CO meter calibrated and at hand 2 START ENGINE 3 CHECK IDLE SPEED SST Idle speed 800 rpm EM7502 4 CHECK OXYGEN SENSOR...

Page 24: ...orrect timing Fouled shorted or improperly gapped plugs Open or crossed ignition wires Cracked llA or distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve w EGR system 4 Leaky intake and exha...

Page 25: ...engine to reach normal operating temperature CHECK IDLE SPEED jSee page EM 22 23 REMOVE COVER 2WD CAP FILTER AND SEPARATOR FROM DP ADJUST DP SETTING SPEED a 2WD Using SST connect terminals TE1 and E1...

Page 26: ...h Repeat steps from cl to e and recheck the DP set ting speed i 2WD w EGA system Connect the VSV connector j 2WD Remove SST from the check connector SST 09843 18020 5 REINSTALL DP SEPARATOR FILTER CAP...

Page 27: ...h c for each cylinder NOTICE This measurement must be done in as short a time as possible Compression pressure 4A FE 13 5 kg cm2 191 psi 1 320 kPal Minimum pressure 10 0 kg cm2 142 psi 981 kPal Differ...

Page 28: ...stem faulty Troubleshoot starting system No fuel supply to carburetor Troubleshoot EFI system No fuel in tank Fuel pump not working Fuel line clogged or leaking EFI system problems Repair as necessary...

Page 29: ...coil I Igniter Inspect igniter Distributor IA Inspect llA Incorrect ignition timing Reset timing EM 20 Incorrect valve clearance Adjust valve clearance EM 16 I Vacuum leaks Repair as necessary PCV lin...

Page 30: ...correct ignition timing Reset timing EM 20 Incorrect valve clearance Adjust valve clearance EM 16 Fuel system clogged Check fuel system Air cleaner clogged Check air cleaner EM 15 EFI system problems...

Page 31: ...es EFI system problem Repair as necessary Vacuum leak I Check hoses and repair as PCV hoses necessary Intake manifold Throttle body Brake booster line Insufficient fuel flow Troubleshoot fuel system I...

Page 32: ...23 Spark plugs faulty Inspect plugs IG 7 EGR system always on w EGR system Check EGR system Low compression Check compression EM 38 Tires improperly inflated Inflate tires to proper pressure Clutch s...

Page 33: ...ing Pulley REMOVAL OF TIMING BELT EMB978 1 REMOVE DRIVE BELT AND WATER PUMP PULLEY 2 REMOVE SPARK PLUGS See page IG 7 3 REMOVE CYLINDER HEAD COVER See steps 8 and 12 on pages EM 60 and 62 4 SET N0 1 C...

Page 34: ...ulley SST 09213 31021 6 REMOVE TIMING BELT COVERS Remove the nine bolts engine wire bracket and timing belt covers 7 REMOVE TIMING BELT GUIDE 8 REMOVE TIMING BELT AND IDLER PULLEY HINT If reusing the...

Page 35: ...ot be removed by hand use two screwdrivers NOTICE Position shop rags as shown to prevent damage 10 REMOVE CAMSHAFT TIMING PULLEY Hold the hexagonal head wrench portion of the camshaft with a wrench an...

Page 36: ...ft timing pulley If there are any defects as shown in the illustrations check the following points a Premature splitting Check the proper instaltation Check the timing cover gasket for damage and prop...

Page 37: ...lt 2 INSPECT IDLER PULLEY Check the turning smoothness of the idler pulley If necessary replace the idler pulley_ 3 INSPECT TENSION SPRING a Measure the free length of the tension spring Free length 3...

Page 38: ...timing mark of the bearing cap 2 INSTALL CRANKSHAFT TIMING PULLEY a Align the pulley set key with the key groove of the pulley b Slide on the timing pulley facing the flange side inward c Using the c...

Page 39: ...lutions from TDC to TDC HINT Always turn the crankshaft clockwise c Check the valve timing Ensure that each pulley aligns with the marks as shown in the illustration d Tighten the timing belt idler pu...

Page 40: ...No 3 timing belt covers and engine wire bracket with the six bolts INSTALL CRANKSHAFT PULLEY a Align the pulley set key with the key groove of the pulley slide on the pulley b Temporarily install the...

Page 41: ...COMPONENTS Adjusting Sh m Valve Lifter I__ _ 3_o 9 131__ I Valve Keepers _Q Valve Spring Retainer Valve Spring J __ Va1ve Stem Oil Seal f Spring Seat Valve Guide Bushing CValve amshaft Bearing Cap r...

Page 42: ...EM 56 57 1 REMOVE llA 2 REMOVE EXHAUST MANIFOLD 2WD a Remove the five bolts and upper heat insulator b Remove the two bolts and manifold stay c Remove the two bolts three nuts exhaust manifold and gas...

Page 43: ...Remove the two bolts and water outlet 4 REMOVE WATER INLET AND INLET HOUSING a Disconnect the following connectors Water temperature sender gauge connector Water temperature sensor connector Start inj...

Page 44: ...t the wire clamp from the wire bracket and EM7o3s disconnect the engine wire from the timing belt EM7306 EM 593 cover 9 DISCONNECT ENGINE WIRE FROM INTAKE MANIFOLD a Disconnect the following connector...

Page 45: ...02 I EM4B9 2 b Disconnect the water by pass hose from the air pipe c Remove the sevon boirs ground strap intake manifold and gasket 4WD a b Disconnect the water by pass hose from the air pipe c Remove...

Page 46: ...ION a Turn the crankshaft pulley and align its groove with the timing mark O of the No 1 timing belt cover b Check that the hole of the camshaft timing pulley is aligned with the timing mark of the be...

Page 47: ...s and adjusting bar 19 REMOVE ENGINE HANGERS Remove the two bolts and engine hangers 20 REMOVE CAMSHAFTS NOTICE Since the thrust clearance of the camshaft is small the camshaft must be kept level whil...

Page 48: ...bearing cap bolts in several passes in the sequence shown e Remove the four bearing caps and camshaft HINT If the camshaft is not being lifted out straight and level reinstall the bearing cap with the...

Page 49: ...not being lifted out straight and level reinstall the No 3 bearing cap with the two bolts Then alternately loosen and remove the two bearing cap bolts with the camshaft gear pulled up NOTICE Do not pr...

Page 50: ...lts in several passes in the sequence shown SST 09205 16010 NOTICE Head warpage or cracking could result from removing the bolts in an incorrect order b Lift the cylinder head from the dowels of the c...

Page 51: ...1 REMOVE VALVE LIFTERS AND SHIMS HINT Arrange the valve lifters and shims in correct order 2 REMOVE VALVES a Using SST compress the valve spring and remove the two keepers SST 09202 70010 b Remove th...

Page 52: ...block c Using compressed air blow carbon and oil from the bolt holes CAUTION Protect your eves whAn using high press ure compressed air 2 CLEAN CYLINDER HEAD A Remove gasket material Using a gasket s...

Page 53: ...linder block and manifolds for warpage Maximum warpage Cylinder block side 0 05 mm 0 0021 in Manifold side 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head B Inspect for...

Page 54: ...st 5 965 5 980 mm 0 2348 0 2354 in c Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance Intake 0 025 0 060 mm 0 0010 0 0024 in Exhau...

Page 55: ...g bore diameter of the cylinder head is greater than 11 027 mm 0 4341 in L machine the bushing bore to the following dimensions Rebored cylinder head bushing bore dimesion 11 050 11 077 mm 0 4350 0 43...

Page 56: ...0 in It the margin thickness is less than minimum replace the valve d Check the valve overall length Standard overall length Intake 91 45 mm 3 6004 in Exhaust 91 90 mm 3 6181 in Minimum overall length...

Page 57: ...ace are concentric If not resurface 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 If not correct the valve seats as follows...

Page 58: ...cks b Using a dial indicator measure the circle runout at the center journal Maximum circle runout 0 04 mm 0 0016 in If the circle runout is greater than maximum replace the camshaft B Inspect cam lob...

Page 59: ...e the free distance between the spring end Free distance 17 1 17 5 mm 0 673 0 689 in If the free distance is not as specified replace the gear spring F Inspect camshaft journal oil clearance a Clean t...

Page 60: ...030 0 085 mm 0 001 2 0 0033 in Exhaust 0 035 0 090 mm EM4166 0 0014 0 0035 in L__ EM4203 Maximum thrust clearance 0 11 mm 0 0043 in If the thrust clearance is greater than maximum replace the camshaft...

Page 61: ...aximum replace the lifter lf necessary replace the cylinder head 12 INSPECT INTAKE AND EXHAUST MANIFOLDS Using precision straight edge and feeler gauge measure the surface contacting the cylinder head...

Page 62: ...g a new cylinder lead spark plug tubes must be installed a Apply adhesive to the spark plug tube hole of the cylinder head Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b Using a press pr...

Page 63: ...g 4 Spring retainer c Using SST compress the valve spring and place the two keepers around the valve stem SST 09202 70010 d Using a plastic faced hammer lightly tap the valve stem tip to assure proper...

Page 64: ...Using SST install and uniformly tighten the ten cylinder head bolts in several passed in the sequence shown SST 09205 16010 Torque 610 kg cm 44 ft lb 60 N m HINT Cylinder head bolts are 90 mm 3 54 in...

Page 65: ...be kept level while it is being installed If the camshaft is not kept level the portion of the cylinder head receiving the shaft thrust may crack or be damaged causing the camshaft to seize or break T...

Page 66: ...hten the ten bearing cap bolts in several passes in the sequence shown Torque 130 kg cm 9 ft lb 13 N m h Apply MP grease to a new oil seal lip i Using SST tap in the oil seal SST 09223 46011 HINT Do n...

Page 67: ...their valve lifters evenly e lnstale the four bearing caps in their proper locations f Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts g Install and uniformly...

Page 68: ...learance Valve clearance Cold Intake 0 15 0 25 mm 0 006 0 010 in Exhaust 0 20 0 30 mm 0 008 0 012 in 5 INSTALL ENGINE HANGERS Install the two engine hangers with the two bolts Torque 280 kg cm 20 ft l...

Page 69: ...he crankshaft clockwise c Check that each pulley aligns with the timing marks as shown in the illustration If the timing marks does not align remove the timing belt and reinstall it d Tighten the idle...

Page 70: ...six bolts 12 INSTALL SPARK PLUGS See page IG 8 Torque 180 kg cm 13 ft lb 18 N m 13 INSTALL SEMI CIRCULAR PLUG a Remove any old packing FIPG material b Apply seal packing to the circular plug Seal pack...

Page 71: ...80 kg cm 69 in lb 7 8 N m 15 INSTALL INTAKE MANIFOLD 2WD a Install a new gasket and the intake manifold with the seven bolts ground strap and two nuts Torque 195 kg cm 14 ft lb 19 N m b Connect the w...

Page 72: ...to vacuum pipe with the wire clamp c Connect the following connectors Throttle position sensor connector ISC valve connector 2WD w EGR system EGR VSV connector Cold start injector connector 18 INSTALL...

Page 73: ...clean both sealing surfaces b Apply seal packing to the inlet housing groove Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut with a 2 3 mm 0 08 0 12 in opening HINT A...

Page 74: ...utlet groove Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut with a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the sur face Parts must be...

Page 75: ...ENGINE MECHANICAL Cylinder Head 4A FE c Install the manifold stay with the two bolts Torque 400 kg cm 29 ft lb 39 N m EM 91 d Install the upper heat insulator with the five bolts EM7032...

Page 76: ...liary Air Valve Fl 131 ELECTRONIC CONTROL SYSTEM Fl 133 Location of Electronic Control Parts Fl 133 EFI Main Relay Fl 134 Circuit Opening Relay Fl 135 Start Injector Time Switch Fl 137 Water Temperatu...

Page 77: ...Ignition Switch Battery Starter EFI SYSTEM System Description SYSTEM DESCRIPTION ECU 0 u Q a Q 15 ro C O 0 c Q f 0 Q 1l a f g t 0 o t Cl c C 0 1l 1 C Fuel Pressure Regulator Start Injector Time Switch...

Page 78: ...t Opening Ignition Switch CHECK ENGINE Warning Light Battery Starter Oxygen Sensor ECU c 0 Vl CJ c O e CJ c O 0 I O a Q CJ s LL EGA Vacuum Modulator Fuel Pressure Regulator g t 0 o t I I c c 0 Q f 0 C...

Page 79: ...flow meter Intake air temperature Coolant temperature Engine rpm Throttle valve opening valve Exhaust oxygen content w TWC etc These signals are utilized by the ECU to determine the injection duratio...

Page 80: ...er or leather parts INSPECTION PRECAUTIONS MAINTENANCE PRECAUTIONS 1 CHECK CORRECT ENGINE TUNE UP 2 PRECAUTIONS WHEN CONNECTING GAUGE a Connect the tachometer test orobe to the IG 8 terminal of the ch...

Page 81: ...ring troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles 5 Do not open the ECU cover 6 When inspecting during rainy weather take care...

Page 82: ...nut or union bolt on the high pressure pipe union observe the following pro cedure a Put a container under the connection b Slowly loosen the connection c Disconnect the connection d Plug the connecti...

Page 83: ...ring b When placing an 0 ring on the injector use care not to damage it in any way c Lubricate the 0 ring with spindle oil or gasoline before installing Never use engine gear or brake oil 4 Install th...

Page 84: ...ure within high pressure line will rise to approx 4 kg cm2 5 7 psi 392 kPa In this state check to see that there are no leaks from any part of the fuel system NOTICE Always pinch the hose Avoid bendin...

Page 85: ...um leaks f Emission control system PCV system EGR system w EGR system g Others Ignition timing Idle speed etc 2 The most frequent cause of problems is simply a bad con tact in wiring connectors Always...

Page 86: ...tart switch A T 4 Wiring Connection SYMPTOM DIFFICULT TO START OR NO START CRANKS OK Diagnosis code s Check for output of diagnosis code Malfunction 4A FE See page Fl 28 See page Fl 25 code s 4A GE Se...

Page 87: ...2 Compression pressure Minimum 10 0 kg cm2 HINT Check compression pressure and valve clearance if necessary CHECK AUXILIARY AIR VALVE See page Fl 130 CHECK INTAKE VALVE CHECK EFI ELECTRONIC CIRCUIT U...

Page 88: ...tor filter See page Fl 95 See oage Fl 109 i OK CHECK AIR FILTER ELEMENT Element Clean or replace OK BAD CHECK IDLE SPEED AND IDLE CO Idle speed Adjust CONCENTRATION NO 4A FE See pages EM 22 23 Standar...

Page 89: ...signal change when the connector or relay is slightly tapped or wiggled 1 Auxiliary air valve BAD 2 Water hose s 3 Air hose s 1 Fuel pump See page Fl 94 BAD 2 Fuel filter 3 Fuel pressure regulator Se...

Page 90: ...TION TIMING Ignition timing Adjust 1 Connect terminals TE1 and E1 of the NO 4A FE See page EM 20 check connector 4A GE See page EM 28 2 Check ignition timing Standard 10 BTDC idle l OK CHECK SPARK PLU...

Page 91: ...INE IDLE SPEED NO DROP CHECK ACCELERATOR LINKAGE Linkage Stuck iOK BAD CHECK AUXILIARY AIR VALVE Auxillary air valve Always open See page Fl 131 BAD OK 4A FE 1 ISC valve CHECK ISC VALVE BAD 2 Air pipe...

Page 92: ...6 Intake air temp sensor 7 Injection signal circuit 1 Injector wiring 2 ECU SYMPTOM ENGINE BACKFIRES Lean Fuel Mixture CHECK DIAGNOSIS SYSTEM Diagnostic code s Check for output of diagnostic code Mal...

Page 93: ...flow meter w Air flow meter 4 Vacuum sensor w o Air flow meter 5 Water temp sensor 6 Intake air temp sensor 7 Throttle position sensor B Injection signal circuit 1 Injector wiring 2 Fuel cut RPM See p...

Page 94: ...SPARK PLUGS 1 Spark plugs Standard 0 8 mm 0 031 in NO 2 Compression pressure HINT Check compression pressure and Minimum 10 0 kg cm2 valve clearance if necessary 142 psi 981 kPa at 260 rpm 3 Valve cl...

Page 95: ...Fl 34 I I BAD Malfunction code s BAD NO BAD BAD BAD Element Clean or replace Diagnostic code s 4A FE See page Fl 28 1 High tension cord s 2 llA or Distributor 3 Ignition coil igniter Ignition timing...

Page 96: ...ver that a malfunction has been detected The light goes out automatically when the malfunction has been cleared CHECK ENGINE WARNING LIGHT CHECK 1 The CHECK ENGINE warning light will come on when the...

Page 97: ...nction the light will blink every 0 5 seconds The first number of blinks will equal the first digit of a 2 digit diagnostic code and after a 1 5 second pause the 2nd number of blinks will equal the 2n...

Page 98: ...nt of future trouble If it is necessary to work on engine components requir ing removal of the battery terminal a check must first be made to see if a diagnostic code is has been recorded 2 After canc...

Page 99: ...from the oxygen sensor does Oxygen sensor circuit Sensor not exceed a set value on the Heater lean side and the rich side Oxygen sensor 2 _jlJl_JL continuously for a centain Fl 50 period Fl 64 Oxygen...

Page 100: ...er Signal engine speed reaches BOO IG switch main relay Fl 47 circuit Fl 61 rpm wiijl vehicle not moving ECU I Fl1398 A C switch circuit A C switch A C amplifier No IDL signal NSW Neutral start switch...

Page 101: ...____ B AT T Battery 1 _J_ FL S 81 AM 2 Ignition witch 30A FL ALT 100A 4 iW L c r o __ CHECK ENGINE Warning Light BATT Fuse STOP 15A Check Connector Fuse EFI 15A E1 E1 ECU Ignition Switch EFI Main Rela...

Page 102: ...h BAD Repair or replace Does CHECK ENGINE warning light go off YES System Normal when the engine is started 2 NO Check wiring between ECU and CHECK ENGINE BAD Repair warning light NO I Is there diagno...

Page 103: ...o first make a simple check of the fuses fusible links and the condition of the connectors The following troubleshooting procedures are based on the supposition that the trouble lies in either a short...

Page 104: ...Troubleshooting with Volt Ohmmeter Fl 35 LOCATION OF FUSES AND FUSIBLE LINKS Cont d FL AM2 30A FL AM1 60A EEBs E ofD 00 DOOIJO Fuse ooo IGN 7 5A oD I CIJIIIJ Fuse UJU U GAUGE 7 5A Fuse EFI 1SA Fuse IG...

Page 105: ...e s can easily come in NOTICE Pay attention to sections A 11 and B in the illustration which can be easily broken c Reconnect the connectors to the ECU HINT Perform all voltage measurements with the c...

Page 106: ...E RESISTOR T CHECK CONNECTOR G8 DISTRIBUTOR VF CHECK CONNECTOR E21 SENSOR GROUND 1 ACT A C AMPLIFIER G1 DISTRIBUTOR SPD SPEED SENSOR NE DISTRIBUTOR FC CIRCUIT OPENING RELAY IGF IGNITER A C A C COMPRES...

Page 107: ...0 5 14 I oy VAF Gf1 G1 IGF IGT Voltage at ECU wiring connectors 4A FE 2WD Condition Ignition SW ON Throttle valve open Ignition SW ON Throttle valve fully closed Ignition SW ON No trouble CHECK ENGINE...

Page 108: ...AE 10A AT 1 STD voltage 10 14V ECU B1 E1 Fl6177 CD There is no voltage between ECU terminals B 81 and E1 IG SW ON Check that there is voltage between ECU terminaI B B1 and body ground IG SW ON NO l OK...

Page 109: ...1 Fl4042 Fl4040 Condition STD voltage 10 14 v ECU BATT 1 E1 Fl1B43 CD There is no voltage between ECU terminals BATT and E1 Check that there is voltage between ECU terminal BATT and body ground NO IOK...

Page 110: ...r 1 DL Fl4439 E1 F10984 CD There is no voltage between ECU terminals IDL and E2 IG SW ON Throttle valve open V Check that there is voltage between ECU terminal B 81 l and body ground IG SW ON NO iOK C...

Page 111: ...rminals No 10 and or No 20 and EO 1 and or E02 IG SW ON Check that there is voltage between ECU terminal No 10 and or No 20 and body ground NO jOK Fl5178 Check wiring between ECU terminal E01 and or E...

Page 112: ...CU Voltmeter CY 0 0 KJr 0 Ohmmeter 1 ri J ECU Ojrt 1 Combination Meter 1 El FI0728 CD CD There is no voltage between ECU terminals Wand El ldlingl Check that there is voltage between ECU terminal W an...

Page 113: ...PIM or VCC and E2 IG SW ON Voltmeter CU Check that there is vottage between ECU terminal B 81 and body ground IG SW ON r i l oj 1 NO NO L_ o Voltmeter 0 Ohmmeter L n I 1 c p 11 1 1 o i I _ I I Fl4048...

Page 114: ...Ii F13572 CD There is no voltage between ECU terminals THA and E2 IG SW ON Check that there is voltage between ECU terminal B 81 and body ground IG SW ON OK iNO Refer to B E1 I trouble section No 1 S...

Page 115: ...inals THW and E2 IG SW ON t Check that there is voltage between ECU terminal B B1 and body ground IG SW ON OK lNO Fl4050 Refer to B E1 trouble section No 1 See page Fl 39 Voltmeter eek wiring between...

Page 116: ...El CD There is no voltage between ECU terminals STA and E1 IG SW START Check starter OK Check wiring between ECU terminal F15170 operation STA and ignition switch terminal ST1 BAD OK jBAD I Replace re...

Page 117: ...U terminals IGT and E1 1 Idling Check that there is voltage between ECU terminal IGT and body ground Idling NO OK fl405i Check wiring between ECU BAD Repair or replace terminal E1 and body ground IOK...

Page 118: ...re is voltage between ECU terminal A C and body ground I 9 ______ J9 it i______ _____ __ NO jOK Ohmmeter LlLJ I 1 9 L _ 2 F14045 ECU Fl4055 Fl4040 Check wiring between ECU terminal E1 and body ground...

Page 119: ...n ECU terminal El and body ground OK BAD Try another ECU Repair or replace Is air leaking into air intake system BAD Repair air leak OK Check spark plugs BAD Repair or replace OK Check distributor and...

Page 120: ...Check Valve OUTLET INLET I t INLET FI0530Fl1479 FL Fuse EFI 15A FL Ignition Switch AM2 AM1 AM2 AM1 30A 40A AE AT 180 60A AT171 FL ALT 1OOA AE AT180 BOA AT171 EFI Main Relay Fuel IGN 1OA AE 7 5A AT Ci...

Page 121: ...k that there is pressure in the hose from the fuel filter HINT At this time you will hear fuel return noise from the pressure regulator d Remove SST from the check connector SST 09843 1 8020 e Turn th...

Page 122: ...move the bolts cold start injector pipe and four gaskets f Drain the fuel from the delivery pipe g Install SST pressure gauge to the delivery pipe with new two gasket and union bolt SST 09268 45012 To...

Page 123: ...the fuel pressure regulator If pressure is low check the following parts Fuel hoses and connection Fuel pump Fuel filter Fuel pressure regulator m Remove SST from the check connector SST 09843 1 8020...

Page 124: ...Pa or more for 5 minutes after the engine is turned off If pressure is not as specified check the fuel pump pressure regulator and or injector t After checking fuel pressure disconnect the battery neg...

Page 125: ...nce between the terminals Resistance 4A FE 3 5 l If the resistance is not as specified replace the injector c Reconnect the cold start injector connector REMOVAL OF COLD START INJECTOR 1 DISCONNECT CA...

Page 126: ...Keep clear of sparks during the test a Install SST two unions to the injector and delivery pipe with new gaskets and the union bolts SST 09268 41045 09268 41080 b Connect SST hose to the union SST 092...

Page 127: ...re to the bat tery and check that the spray is as shown SST 09842 30055 NOTICE Perform this check within the shortest possible time 2 INSPECT LEAKAGE a In the condition above disconnect the test probe...

Page 128: ...with the two bolts Torque 4A FE 95 kg cm 82 in lb 9 3 N m 2 INSTALL COLD START INJECTOR PIPE Install the injector pipe with four new gaskets and the two union bolts Torque 4A FE 180 kg cm 13 ft lb 18...

Page 129: ...ressure Regulator 4A FE Spring Diaphragm Vacu ing Hose Fuel Pressure Regulator Fuel Return Hose F13093 Fl6013 ON VEHICLE INSPECTION INSPECT FUEL PRESSURE See page Fl 95 REMOVAL OF FUEL PRESSURE REGULA...

Page 130: ...ring from the pressure regulator INSTALLATION OF FUEL PRESSURE REGULATOR 1 INSTALL FUEL PRESSURE REGULATOR a Apply a light coat of gasoline to a new 0 ring and install it to the pressure regulator b...

Page 131: ...jector Connector Terminal INLET ON VEHICLE INSPECTION 1 INSPECT INJECTOR OPERATION Check operation sound from each injector a With the engine running or cranking use a sound scope to check that there...

Page 132: ...no sound or an unusual sound is heard check the wiring connector injector or injector signal from the ECU 2 INSPECT INJECTOR RESISTANCE a Disconnect the injector connector b Using an ohmmeter measure...

Page 133: ...DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 4 DISCONNECT INJECTOR CONNECTORS 5 DISCONNECT HOSE FROM FUEL RETURN PIPE 6 DISCONNECT FUEL INLET HOSE FROM DELIVERY PIPE a 4A FE Remove the...

Page 134: ...delivery pipe together with the four injectors NOTICE Be careful not to drop the injector when removing the delivery pipe b 4A FE Remove the four insulators and two spacers from the cylinder head c Pu...

Page 135: ...re regulator from the delivery pipe and connect the fuel hose to pressure regulator d Install a new 0 ring to the pressure regulator e Connect the SST hose to the pressure regulator with SST union and...

Page 136: ...per 15sec Difference between each injector Sec 0 3 cu in or less If the injection volume is not as specified replace the injector 2 INSPECT LEAKAGE a In the condition above disconnect the test probes...

Page 137: ...ace the four insulators and two spacers in position on the cylinder head 4A GE Place the four insulators and three spacers in position on the cylinder head e Place the injectors together with the deli...

Page 138: ...Fl 118 r i EFI SYSTEM Fuel System h 4A FE Install and torque the two bolts 4A GE Install and torque the three bolts Torque 4A FE 150 kg cm 11 ft lb 15 N m...

Page 139: ...two new gaskets and the union bolt Torque 300 kg cm 22 ft lb 29 N m 4 CONNECT FUEL RETURN HOSE 5 CONNECT INJECTOR CONNECTORS 6 CONNECT VACUUM SENSING HOSE 7 INSTALL COLD START INJECTOR PIPE See step...

Page 140: ...nt Power Point Fl3800 F16040 F10451 FtQ462 a Check that the throttle linkage moves smoothly b Check the vacuum at each port Start and warm up the engine Check the vacuum with your finger Port Throttle...

Page 141: ...uity No continuity No continuity No continuity No continuity No continuity No continuity Continuity No continuity jd Reconnect the sensor connector REMOVAL OF THROTTLE BODY 1 DISCONNECT CABLE FROM NEG...

Page 142: ...and apertures NOTICE To prevent deterioration do not clean the throttle position sensor 2 INSPECT THROTTLE BODY VALVE Check that there is no clearance between the throttle stop screw and throttle lev...

Page 143: ...No No 7 5 from vertical continuity continuity 4 IF NECESSARY ADJUST THROTTLE POSITION SENSOR a Loosen the two set screws of the sensor b c d Insert a 0 70 mm 0 028 in l feeler gauge between the throt...

Page 144: ...cm 16 ft lb 22 N ml 2 CONNECT FOLLOWING HOSES a No 2 water by pass hose b PCV hose to the throttle body c Vacuum hose s to the port s 3 CONNECT THROTTLE POSITION SENSOR CONNECTOR 4 INSTALL CABLE BRACK...

Page 145: ...should drop After warm up Check that engine RPM does not drop more than 100 rpm c Install the air cleaner hose If operation is not as specified replace the air valve w Air Flow Meter Check the engine...

Page 146: ...4A FE Remove the three screws air valve gasket and 0 ring 4A GE Remove the five screws air valve gasket and 0 ring INSTALLATION OF AIR VALVE 1 INSTALL AIR VALVE TO THROTTLE BODY a Place new gasket and...

Page 147: ...4WD c Start Injector Time Switch Oxygen Sensor w TWC ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts Vacuum Sensor ECU Variable Resistor w o TWC C L_ Check Connector C AT l _ ___ L ___...

Page 148: ...between terminals 1 and 2 b Check that there is no continuity between terminals 3 and 4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across ter...

Page 149: ...l Pump Switch Circuit Opening Relay To ECU FC I Air Flow Meter LL Fl6174 INSPECTION OF CIRCUIT OPENING RELAY w o Air Flow Meter 1 INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is conti...

Page 150: ...T RELAY CONTINUITY a Using an ohmmeter check that there is continuity between terminals STA and E1 _ b Check that there is continuity between terminals B and FC_ c Check that there is no continuity be...

Page 151: ..._ Start Injector Time Switch STA INSPECTION OF START INJECTOR TIME SWITCH INSPECT START INJECTOR TIME SWITCH Fil 273 Using an ohmmeter measure the resistance between each terminal Resistance STA STJ...

Page 152: ...1 r3 0 8 cc 0 6 0 4 0 2 20 0 20 40 60 80 100 120 4 32 68 104 140 1 76 21 2 248 TEMPERATURE C F I F13828 FIGl709 INSPECTION OF WATER TEMPERATURE SENSOR INSPECT WATER TEMPERATURE SENSOR Using an ohmmet...

Page 153: ...4 w u z 2 r t 1 U5 0 8 0 6 0 4 0 2 20 0 20 40 60 80 100 120 4 32 68 104 140 1 76 21 2 248 TEMPERATURE C F F12s3of10109 INSPECTION OF INTAKE AIR TEMPERATURE SENSOR INSPECT RESISTANCE OF INTAKE AIR TEM...

Page 154: ...er FROM INTAKE MANIFOLD Voltmeter Voltmeter Fl4918 Fl4920 F14916F14917 E1 Fl4424 F14 548 Fil 226 INSPECTION OF VACUUM SENSOR 1 INSPECT POWER SOURCE VOLTAGE OF VACUUM SENSOR a Disconnect the vacuum sen...

Page 155: ...nsor in 100 mmHg 3 94 in Hg 13 3 kPa segments to 500 mmHg 19 69 in Hg 66 7 kPa e Measure voltage drop from step c above for each segment Voltage drop Applied Vacuum 100 200 mmHg 3 94 7 87 in Hg 13 3 2...

Page 156: ...r EFI SYSTEM Electronic Control System Variable Resistor w o TWC ECU B B vcc VAF E2 INSPECTION OF VARIABLE RESISTOR 1 INSPECT VOLTAGE OF VARIABLE RESISTOR Fl1402 la Using a voltmeter measure the volta...

Page 157: ...slowly turning idle mixture adjusting screw first fully counterclockwise and then fully clockwise c Check that the voltage changes smoothly from 0 V to approx 5 V 2 INSPECT RESISTANCE OF VARIABLE RESI...

Page 158: ...ectronic Control System c Turn the idle mixture adjusting screw fully coun terclockwise d Connect an ohmmeter to terminals VAF and E2 Turn the adjusting screw fully clockwise and check that the resist...

Page 159: ...Zero again I After replacing I the oxygen sensor I I I Check the number of times the voltmeter needle fluctuates in 10 seconds I 4A FE Less than 8 times 4A FE I ze 8 times or more ro Warm up the oxyge...

Page 160: ...ure voltage between terminals VF1 and E1 ov 5V Measure voltage between terminals VF1 and E1 More than 0 V _R_e_p_ai_r_ _O_v_e_r_ri_c_h_ _ Replace the oxygen sensor Disconnect the water temp sensor con...

Page 161: ...CU INSPECTION OF ECU HINT The EFI circuit can be checked by measuring the resistance and voltage at the wiring connectors of the ECU 1 PREPARATION See page Fl 36 2 INSPECT VOLTAGE OF ENGINE ECU Check...

Page 162: ...E light off and engine running 10 14 PIM E2 3 3 3 9 Ignition SW ON VCC E2 4 5 5 5 THA E2 Intake air temperature 20 C 68 F 2 0 2 5 Ignition SW ON THW E2 Coolant temperature 80 C 1 76 F 0 4 0 7 STA E1 C...

Page 163: ...SW ON Throttle valve fully open 3 5 5 5 4 5 5 5 Idling 0 7 1 0 Cranking 6 14 Ignition SW ON 10 14 No trouble CHECK ENGINE warning light off and engine running 10 14 3 3 3 9 Ignition SW ON 4 5 5 5 Int...

Page 164: ...ance between each terminal of the wiring connectors Disconnect the connectors from the ECU Measure the resistance at each terminal F14559 Resistance of ECU Wiring Connectors 4A FE Condition Resistance...

Page 165: ...m the throttle position sensor c Connect circuit terminals IDL and E2 on the wir ing connector side d Gradually raise the engine rpm and check that there is fluctuation between the fuel cut and fuel r...

Page 166: ...accessories switched off b Using a voltmeter check that it indicates battery voltage during cranking and for ten seconds after starting 2 INSPECT IDLE UP VSV A Inspect VSV for open circuit Using an o...

Page 167: ...ntrol System Fl5145 fl5 62 C Inspect VSV operation a Check that air flows from pipe E to pipe F b Apply battery voltage across the terminals c Check that air flows from pipe E to pipe F lf operation i...

Page 168: ...T171 F14S87 From EFI Main Relay _ INSPECTION OF ISC VALVE INSPECT ISC VALVE A Inspect ISC Valve for open circuit B 81 F15347 Using an ohmmeter check that there is continuity bet ween the terminals B R...

Page 169: ...Control System Fl 169 Air C Inspect ISC valve operation a Check that air does not flow from pipes E to F bl Apply battery voltage across the terminals c Check that air flows pipes E to F If operation...

Page 170: ...C0 1 COOLING SYSTEM Page DESCRIPTION C0 2 TROUBLESHOOTING C0 4 CHECK AND REPLACEMENT OF ENGINE COOLANT C0 5 WATER PUMP C0 6 THERMOSTAT C0 13 RADIATOR C0 15 ELECTRIC COOLING FAN C0 21 m...

Page 171: ...tilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by pass valve mounted on the inlet side 4A FE Water Outlet WaterPump lf FROM RADIATOR I Water Inlet...

Page 172: ...urization of the radiator as the coolant expands The pressuriza tion prevents the coolant from boiling even when the coolant temperature exceeds 100 C 212 F A relief valve pressurization valve and a v...

Page 173: ...gasket leakage Thermostat faulty Check thermostat C0 13 Ignition timing retarded Set timing Electric cooling system faulty Inspect electric cooling system C0 21 Radiator hose plugged or rotted Replace...

Page 174: ...am can be blown out under pressure b Drain the coolant from the radiator and engine drain cocks The engine drain cock is near the oil filter c Close the drain cocks Torque Engine drain cock 350 kg cm...

Page 175: ...Seal Water Pump Body Rotor Gasket REMOVAL OF WATER PUMP 1 DRAIN COOLANT See page C0 5 0 Ring C00499 2 REMOVE DRIVE BELT AND WATER PUMP PULLEY 3 REMOVE N0 3 AND N0 2 TIMING BELT COVERS 4A FE See steps...

Page 176: ...ve the bolt and pull out the dipstick guide Plug the guide installation hole of the oil pump c Remove the 0 ring from the dipstick guide 6 REMOVE WATER PUMP a Remove the three bolts and water pump_ b...

Page 177: ...bearing shaft SST 09236 00101 09237 00010 09237 00040 3 REMOVE WATER PUMP BEARING a Using a grinding wheel grind the water pump rotor as shown NOTICE Do not grind water pump bearing shaft b Heat the...

Page 178: ...00101 09237 00020 HINT The bearing end face should be flush with the body top surface 2 INSTALL SEAL 3 a Apply a seal packing No 1282 B to a new seal and pump body Seal packing Part No 08826 00100 or...

Page 179: ...shown in the figure the distance from the rotor edge to the installation surface of the pump body should 6 0 mm be 6 0 mm 0 236 in C00506 C00607 5 CHECK WATER PUMP After assembly make sure that the ro...

Page 180: ...LL OIL DIPSTICK GUIDE AND DIPSTICK a Install a new 0 ring to the dipstick guide b Apply soapy water to the 0 ring c Push in the dipstick guide and install it with the bolt Torque 95 kg cm 82 in lb 9 3...

Page 181: ...hoses to the inlet pipe 4 INSTALL N0 2 AND N0 3 TIMING BELT COVERS 4A FE See steps 11 14 and 18 on page EM 86 and 88 5 TEMPORARILY INSTALL WATER PUMP PULLEY 6 INSTALL ALTERNATOR DRIVE BELT 7 ADJUST D...

Page 182: ...the thermostat in water and gradually heat the water b Check the valve opening temperature Valve opening temperature 80 84 C 176 183 F If the valve opening temperature is not as specified rep lace the...

Page 183: ...ud bolt and insert the thermostat in the water inlet housing_ HINT The jiggle valve be set within 10 of either side of the pressribed position 2 INSTALL WATER INLET Install the water inlet with the tw...

Page 184: ...R CAP Using a radiator cap tester pump the tester until relief valve opens Check that valve opens between 0 75 kg crn2 10 7 psi 74 kPa and 1 05 kg cm2 14 9 psi 103 kPa Check that the pressure gauge do...

Page 185: ...0 SOA AT1 7 1l Fuse IGN 1OA AE 7 5A AT Engine Main Relay Fan Fan Motor Fan Shroud ELECTRIC COOLING FAN Radiator Cooling Fan SYSTEM CIRCUIT FL ROI FAN 30A COMPONENTS AT Fan C00775 Cooling Fan Motor Fan...

Page 186: ...RATURE SWITCH CONNECTOR Check that the fan rotates If it does not check the fan relay fan motor ignition relay and fuse and check for a short circuit between the fan relay and temperature switch C0061...

Page 187: ...witch INSPECT ENGINE MAIN RELAY LOCATION In the engine compartment relay box A Inspect relay continuity a Using an ohmmeter check that there is continuity between terminals 1 and 3 b Check that there...

Page 188: ...nuity is not as specified replace the relay B Inspect relay operation a Apply battery voltage across terminals 1 and 2 b Check that there is no continuity between terminal and 4 If operation is not as...

Page 189: ...LUBRICATION SYSTEM Page DESCRIPTION LU 2 TROUBLESHOOTING LU 5 Oll PRESSURE CHECK LU 6 REPLACEMENT OF ENGINE Oll AND Oll FILTER LU 7 Oll PUMP LU 9 LU 1...

Page 190: ...FE Oil Cooler Oil Strainer Relief Valve I PISTON i __ C_Y_L_IN_D_E_R_S_ I CONNECTING RODS I I I I ____ CRANKSHAFT I RELIEF VALVE CAMSHAFT DRIVE r i GEAR EX 1 VALVE LIFTERS VALVE STEMS CAMS CAMSHAFT J...

Page 191: ...is changed as they rotate Oil is drawn in when the space is wide and is discharged when the space in narrow OIL PRESSURE REGULATOR At high engine speeds the engine oil supplied by the oil pump exceeds...

Page 192: ...LU 13 Gasket faulty Replace gasket Low oil pressure Oil leakage Repair as necessary Relief valve faulty Repair relief valve LU 12 13 Oil pump faulty Repair oil pump LU 9 Poor quality engine oil Repla...

Page 193: ...SENDER GAUGE AND INSTALL OIL PRESSURE GAUGE a 4A FE Remove the alternator and bracket b Remove the oil pressure switch 4A FE HINT w Sender gauge Use SST SST 09027 12140 c Install an oil pressure gauge...

Page 194: ...quency and length of time your skin is exposed to used engine oil Protec tive clothing and gloves that cannot be penetrated by oil should be worn The skin should be thorough ly washed with soap and wa...

Page 195: ..._ _ _ _ _ _ _ _ _ L_u04 9o Torque 350 kg cm 25 ft lb 34 N m LU0488 b Fill the engine with new oil API grade SD SE SF SG or better Capacity 4A FE c Drain and refill Without oil filter change 3 0 liters...

Page 196: ...ION SYSTEM Oil Pump OIL PUMP COMPONENTS Oil Pump Body Oil Pump Body Cover Gasket Driven Rotor 0 Ring Drive Rotor Oil Seal Relief Valve G asket Spring Retainer Oil Strainer i r _Snap Ring Non reusable...

Page 197: ...IGNITION SYSTEM Page PRECAUTIONS IG 2 TROUBLESHOOTING IG 3 IGNITION SYSTEM CIRCUIT IG 4 ON VEHICLE INSPECTION 4A FE IG 6 INTEGRATED IGNITION ASSEMBLY llA 4A FE IG 15 IG 1...

Page 198: ...e tachometer to termil IG 8 of the check connector 3 As some tachometers are not compatible with this ignition system we recommended that you confirm the compatibility of your unit before using 4 NEVE...

Page 199: ...conditions Using data provided by sensors which monitor various engine functions rpm intake air volume eng temperature etc the microcomputer ECU trig gers the spark at precisely the right instant Ign...

Page 200: ...not occur perform the test as follows BAD Replace the cords CHECK POWER SUPPLY TO IGNITION COIL Check wiring between ignition switch 1 Ignition switch turn to ON BAD to ignition coil 2 Check that ther...

Page 201: ...ng the llA cap Maximum resistance 26 kfl per cord If the resistance is greater than maximum check the ter minals If necessary replace the high tension cord and or llA cap 4 REINSTALL llA CAP 5 RECONNE...

Page 202: ...TANCE 2 Using an ohmmeter measure the resistance between the positive and negative terminal Primary coif resistance Cold 2WD 1 28 1 56 kO If the resistance is not as specified replace the ignition coi...

Page 203: ...IG1143 2 INSPECT SIGNAL GENERATOR PICK UP COIL RESISTANCE Using an ohmmeter measure the resistance between the terminals G 1 and G 8 NE and G 8 Pickup coll resistance Cold 140 180 fi If the resistance...

Page 204: ...ap 0 o lgniter Gasket u __ lgnition Coil Dust Cover 0 Ring 0 r lgnition Coil Gasket IGl314 DISASSEMBLV OF llA 1 REMOVE DISTRIBUTOR CAP GASKET AND ROTOR 2 REMOVE IGNITION COIL DUST COVER 3 REMOVE IGNIT...

Page 205: ...gniter terminals b Remove the two screws and igniter 6 REMOVE llA WIRE a Disconnect the connector from the cord clamp b Remove the screw and condenser c Remove the grommet of the wire from the housing...

Page 206: ...all the llA wire with the screw c Install the connector to the cord clamp 2 INSTALL IGNITER a Install the igniter with the two screws b Connect the three wires to the igniter terminals with the three...

Page 207: ...YLINDER TO TDC COMPRESSION Turn the crankshaft clockwise and position the slit of the intake camshaft as shown in the figure 2 INSTALL llA a Install a new 0 ring to the housing b Apply a light coat of...

Page 208: ...ST 1 STARTING SYSTEM Page TROUBLESHOOTING ST 2 STARTING SYSTEM CIRCUIT ST 2 PLANETARY TYPE STARTER ST 3...

Page 209: ...link Starter faulty Repair starter Ignition switch faulty Replace ignition switch Battery charge low Check battery specific gravity Charge or replace battery Battery cables loose corroded or worn Rep...

Page 210: ...CONPONENTS TYPE STARTER Magnetic Switch St 0 Armature Ring Magnetic Switch 4A GE CJ _ Plate Carrier S Planetary G haft ear h I Plate Washer Through Bolt Non reusable part Commutor End Frame 0 Ring Fi...

Page 211: ...ch pinion gear does not move replace the mag netic switch 2 PERFORM HOLD IN TEST With the battery connected as above and with the pinion out disconnect the negative lead from terminal C Check that the...

Page 212: ...lar Standard clearance 1 5 mm 0 04 0 20 in 5 PERFORM NO LOAD PERFORMANCE TEST a Connect the field coil lead terminal C Check that the lead is not grounded bl Connect the battery and ammeter to the sta...

Page 213: ...CH 1 CHARGING SYSTEM Page PRECAUTIONS CH 2 TROUBLESHOOTING CH 2 CHARGING CIRCUIT CH 2 ON VEHICLE INSPECTION CH 3 ALTERNATOR CH 7...

Page 214: ...ester 4 Never disconnect the battery while the engine is run ning TROUBLESHOOTING Possible cause Remedy Page Fuse blown Check CHARGE and IGN fuses Light burned out Replace light Wiring connection lose...

Page 215: ...to comfirm that the belt has not slipped out of the groove on the bottom of the crank pulley After installing the belt run the engine for approx 5 minutes and recheck the deflection or tension 4 VISUA...

Page 216: ...ammeter to terminal 8 of the alterna tor Connect the positive lead of the voltmeter to terminal B of the alternator Ground the negative lead of the voltmeter b Check the charging circuit as follows W...

Page 217: ...SPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the heater blower switch at HI s 0 b Check the reading on the ammeter CH0068 CH0069 S...

Page 218: ...rush Rectifier Holder Rear End Cover Brush Holder with Cover Rectifier End Frame Drive End Frame 1 IC Regulator Terminal Insulator Rotor Retainer Pulley I Front Bearing Rubber Insulator B h H Id f J r...

Page 219: ...SERVICE SPECIFICATIONS Page ENGINE MECHANICAL 4A FE A 2 EFI SYSTEM 4A FE A 10 COOLING SYSTEM A 15 LUBRICATION SYSTEM A 16 IGNITION SYSTEM 4A FE A 16 A 1...

Page 220: ...qts 4 9 Imp qts 5 2 liters 5 5 US qts 4 6 Imp qts 3 0 liters 3 2 US qts 2 6 Imp qts 3 3 liters 3 5 US qts 2 9 Imp qts 3 7 liters 3 9 US qts 3 3 Imp qts 3 0 liters 3 2 US qts 2 6 Imp qts 3 3 liters 3 5...

Page 221: ...rusion height 12 7 13 1 mm 0 500 0 51 6 in Replacing temperature cylinder head side 80 00 C 176 212 F Valve Valve overall length STD Intake 91 45 mm 3 6004 in Exhaust 91 90 mm 3 6181 in Limit Intake 9...

Page 222: ...n On standard sized piston Limit 81 23 mm 3 1980 in On O S 0 50 sized piston Limit 81 73mm 3 21 77 in Cylinder bore wear Limit 0 2 mm 0 008 in Difference of bore between cylinder 0 05 mm 0 0020 in Tap...

Page 223: ...014 mm 0 0792 0 0793 in Mark 5 2 014 2 017 mm 0 0793 0 0794 in U S 0 25 2 121 2 127mm 0 0835 0 0837 in Crank pin diameter STD 39 985 40 000 mm 1 5742 1 5748 in Crank pin finished diameter U S 0 25 39...

Page 224: ...y 73 M T 63 A T No continuity No continuity 79 M T 69 A T No continuity Continuity Start injector Resistance STA STJ 20 4o n Below 30 86 F time switch 40 60 fl Above 40 C 104 F STA Ground 20 80 fl Wat...

Page 225: ...mm 0 0079 in Tip clearance STD 0 025 0 085 mm 0 001 0 0 0033 in Limit 0 35 mm 0 0138 in Side clearance STD 0 025 0 085 mm 0 0010 0 0033 in Limit 0 10 mm 0 0039 in IGNITION SYSTEM 4A FE Ignition timing...

Page 226: ...B 1 STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS B 2...

Page 227: ...T Bolt 6 6T head No 7 _ 7T _ No mark 8 ST 9 9T 4T 10 10T 11 11T I 0 No mark 4T Hexagon 0 Nomark flange bolt w washer 4T Grooved hexagon bolt j 6T Hexagon C head bolt Two protruding 5T lines Hexagon 0...

Page 228: ...1 400 101 140 6 1 80 69 in lb 8 90 78 in lb 9 8 1 25 195 14 19 210 15 21 10 1 25 400 29 39 440 32 44 6T 12 1 25 730 53 810 59 80 71 14 I 1 5 1 100 80 110 1 250 90 125 16 1 5 1 750 127 170 6 1 110 8 10...

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