Toyota 3S-GTE Repair Manual Download

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Summary of Contents for 3S-GTE

Page 1: ... TOYOTA FIEPMR MANUAL SUPPLEMENT Feb 1994 I _ ...

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Page 3: ...N I TE The funhmhg mraan M tﬂ Iﬂ Jam 1 aaari an ra in r to 35 GE Engine RupaIr Mlrlual Pub N0 RM3QBE INTRODUCTION ENGINE STARTING SYSTEM CHARGING SYSTEM I_L 31 __ l _ _ r _ L _ _ J II P Q __ 1 Ir I r _I ...

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Page 5: ... 1 INTRODUCTION HOW TC USE THIS MANUAL IN IDENTIFICATION INFORMATION IN y paE _u1 Q W GENERAL REPAIR INSTRUCTIONS ABE REVIATICN5 USED IN THIS MAHUM_ STANDARD BOLT TDRCIUE SPECIFICATIONS TIJ1 II Fl ...

Page 6: ...air task TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause mm PREPARATION I en 7l lIO0N ﬂI Preparation lists the SST Special Service Tools recommended tools equipment lubricant and SSM Special Service Materials which should be prepared before beginning the operation and explains the purpose of each one REPAIR PROCEDURES moo M Mo...

Page 7: ...to do task b Install the b6l t Torque 30 N m 310 kgf cm 2 ft lbf Specification IUDI This format provides the experienced technician with a FAST TRACK to the information needed The upper case task heading can be read at a glance when necessary and the text below it provides detailed information Important specifications and warnings always stand out in bold type REFERENCES References have been kept ...

Page 8: ...I HINTS are separated from the text but do not appear in bold They provide additional information to help you efficiently perform the repair SI UNIT The UNIT given in this manual are primarily expressed with the SI UNIT International System of Unit and alternately expressed in the metric system and in the yard pound system Example Torque 30 N m 310 kgf cm 22 ft lbf IDENTIFICATION INFORMATION ENGIN...

Page 9: ...stall the cable ends to the battery terminals with the nut loose and tighten the nut after installation Do not use a hammer to tap the cable ends onto the termi nals Be sure the cover for the positive terminal is prop erly in place Check hose and wiring connectors to make sure that they are secure and correct Non reusable parts Always replace cotter pins gaskets 0 rings and oil seals etc with new ...

Page 10: ...placing fuses be sure the new fuse has the correct amperage rating D0 NOT exceed the rating or use one with a lower rating Illustration Symbol Part Name Abbreviation 1 we B55594 iQ_ vi FUSE FUSE INO385 BE 5595 é MEDIUM CURRENT FUSE M FUSE M0366 BE5596 _ _ HIGH CURRENT FUSE H FUSE INOSB7 I BE5597 Avie FUSIBLE LINK FL moan BE5598 CIRCUIT BREAKER CB moses 11 la V3376 Care must be taken when jacking u...

Page 11: ...be replaced and not reused When steam cleaning an engine protect the distribu tor igniter and air filter from water Never use an impact wrench to remove or install temperature switches or temperature sensors When checking continuity at the wire connector insert the tester probe carefully to prevent terminals from bending When using a vacuum gauge never force the hose onto a connector that is too l...

Page 12: ...create an extra load on the converter 6 Avoid coasting with ignition turned off and prolonged braking 7 Do not dispose of used catalyst along with parts contaminated with gasoline or oil IF VEHICLE IS EOUIPPED WITH MOBILE COMMUNICATION SYSTEM H For vehicles with mobile communication systems such as two way radios and cellular tele phones observe the following precautions Install the antenna as far...

Page 13: ...GR Exhaust Gas Recirculation FIPG Formed in Place Gasket FL Fusible Link H Fuse High Current Fuse IC Integrated Circuit IG Ignition ISC ldle Speed Control LH Laft Hand M Fuse Medium Current Fuse MP Multipurpose PCV Positive Crankcase Ventilation PS Power Steering RH Right Hand SSM Special Service Materials SST Special Service Tools STD Standard SW Switch TCCS TOYOTA Computer controlled System TDC ...

Page 14: ...n 4 4T ST Bolt 6 6T head No 7_ 71 4 8T 9 10 9T 1 OT 11 11T No mark 4T Hexagon flange bolt wl washer hexagon bolt No mark 4T Hexagon head bolt G 2 protruding lines 5T Hexagon flange bolt wl washer hexagon bolt 2 protruding lines 6T Stud bOII IL O _ No mark l G _J Grooved Hexagon head bolt 3 protruding lines 7T Hexagon head bolt 4 protruding lines 3T Welded bolt JIlfI7S ...

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Page 16: ... 65 13 26 48 76 in lbf 6 1 8 1 25 10 1 25 12 1 25 14 1 5 16 1 5 6T 8 19 39 71 110 170 80 195 400 730 1 100 1 750 69 14 29 53 80 27 in Ibf 9 21 44 80 125 90 210 440 810 1 250 78 15 32 59 90 in Ibf 6 1 8 1 25 10 1 25 12 1 25 14 1 5 16 1 5 7T 10 5 25 52 95 145 230 1 10 260 530 970 1 500 2 300 8 19 38 70 108 166 12 28 58 105 165 120 290 590 1 050 1 700 9 21 43 76 23 8 1 25 8T 10 1 25 12 1 25 29 61 110...

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Page 18: ...ELAY TURBO PRESSURE SENSOR VSV For Turbocharging Pressure SERWCE spEC F cAT QNS EF SYSTEM 0PERAT QN TROUBLESHOOTING w VOLT EG INTAKE AIR TEMPERATURE SENSOR EG I68 FUEL PUMP RELAY AND RESISTOR EG 1TU SERVICE SPECIFICATIONS EG IT2 COOUNG SYSTEM EG_115 OpERA 0N EG_115 SERVICE SPECIFICATIONS EG IT3 SERVICE SPECIFICATIONS EG I83 REFER TO 3S GE ENGINE REPAIR MANUAL Pub No RM396EI NOTE The above pages co...

Page 19: ...ylinder 2 0 liter DOHC 16 vaIve engine OPERATION E6430 006 01 nﬁﬂﬁ ill 21 4 Y Q 3 I9 6 1 C I00 Q3 L 1 1 5 I P 5 4 I 3 11 _ _ _ 1 g_ _k 0 T1 J a t p ﬁll I 1 I s r A w _ _ i 1 11 3 it I ﬁixyvk _ III II r_ I V 1 gr 4 J I l it I Q r 7 Kg I E tr l w X 2 77 I A I EL Z ré 4 ﬁe ﬁe 1 2 m Q 13 l 2 1 i PIKJ48 ...

Page 20: ...replace the shims the camshafts must be removed Pistons are made of high temperature resistant aluminum alloy and a depression is built into the piston head to prevent interference with the valves Piston pins are the fu l f oating type with the pins fastened to neither the piston boss nor the connecting rods Instead snap rings are fitted on both ends of the pins preventing the pins from falling ou...

Page 21: ... Belt Tension Gauge Cable 09223 4601 1 Crankshaft Front Oil Seal Replaoer l 09249 63010 Camshaft Torque Wrench Adaptor 09843 18020 Diagnoais Check oil seal er head may er Cylind bolt Wire 09960 10010 Verieble Pin Wrench Set t oaééil di 666i Varieble Pi V W n H iéiiiighaf Qéiiiiiiii Oil pump pulley RECOMMENDED TOOLS Q B 0 Q mg pulleyIIIIIH 09200 0001 0 Engine Adjust Kit IOIIW ...

Page 22: ...ssification Engine oil Dry fill Drain and refill w Oil filter change w o Oil filter change 5 2 liters 5 5 US qts 4 6 Imp qts 4 5 liters 4 8 US qts 4 0 Imp qts 4 0 liters 4 2 US qts 3 5 Imp qts API grade SG or SH multigrade engine oil or ILSC multigrade engine oil and recommended viscosity oil SSM SERVICE SPECIAL MATERIALS 9010 OI 08826 00080 Seal Packing Black or equivalent FIPG Camshaft bearing c...

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Page 24: ...not remove the radiator cap while the engine and radiator are still hot as fluid and steam can be blown out under pressure There should not be any excessive deposits of rust or scale around the radiator cap or water filler hole and the coolant should be free from oil If excessively dirty replace the coolant Reinstall the radiator cap lo0el ev ENGINE OIL INSPECTION CHECK ENGINE OIL QUALITY Check th...

Page 25: ...ach cell Standard specific gravity at 20 C 68 F 1 25 1 27 If the gravity is less than specification charge the battery _ 2 CHECK BATTERY TERMINALS FUSIBLE LINK AND FUSES a Check that the battery terminals are not loose or corroded b Check the fusible link and fuses for continuity lGHV Ol AIR FILTER INSPECTION AND CLEANING 1 REMOVE AIR FILTER 2 INSPECT AND CLEAN AIR FILTER a Visually check that the...

Page 26: ...onnect the intercooler from the turbocharger and REMOVE COOL AIR INLET Remove the 2 bolts and cool air inlet DISCONNECT HlGH TENSlON CORDS FROM SPARK PLUGS Remove the 3 bolts and disconnect the high tension cord clamp from the cylinder head cover Disconnect the high tension cords at the rubber boot Do not pull on the high tension cords NOTICE Pulling on or bending the cords may damage the conducto...

Page 27: ... I566 lr er tr 1 Sig it 6 REINSTALL HIGH TENSlON CORDS 7 REINSTALL COOL AIR INLET Install the cool air inlet with the 2 bolts _ 8 REINSTALL INTERCOOLER 5 9 3 Connect the intercooler to the turbocharger and P P Q Q _ g intake air connector and install the intercooler with the 3 bolts Q wer Q I Y Pl82 Q 9 REFILL INTERCOOLER WITH COOLANT See page EG 9 10 START ENGINE AND CHECK FOR LEAKS ...

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Page 29: ... at the points indicated in the illustration with 98 N 10 98N 98N kgf 22 lbf of pressure Idler Drive belt deflection Pulley w A C New belt fdﬁgy 1o 11 mm 0 39 0 43 in Crankshaft A C Crankshaft used belt Compressor mm 13 16 mm 0 51 0 63 in w 0 A C 1 rye N I 4 New belt 11 14 mm 0 43 0 55 in I 4 E Used belt 12 1a mm 0 47 0 11 in I S I If the belt deflection is not as specified adjust it jg 0 7 6 19 R...

Page 30: ...hich has been used on a running engine for 5 minutes or more I After installing a belt check that it fits properly in the ribbed grooves o Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley 0 After installing a new belt run the engine for about 5 minutes and recheck the belt deflection or tension D5403 01 VALVE CLEARANCE INSPECTION AND ADJUS...

Page 31: ...he ventilation case from the bracket 0 7 r isss4 l r e 5 i r P1825 DISCONNECT HIGH TENSlON CORDS FROM 4 fl SPARK ewes id a Remove the 3 bolts and disconnect the high tension cord clamp from the cylinder head cover 4 b Disconnect the high tension cords at the rubber CORRECT 1 boot Do not pull on the high tension cords NOTICE Pulling on or bending the cords may damage the conductor inside 5 DISCONNE...

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Page 33: ...rom throttle opener 4 Throttle position sensor connector 5 ISC valve connector 232 Remove the 6 bolts and air connector stay and dis connect the throttle body from the intake manifold Remove the throttle body gasket Remove the No 3 cylinder head cover gasket and spacen Disconnect the following hoses from the throttle body and remove the throttle body 1 Air hose from No 1 air tube 2 2 ISC water byp...

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Page 35: ...wire protector as shown in the illustration e Remove the 10 bolts seal washers cylinder head cover and 2 gaskets 9 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover b Check that the grooves of the camshafts are aligned with the dot marks of the No 1 camshaft bearing caps If not turn the crankshaft I revolution 36...

Page 36: ...he required replacement adjusting shim Valve clearance Cold Intake 0 15 0 25 mm 0 006 0 010 in Exhaust 0 28 0 38 mm 0 011 0 015 in Turn the crankshaft 1 revolution 360 and align the mark as above See procedure in step 9 Check only the valves indicated as shown Measure the valve clearance See procedure in step a ADJUST VALVE CLEARANCE Remove alternator Loosen the pulley nut and adjusting bolt Remov...

Page 37: ...or bracket Remove the 3 bolts engine hanger and alternatol bracket C Remove No 2 timing belt cover Remove the 3 bolts timing belt cover and gasket D Set No 1 cylinder to TDC compression a Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover b Check that the grooves of the camshafts are aligned with the dot marks of the No 1 camshaft bearing caps If not t...

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Page 39: ...he pulley brack et and cylinder head pass a 3 0 mm hexagon wrench through the holes to keep the setting position of the pulley bracket Torque 69 N m 700 kgf crn 51 ft lbf 48 N m 490 kgf cm 35 ft lbf for SST HINT On vehicle I Use SST SST 09249 63010 0 Use a torque wrench with a fulcrum length of 340 mm 13 39 in Hold the hexagon wrench head portion of the cam shaft with a wrench and loosen the intak...

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Page 41: ...nch head portion of the cam shaft with a wrench and loosen the pulley bolt Remove the bolt timing pulley and knock pin NOTICE 0 Be careful not to drop anything inside the timing belt cover O Do not allow the belt to come into contact with oil water or dust Remove camshafts Uniformly loosen and remove the 10 bearing cap bolts in several passes in the sequence shown and remove the 5 bearing caps oil...

Page 42: ...e clearance comes within the specified value T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 33 mm 0 013 in I Select a new shim with a thickness as close as possible to the calculated value HINT Shims are available in 19 sizes 18 sizes are available in equal increments of 0 05 mm 0 002O in from 2 50 mm 0 0984 in to 3 35 m...

Page 43: ...mHHmHHHHmﬁ ﬂaggm HgﬁgasHEgBggHHHHmHmﬂHgmmﬂ HmﬂgmmnmmmEggHEREgEHHHHHmHHHHHHHgmmmH mmgmmmmmﬁmmnnmHmmgHHgﬁgHHHHHHHHmHmmmmmmmmHmHgH mmEmmggaggmmgEHgggggmﬂmHHHHHgHmHmHHHmHHgH EHﬂagmﬂmmmﬁﬁmHgmggggEnHm HmﬁHmHmmmmHmHﬂm_mQHmn_Hg Hmﬁm ﬁgHﬁﬂﬁmﬂgHﬁggaggmHmmmﬁmmmmmmmﬂmmHHHH_HHﬂﬂm__ﬂ M EngmammmgmggggggggmEEHHHHHEHkmﬂmmmmﬂmmggngHHg_HmEH k HmnmmﬁmmmmmmﬁmﬁﬁﬂEggBEEHHHHHHHHmmmmmmmmmmﬂmmﬂnnﬁﬂﬂgﬂmmmmHHmmm gamma mmmmmﬁ...

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Page 45: ...lIJI Jl 3 HUHHUUHEEEEEDHIICIHYJDDFIl ITInI II Il II 1FIﬁI IﬂrIHI3 HHHHHHHEEEEHDH IZIDUHUl III lI II II II Il II IﬁI II I Il IfJI l ﬁﬂnnnﬂﬂliiiﬂEBE CII IIT IIT IDl Il Il IlI II IEIl II T II I II Il 1l II3I3 IFlUHFlI Il IlTIE IQBI3IQD EIHHHHETHHUHHHHITIHHFIFIHDTJ 0 0 out IIl Il IFIFII Il II IQEFSIEQIEIIJIIIIHHUFIFIUUFIHHHHFIHHHHDIJ FIFIHnﬂﬁﬂBEEEEIITIITIl JII III JIl Iﬂ 1l Il If1I7 IFII TlI 1I InI II...

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Page 47: ... that the valve lifter rotates smoothly by hand Aug kw K Reinstall camshafts _ la Align the cutout portion of the coupling with the l J 4 K groove of the distributor housing Attach the slit of the intake camshaft to the coupling of the distributor Place the camshafts on the cylinder head with the No 1 cam lobes facing outward as shown HINT Intake camshaft have an slit exhaust camshaft do not lb 0 ...

Page 48: ...der the heads of the bearing cap bolts Install and uniformly tighten the 10 bearing cap bolts on one side in several passes in the sequence shown Torque 19 N m 190 kgf cm 14 ft lbf fl 9 L Check valve clerance Turn the camshaft and position the cam lobe upward and check and adjust the valve clearance Valve clearance Cold Intake 0 15 0 25 mm 0 006 0 010 in Exhaust 0 28 0 38 mm 0 011 0 015 in Reinsta...

Page 49: ...T HINT On vehicle 0 Use SST SST 09249 6301 0 0 Use a torque wrench with a fulcrum length of 340 mm 13 39 in Set No 1 cylinder to TDC compression Turn the crankshaft pulley and align its groove with timing mark 0 of the No 1 timing belt cover b Turn the hexagon head portion of the camshaft align the groove of the camshaft with the dot mark of the No 1 camshaft bearing cap Reconnect timing belt to c...

Page 50: ...keep them clean Align the matchmarks of the timing belt and intake camshaft timing pulley and hang the timing belt on the intake camshaft timing pulley facing mark S outward Slide the intake camshaft timing pulley on the cam shaft Turn the hexagon wrench head portion of the cam shaft with a wrench and align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the ...

Page 51: ...fulcrum length of 340 mm 13 39 in Check valve timing Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC NOTICE Always turn the crankshaft clockwise Check that each pulley aligns with the timing marks as shown in the illustration If the timing marks do not align disconnect the timing belt and reconnect it Reinstall No 2 timing belt cover Install the gasket to the timing belt cover Inst...

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Page 53: ...d 19Nm 190 kg c 14 mm head 52 N m 530 kgf cm 38 ft lbf Install the engine wire protector and ground strap lb Y 9 551 with the 2 bolts Ground wmllll 1 Connect the following wires and connectors Oxygen sensor connector to bracket Oxygen sensor connector Oxygen sensor wire clamp to bracket Alternator connector Alternator wire 1 I 2 I3 4 5 Install the drive belt with the adjusting bolt Tighten the pul...

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Page 55: ...shers and screws Uniformly tighten the screw in several passes Torque 6 0 N m 61 kgf cm 53 in lbf HINT Each bolt length is indicated in the illustration Bolt length A 25 mm 0 98 in B 50 mm 1 97 in 0 dl Settle in the engine wire protector as shown in the illustration e Install the 2 bolts holding the No 2 timing belt cover to the No 4 timing belt cover HINT Use the 25 mm 0 98 in long bolt f Connect...

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Page 57: ...asket c Attach a new gasket to the throttle body facing the Profrusion protrusion upward vrﬁg 4 A 9 A dl Install the gasket throttle body and air connector stay with the 6 bolts in several passes Torque 21 N m 210 kgf cm 15 ft lbf HINT Different bolt lengths are used for locations A B and C Bolt length A 40 mm 1 57 in B 80 mm 3 15 in C 70 mm 2 76 in Connect the following connectors and hoses ISC v...

Page 58: ...ILATION CASE a Install the ventilation case to the bracket b Connect the No 3 water bypass hose for PCV hose to the ventilation case c Connect the No 2 PCV hose to the cylinder head cover 15 RECONNECT NO 1 PCV HOSE 16 RECONNECT HlGH TENSlON CORDS TO SPARK PLUGS a Connect the 4 high tension cords to the spark plugs b Install the high tension cord clamp with the 3 bolts 17 REINSTALL COOL AIR INLET I...

Page 59: ...HZ OZ IGNITION TIMING INSPECTION AND ADJUSTMENT WARM UP ENGINE Allow the engine to warm up to normal operating temperature CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the tester probe of a tachometer to terminal lG of the check connector NOTICE O Never allow the tachometer terminal to touch ground es it could result in damage to the igniter end or ignition coil I As some techometers are ...

Page 60: ...gnition timing _ H N bi lgnitiontiminq L I k 4 10 BTDC idle Transmission in neutral position c Loosen the 2 bolts and adjust by turning the distribu 1718526 SST _ 9 O7 1 10 Tighten the 2 bolts and recheck the ignition timing Torque 39 N m 400 kgf cm 29 ft lbf Y g e Remove the SST from the check connector d I SST 09843 18020 4 K W Check Connector Y M8611 F Transmission In neutral position HINT The ...

Page 61: ...tly H bl cl d All accessories switched OFF B fl 9 h Transmission in neutral position 2 CONNECT TACHOMETER See step 2 on page EG 31 Z500 rpm 90 seconds 3 INSPECT IDLE SPEED a Race the engine at 2 500 rpm for approx 90 seconds R PM Tachometer EC0137 EMB144 men ___ oi ORPM Tachometer P02463 Z9997 b Check the idle speed Idle speed w Daytime running light system 750 1 50 rpm w o Daytime running light s...

Page 62: ... and hoses of air induction system connected d All accessories switched OFF e All vacuum lines properly connected f EFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 180 SECONDS 4 INSERT CO HC METER TESTING PROBE AT LEAST 40 cm 1 3 ft INTO...

Page 63: ...pped plugs e Open or crossed highstension cords 0 Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve 4 Leaky intake and exhaust valves 5 Leaky cylinder High Low Rough idle 1 Vacuum leaks I Fluctuating HC reading e PCV hose O EGR valve e Intake manifold e Throttle body 1 e ISC valve e Brake booster line 2 Lean mixture causing misfire High High Rough Idle 1 Restricted air filter B...

Page 64: ... up to normal operating temperature 2 DRAIN INTERCOOLER COOLANT See page EG 97 3 REMOVE INTERCOOLER I 11 a Remove the 3 bolts b Disconnect the intercooler from the turbocharger and intake air connector and remove the intercooler and _ air hose W QT Y P182132 4 REMOVE COOL AIR INLET Remove the 2 bolts and cool air inlet 5 DISCONNECT DISTRIBUTOR CONNECTOR SPARK PLUGS 6 DISCONNECT HlGH TENSlON CORDS ...

Page 65: ... a fully charged battery to obtain engine speed of 250 rpm or more Repeat steps Ia through c for each cylinder NOTICE This measurement must be done in as short a time es possible Compression pressure 1 130 kPe 11 5 kgf cm 164 psi or more Minimum pressure 880 kPe 9 0 kgf cm 128 psi Difference between each cylinder 100 kPe 1 0 kgf cm I4 psi or less If the cylinder compression in one or more cylinder...

Page 66: ...ENSlON CORDS TO SPARK PLUGS a Connect the 4 high tension cords to the spark plugs b Install the high tension cord clamp with the 3 bolts 11 RECONNECT DISTRIBUTOR CONNECTOR 12 REINSTALL COOL AIR INLET Install the cool air inlet with the 2 bolts 13 REINSTALL INTERCOOLER Connect the intercooler to the turbocharger and intake air connector and install the intercooler with the 3 bolts 14 FILL WITH INTE...

Page 67: ...ulator Gasketi it 1 pi 6 a Q j j _ Turbine I I i i O S n r Outlet Elbow xygen e so _ g 01 q Turbocharger 6 Gasket Q o Stay Y I Turbine Outlet Elbow _ _ P Q 9 Heat Insulator w __ _ é G O Gasket I P Turbocharger Com Air n et Heat Insulator ii 4 RH Front Engine Hanger J Alternator Bracket y e Gasket I I W W I l I I 59l 43 gr 1 I RH Catalytic g _ Converter Stay 1 Ground Strap 0 Q I 59 Engine Wire Prot...

Page 68: ...ifi Throttle Body 9 Gasket Q2 Q K P I Q f L x V P i l acuum ipe 0 v l t T0 9 3 C7 l g W 0 0 C 0 QQOQ4 K W Ir IIIII I Q Engine Wire O Gasket I I L _ Intake Manifold _ Q M d 3 r wd St ls VSV R Q 3 Q _ 0I _ __ 5 5 Jul Q __ r 5 s Intake Air Connector K All l VSV for 1 5 Turbocharging Pressure Connector 4 _ Stay Accelerator m f_ 1 Cable Bracket I Mr L 0 9 E V A Gasketi Spacer w Fuel Return Hose I 1 O G...

Page 69: ...e EG 55 Plate Washer std4_ 50g638l 181430 35 _ I1 urn Cylinder Head N0 3 l ming BeltCover _ 9 _ __ ressure Plate Washer D Switch No 1 Idler Pulley and Gasket mi A C 6 E 0 Cylinder A 4 Head l Gasket la I liming Belt _ 11 _ r 4 _ E I ea e I I No 2 liming Belt Cover i Timing Belt Tensioner Nm kgf cm ft lbfl Specified torque Q Non reusable part at Precoated part For use with SST T ti ll at Q W _ 5 Q0 ...

Page 70: ...tributor connector i M8286 5 b Remove the 2 bolts and cool air inlet li 3 t Y I t_ J 4 Q Q O I J PIBQIQ Q lc Remove the 3 bolts and disconnect the high tension Q 1 cord clamp from the cylinder head cover d Disconnect the high tension cords at the rubber I o ull th hi h rd cORHECT mi oot o not p on e g tension co s __ F NOTICE Pulling on or bending the cords may damage the A f t WRONG 9 Q go conduc...

Page 71: ...EMOVE ALTERNATOR a Disconnect the following wires and connectors Alternator wire 2 Alternator connector 3 Oxygen sensor connector 4 Oxygen sensor wire from wire clamp 5 Oxygen sensor connector from wire bracket b Remove the 2 bolts and ground strap and disconnect the engine wire protector from the brackets c Remove the 2 bolts and alternator 5 REMOVE RH FRONT ENGINE HANGER AND i ALTERNATOR BRACKET...

Page 72: ...ALYTIC CONVERTER Remove the 3 bolts 2 nuts catalytic converter and gasket 8 REMOVE TURBOCHARGER See steps 6 to 14 on pages EG 88 to 90 PI8248 vi L 9 REMOVE EXHAUST MANIFOLD H Remove the 8 nuts exhaust manifold and gasket 4 W Q 9 I 1 10 REMOVE WATER OUTLET a Dlsconnec n conne or 5 t the follow g ct s 1 Oll pressure swltch connector 3 2 Water temperature sensor connector l ﬁ 3 Water temperature send...

Page 73: ...r Bypass Hose P18252 outlet and remove the water outlet and gasket REMOVE WATER BYPASS PIPE Disconnect the following hoses from the water bypass pipe 1 ISC water bypass hose 2 Air hose from turbocharging pressure VSV 1 b Remove the 2 bolts and 2 nuts 35 _ ss 1 l_ M8288 J 9 o Tl J L 7 V e1 yd 5 K O water pump cover and oil cooler and remove the Gasket R A c Disconnect the water bypass pipe and hose...

Page 74: ... tube and ventilation case Q N assembly 6 l Mso Pi 3 3 c M2 k 2 N M8255 _ 2 I 13 REMOVE EGR VACUUM MODULATOR AND VSV ASSEMBLY Disconnect the following connector and hoses 1 VSV connector for EGR 2 Vacuum hose from throttle body 3 Vacuum hose from EGR valve 4 EGR hose from EGR valve Qttqét mes b Remove the 2 bolts EGR vacuum modulator and VSV assembly 3 AT Q A 14 REMOVE EGR VALVE AND PIPE 11 Remove...

Page 75: ...throttle body 2 Vacuum hose from throttle opener 3 Throttle position sensor connector 4 ISC valve connector 5 2 ISC water bypass hoses from No 1 air tube 6 Air hose from No 1 air tube 7 PCV hose from cylinder head c Remove the 6 bolts air connector stay throttle body and hose assembly and gasket d Remove the gasket and spacer 16 REMOVE NO 1 AIR TUBE a Disconnect the following hoses 1 Air hose from...

Page 76: ...n av L Elf 18225 DISCONNECT HOSES HINT On vehicle Disconnect the following hoses 1 Brake booster vacuum hose from intake manifold 2 Vacuum hose from vacuum pipe Disconnect the following hoses 1 PCV hose from PCV valve 2 Vacuum sensing hose from fuel pressure regula tor 3 Vacuum hose from gas filter Remove the bolt and vacuum pipe DISCONNECT ENGINE WIRE Disconnect the following connectors and groun...

Page 77: ...nnect the engine wire protector from the intake manifold _ c Disconnect the engine wire protector from the 2 mou D 5 l Disconnect _ nting bolts of the No 2 timing belt cover t e as C M8265 Fuel Inlet Hose Z T 20 DISCONNECT FUEL INLET HOSE Remove the union bolt and 2 gaskets and disconnect the inlet hose from the delivery pipe 21 DISCONNECT FUEL RETURN HOSE FROM RETURN PIPE 22 REMOVE VSV FOR TURBOC...

Page 78: ...FI I v 2 5 PI3267 23 REMOVE INTAKE MANIFOLD Remove the 4 bolts 3 nuts intake manifold and gasket 24 REMOVE DELIVERY PIPE ASSEMBLY a Remove the 3 bolts and delivery pipe assembly b Remove the 4 insulators from the delivery pipe Remove the 3 spacers from the cylinder head 25 REMOVE LH ENGINE HANGER Remove the 3 bolts and engine hanger 26 REMOVE OIL PRESSURE SWITCH ...

Page 79: ...6 on pages EG 5O to 51 29 REMOVE EXHAUST CAMSHAFT TIMING PULLEY a Using SST loosen the pulley bolt SST 09960 10010 09962 01000 09963 01000 b Remove the bolt timing pulley and knock pin 30 REMOVE NO 1 IDLER PULLEY a Turn the No 1 idler pulley bolt to obtain the specified torque or less and remove the 3 0 mm hexagon wrench Torque 69 N m 700 kgf cm 51 ft lbf 48 N m 490 kgf cm 35 ft lbf for SST HINT O...

Page 80: ...lts and tensioner 32 REMOVE NO 3 TIMING BELT COVER Remove the 5 bolts and timing belt cover 33 REMOVE NO 4 TIMING BELT COVER Remove the 3 bolts and timing belt cover NOTICE 0 Be careful not to drop anything inside the timing belt cover O Do not allow the belt to come into contact with oil water or dust 34 REMOVE CYLINDER HEAD COVER Remove the 10 bolts seal washers cylinder head cover and 2 gaskets...

Page 81: ...in the sequence shown 331 SST 09043 38100 HINT Cylinder head warpae or cracking could result from removing in the incorrect order _ii 1 ill 3Y gL UO I4 O O 3 terse iaia O0 Q IF SO 001 ll I Z131 1 Q I Iii _g pq LI ai Qdiﬁii 2 15 P l8Z7I 918272 b Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench _l j V HINT If the cylinder head is of...

Page 82: ...1 6299 in Exhaust 41 00 mm 1 61 2 in If the cam lobe height is less than minimum replace the camshaft 2 INSPECT MANIFOLDS Intake Manifold Using a precision straight edge and feeler gauge mea sure the surfaces contacting the cylinder head for warpage Maximum warpage 0 30 mm 0 0118 in If warpage is greater than maximum replace the man ifold Exhaust Manifold Using a precision straight edge and feeler...

Page 83: ...cylinder head gasket B Install cylinder head bolts HINT 0 The cylinder head bolts are tightened in 2 pro gressive steps steps b and d I If any cylinder head bolt is broken or deformed replace it a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b Install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes in the se que...

Page 84: ...ng cap as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install the bearing caps in their proper locations HINT Each bearing cap has a number and front mark Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts Install and uniformly tighten the 10 bearing cap bolts on one side in several passes in the sequence shown Torque 19 N m 19...

Page 85: ... oil seals 5 SST 09223 4601 I 5 INSTALL CYLINDER HEAD COVER a Turn the hexagon head portion of the camshaft align the groove of the camshaft with the dot mark of the N No 1 camshaft bearing cap I PIQGS b Apply seal packing to the cylinder head as shown in the illustration t1 i igi i iia igi iirii i_i i i 3 ck g Qp fcxc C Pm No oaaza oooeo or equivalent E igi _ igiliililligiliie i i i i c Install t...

Page 86: ...IMING BELT COVER Install the timing belt cover with the 3 bolts Torque 8 0 N m 82 kgf cm 71 in Ibf 7 INSTALL NO 3 TIMING BELT COVER Install the timing belt cover with the 5 bolts Torque 8 0 N m 82 kgf cm 71 in Ibf P182411 8 SET TIMING BELT TENSIONER a Using a press slowly press in the push rod using 981 9 807 N 100 1 000 kgf 220 2 205 Ibf of force b Align the holes of the push rod and housing pass...

Page 87: ...Ibf Check that the idler pulley moves smoothly INSTALL EXHAUST CAMSHAFT TIMING PULLEY Slide the timing pulley onto the camshaft facing mark S outward Align the pin holes of the camshaft and timing pulley and insert the knock pin Using SST A install the pulley bolt SST 09960 10010 09962 01000 09963 01000 Torque 89 N m 700 kgf cm 51 ft Ibf 48 N m 490 kgf cm 35 ft Ibf for SST HINT On vehicle I Use SS...

Page 88: ...3 ft Ibf 14 INSTALL OIL PRESSURE SWITCH a Apply adhesive to 2 or 3 threads Adhesive Part No 08833 00080 THREE BOND 1324 or equivalent b Install the oil pressure switch Torque 15 N m 150 kgf cm 11 ft Ibf 15 INSTALL LH ENGINE HANGER Install the LH engine hanger with the 3 bolts Torque 44 N m 450 kgf cm 32 ft Ibf 16 INSTALL DELIVERY PIPE ASSEMBLY a Install 4 new insulators to the delivery pipe b Inst...

Page 89: ... and the intake manifold with the 4 bolts and 3 nuts Uniformly tighten the bolts and nuts in several passes Torque 20 N m 200 kgf cm 15 ft Ibf INSTALL VSV FOR TURBOCHARGING PRESSURE Install the VSV with the 2 bolts CONNECT FUEL RETURN HOSE T0 RETURN PIPE CONNECT FUEL INLET HOSE Connect the fuel inlet hose to the delivery pipe with 2 new gaskets and the union bolt Torque 32 N m 330 kgf cm 24 ft Ibf...

Page 90: ... 2 Knock sensor connector 3 Ground cable 4 Intake air temperature sensor connector 5 4 injector connectors HINT The No 1 and No 3 injector connectors are brown and the No 2 and No 4 injector connectors are black CONNECT HOSES Install the vacuum pipe with the bolt Connect the following hoses 1 PCV hose to PCV valve 2 Vacuum sensing hose to fuel pressure regulator 3 Vacuum hose to gas filter HINT On...

Page 91: ...old stay with the 2 bolts Install the 2 manifold stays Torque 39 N m 400 kgf cm 29 ft Ibf INSTALL NO 1 AIR TUBE Install the No 1 air tube with the 3 bolts Connect the following hoses 1 Air hose to intake manifold 2 2 PS air hoses to air tube 3 Air hose to air tube INSTALL THROTTLE BODY Insert the spacer into the cylinder head cover and install the gasket Attach a new gasket to the throttle body fa...

Page 92: ...Connect the following hoses and connectors 1 Vacuum hose from lower port of BVSV to throt tle body 2 Vacuum hose to throttle opener 3 Throttle position sensor connector 4 ISC valve connector 5 2 ISC water bypass hoses to No 1 air tube 6 Air hose to No 1 air tube 7 PCV hose to cylinder head P182510 I e Install the accelerator cable bracket and intake air connector with the 4 bolts J9 15 Torque 21 N...

Page 93: ...tle body 3 Vacuum hose to EGR valve 4 EGR hose to EGR valve INSTALL NO 2 AIR TUBE AND VENTILATION CASE ASSEMBLY Install the No 2 air tube and ventilation case assembly with the bolt Connect the following hoses 1 PCV hose to cylinder head cover 2 PCV hose from cylinder head to ventilation case 3 Vacuum hose from No 2 air tube to intake man ifold 4 Air hose to No 1 air tube INSTALL WATER BYPASS PIPE...

Page 94: ...ss hose 2 Air hose from turbocharging pressure VSV INSTALL WATER OUTLET Install a new gasket to the cylinder head Connect the water bypass hose to the water outlet and install the water outlet with the 3 nuts Torque 20 N m 200 kgf cm 15 ft Ibf 30 Ia bl c Connect the following hoses ISC water bypass hose to water outlet Vacuum hose from charcoal canister to upper port of BVSV 3 Vacuum hose from por...

Page 95: ... gasket and the catalytic converter with the 3 bolts and 2 nuts ﬁg Torque 29 N m 300 kgf cm 21 ft Ibf LH side A 34 INSTALL LH AND RH CATALYTIC CONVERTER Cd A STAYS Install bolts A and D to converter stays LH and RH Ia CH 9 and tighten them by hand b Temporarily tighten bolts C and F so that the convert g G er and stays fit securely together I i Torque 10 N m 100 kgf cm 7 ft Ibf _ V c Torque the bo...

Page 96: ...8 ft Ibf b Install the engine wire protector and ground strap c Connect the following wires and connectors W Q 1 Oxygen sensor connector to wire bracket 2 _ if 5 2 OXY99n sensor connector ff _ _ 1 3 Oxygen sensor wire to wire clamp If _ _ iii 4 Alternator connector Q Ll cf __ 0 Slit C P18282 H3372 Wm 5 Alternator wire 4l I P181720 Hwy I 37 INSTALL DISTRIBUTOR f 3 a Turn the crankshaft clockwise an...

Page 97: ... the groove of the housing e Insert the distributor aligning the center of the flange with that of the bolt hole on the cylinder head L t 5 I Qpfcﬁvg _y 6 Jil ﬁr I 9 1 22 és I 1 P182811 7 PR ix 0 1 6 2 J Q f Lightly tighten the 2 bolts g Connect the 4 high tension cords to the spark plugs _ I J PI8243 44 03 é i Install the cool air inlet with the 2 bolts h Install the high tension cord clamp with ...

Page 98: ...t the distributor connector I K Q 1 38 INSTALL INTERCOOLER See steps 13 and 15 on page EG 95 39 FILL RADIATOR WITH ENGINE COOLANT 40 START ENGINE AND CHECK FOR LEAKS 41 PERFORM ENGINE ADJUSTMENT See pages EG 31 and 32 42 RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL ...

Page 99: ...t as 8 1 ﬁe Ta I 1 i O0 Ring O Pump Q 2 i 1 0 c k h ft i S 2 2 Oil Cooler Bracket fan S 3 Crankshaft I J ll _ Front Oil v O Ring 9 Seal 25 mm Length Bolt Mam Bea 9 0 I92 B0 in Ibf 35 mm Length Bolt 8 0 82 71 in lbfl 5 0 I92 DO IIIJIDN 0 Gasket 1 _ I jg No 1 Rear End Plate 0 D p I R2 End Plate fa 51 i 199st r_ 1 it 2 1 J I __ kn lﬁt m I Crankshaft _ Rear Oil Seal GR Real Oil Seal Q 5 Retainer Q Gas...

Page 100: ...T NG ROD 7 N PECT QN Front Mark 7 1 INSPECT PISTON Ca tY 1 Inspect piston oil clearance h 1 2 r3 I av I I I I I I ter marked 1 2 and 3 accordmgly The mark s W stamped on the piston top i Mark HINT There are 3 sizes of the standard piston diame P1815 ...

Page 101: ...86 785 N 70 80 kgf 294 441 N 30 45 kgf 461 706 N 47 72 kgf 353 610 N 36 62 kgf 0 15 0 25 mm 0 006 0 010 in 0 28 0 38 mm 0 011 0 015 in 2 500 mm 0 09B4 in 2 550 mm 0 1004 in 2 600 mm 0 1024 in 2 850 mm 0 1043 in 2 700 mm 0 1063 in 2 750 mm 0 1083 in 2 800 mm 0 1 I02 in 2 850 mm 0 1 122 in 2 900 mm 0 1 142 in 2 950 mm 0 1161 in 3 000 mm 0 1181 in 3 050 mm 0 1201 in 3 100 mm 0 1220 in 3 150 mm 0 1240...

Page 102: ...m 0 0010 0 0023 in 0 030 0 063 mm 0 0012 0 0025 in 0 08 mm 0 0031 in 0 10 mm 0 0039 in 0 8 1 2 mm 0 031 0 047 in 0 5 mm 0 020 in Valve spring Squareness Free length Limit Intake Exhaust Installed tension at 35 4 mm 1 394 in Intake Exhaust 2 0 mm 0 079 in 43 18 mm 1 7000 in 43 34 mm 1 7063 in 163 I90 N 16 6 19 4 kgf 36 6 42 8 153 180 N 15 6 18 4 kgf 34 4 40 6 lbf lbf Valve lifter Lifter diameter Li...

Page 103: ... in 0 330 0 550 mm 0 0130 0 0217 in 0 0 450 0 670 mm 0177 0 0264 in 0 150 0 500 mm 0 0059 0 0197 in 0 85 mm 0 0335 in 0 97 mm 0 0382 in 0 80 mm 0 0315 in Connecting rod STD Limit Thrust clearance Connecting rod bearing center wall thickness Reference STD Mark 1 Mark 2 Mark 3 Connecting rod oil clearance STD STD U S 0 25 Limit Rod bend Limit per 100 mm 3 94 in Rod twist Limit per 100 mm 3 94 in Bus...

Page 104: ... 000 2 003 mm 0 0787 0 0789 in 2 003 2 006 mm 0 0789 0 0790 in 2 006 2 009 mm 0 0790 0 0791 in 2 008 2 012 mm 0 0791 0 0792 in 47 905 4e 0oo mm 1 8892 1 8898in 41 745 47 755 mm 1 879 1 8801 in 0 0a mm 0 0024 in 0 02 mm o 000e in 0 02 mm 0 0008 in TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Distributor x Cylinder head 39 4 00 29 Spark plug x Cylinder head 18 180 13 Oil pump pulley x Oil p...

Page 105: ...52 530 38 Catalytic converter x Turbine outlet elbow 29 300 21 LH catalytic converter stay x Cylinder block 59 600 43 LH catalytic converter stay x Catalytic converter 59 600 43 RH catalytic converter stay xICylinder block 59 600 43 RH catalytic converter stay x Catalytic converter 59 600 43 Oil nozzle x Cylinder block 9 0 92 80 in lbf Main bearing cap x Cylinder block 59 600 44 Connecting rod cap...

Page 106: ...d intercooler with improved cooling capability The intercooler located above the engine cools the turbocharged air by way the cooled water from 3 33 Q the sub radiator located in the front of the vehicle 8940 02 P184195 P18390 Oxygen Sensor Turbine Wheel Waste Gate Valve 7 lntercooler Sub Radiator _ l Oil Passage 77 _ E S 3 s E _ Water Cooling Channel lmpellerWheel l l I sgy _ f 8 _ __ mu l_ iI _n...

Page 107: ...2 1M I lntercooler I I C I I 1 A Water Pum I l BTCOO BF 00 an P Wm Lave Sam H Fuse ALT 100A M Fuse cos 30A Y H8491 SYSTEM CIRCUIT Mili Check En ine lgnmon swltch UGE Waming Light To Turbo Meter Engine ECU R aY vgv E2 Q l T _ 60 100A lntercooler CDS Water Level 306 Sensor MAIN 5 2 14 LEV I _ é E 9I _ _ lntercooler Main Ie ay Relay nZ 4 h 5 Battery _ 8 M lntercooler t l OM 0 iiessure A 2 PM ansoE2 E...

Page 108: ...um of approximately 120 000 rpm The consequent increase in the impeller rpm increases the pressure of the intake air which when accurately combined with an appropriate quantity of fuel increases engine power Waste Gate Valve Although turbocharging increases engine power if the turbocharged air pressure becomes too high knocking occurs which reduces engine power If the intake air pressure exceeds a...

Page 109: ...tester Torque wrench COOLANT Capacity ME Classification Item lntercooler coolant Engine coolant LUBRICANT 2 5 liters 2 6 US qts 2 2 Imp qts 7 0 liters 7 4 US qts 6 2 Imp qts Capacity Ethylene glycol base Ethylene glycol base 113 1 Classification SH or ILSAC multigrade Item Engine oil Dry fill Drain and refill w Oil filter change w o Oil filter change 5 2 liters 5 5 US qts 4 6 Imp qts 4 5 liters 4 ...

Page 110: ...and reinstalling the tur bocharger assembly Do not drop it or bang it aga inst anything or grasp it by easily deformed parts such as the actuator or rod when moving it Before removing the turbocharger plug the intake and exhaust ports and oil inlet to prevent entry of dirt or other foreign material If replacing the turbocharger check for accumula tion of sludge particles in the oil pipes and if ne...

Page 111: ...ck intake air system and repair or replace parts as B 65 8I Y See page EG 85 3 LEAK IN INTAKE AIR SYSTEM Check intake air system and repair or replace parts as necessary See page EG 85 4 RESTRICTED EXHAUST SYSTEM i Check exhaust system and repair or replace parts as necessary See page EG 85 5 LEAK IN EXHAUST SYSTEM Check exhaust system and repair or replace parts as necessary See page EG 85 6 ERRA...

Page 112: ...SIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST Possible Cause Check Procedure and Correction Method FAULTY TURBOCHARGER OIL SEAL Check for oil leakage in exhaust system I Remove the turbine elbow from the turbocharger and checkfor excessive carbon deposits on the turbine wheel Excessive carbon deposits indicate a faulty turbocharger Check for oil leakage in intake air system 0 Ch...

Page 113: ...replace 0 Foreign material in passages Remove I Leakage from components Repair or replace I Cracks in components Check and replace INSPECT TURBOCHARGING PRESSURE Using a 3 way connector connect SST turbochar ger pressure gauge to the hose between the vacuum pipe and turbo pressure sensor SST 09992 00241 While driving in 2nd gear with the engine running at 4 000 rpm or more with the throttle valve ...

Page 114: ...ive when a pressure is applied to the turbo pressure sensor with SST turbo pressure gauge SST 09992 00241 INSPECT EFI MAIN RELAY Inspect relay continuity Using an ohmmeter check that there is continuity between terminals 1 and 2 A Check that there is no continuity between terminals 3 and 5 If continuity is not as specified replace the relay Inspect relay operation Apply battery voltage across term...

Page 115: ...gen Sensor Q Gasket Gaske Heat Insulator O Side Beanng Gasket Housing Plate Oxygen Sensor 1 X Q Gasket Q _ gt Turbocharger I lie 3 1 F Turbine Outlet Elbow T rb h Sta Heat Insulator _ l U 0 arger y 1 e O Gasket b FiH Catalytic Converter Stay Turbine Outlet Elbow Turbine Outlet Elbow H t l I t ea nsu a or LH Catalytic Converter Stay 1 lF_ I Catalytic Convener I N m l gi cm it Ibf Specified torque T...

Page 116: ...ee steps 6 and 7 on page EG 44 5 REMOVE INTERCOOLER a Remove the 3 bolts bl Disconnect the intercooler from the turbocharger and intake air connector and remove the intercooler and air connector 6 REMOVE TURBOCHARGER HEAT INSULATOR Remove the 3 bolts and heat insulator 7 REMOVE OXYGEN SENSOR Remove the 2 nuts heat insulator oxygen senso and a REMOVE on DIPSTICK AND cums Q Q a Pull out the oil dips...

Page 117: ...tor 10 REMOVE TURBING OUTLET ELBOW Remove the 7 nuts outlet elbow and gasket 4 11 DISCONNECT WATER BYPASS HOSES FROM TURBO WATER PIPE 12 DISCONNECT AIR HOSE FROM ACTUATOR 13 REMOVE TURBOCHARGER STAY Remove the 3 bolts and turbocharger stay 14 REMOVE TURBOCHARGER a Remove the 2 nuts holding the turbo oil outlet pipe to the No 1 oil pan Remove the gasket b Remove the bolt and union bolt holding the ...

Page 118: ...3 1 Y H8203 ii c Remove the 4 nuts turbocharger and turbo OII pipe L assembly and gasket 15 REMOVE TURBO OIL PIPE AND OUTLET PIPE ASSEMBLY Remove the 2 nuts oil pipe and gasket 16 REMOVE TURBO WATER PIPE Remove the 2 nuts bolt water pipe and gasket 17 REMOVE SIDE BEARING HOUSING PLATE Remove the 2 nuts housing plate ari 1 gasket ...

Page 119: ...urbine wheel and turn it Check that the impeller wheel turns smoothly If the impeller wheel does not turn or if it drags heavily replace the turbocharger assembly INSPECT AXIAL PLAY OF IMPELLER WHEEL Insert a dial indicator into the intake side hold the turbine wheel edge by hand and check the axial play Standard clearance 0 110 mm_ 0 0043 in or less If the axial D_l _ l not as specified replace t...

Page 120: ...PLATE Install a new gasket and the housing plate with the 2 l IU I Torque 11 5 N m 120 kgf cm 9 ft Ibf INSTALL TURBO WATER PIPE Install a new gasket and the water oipe with the 2 nuts and bolt Torque 11 5 N m 120 kgf cm 9 ft Ibf for nut INSTALL TURBO OIL PIPE AND OUi I LET PIPE AS SEMBLY Align the oil holes of the a new gasket and the turbo charger housing Install the gasket and oil pipe with the ...

Page 121: ...orque 37 N m 380 kgf cm 27 ft Ibf e Install a new gasket and tighten the 2 nuts holding the turbo oil outletppipe to the No 1 oil pan Torque 20 N m 200 kgf cm I I5 ft Ibf f Tighten the 4 nuts holding the turbocharger to the exhaust manifold Torque 64 N m 650 kgf cm 47 ft Ibf _ 5 INSTALL TURBOCHARGER STAY Install the turbocharger stay with the 3 bolts Torque Turbocharger side 69 N m 705 kgf cm 51 f...

Page 122: ...the RH heat insulator with the 3 bolts Install the LH heat insulator with the 2 bolts INSTALL OIL DIPSTICK AND GUIDE Install a new O ring to the oil dipstick guide Apply soapy water to the O ring Install the oil dipstick guide with the bolt Insert the oil dipstick INSTALL OXYGEN SENSOR Install a h3 w gasket the oxygen sensor and heat insulator with the 2 nuts Torque 20 N m 200 kgf cm I5 ft Ibf INS...

Page 123: ...e turbocharger and intake air connector and install the intercooler with the 3 bolts INSTALL CATALYTIC CONVERTER See steps 33 and 34 on page EG 67 FILL WITH INTERCOOLER COOLANT See page EG 97 I FILL WITH ENGINE COOLANT FILL WITH ENGINE OIL START ENGINE AND CHECK FOR LEAKS CHECK COOLANT AND OIL LEVELS ...

Page 124: ...n out under pressure _ There should not be any excessive deposits of rust or scale around the filler cap or hole and the coolant should be free from oil If excessively dirty clean the coolant passages and replace the coolant Check that the level of intercooler coolant is full HINT The coolant level should be within 37 mm 1 46 in from the top of the hole as shown in the illustra tion If the coolant...

Page 125: ...T a Slowly fill coolant until it reaches the top of the inter cooler refill inlet I Use a good brand of ethylene glycol base cool ant and mix it according to the manufacturer s directions I Using coolant which includes more than 50 ethylene glycol but not more than 70 is recommended NOTICE 0 Do not use an alcohol type coolant O The coolant should be mixed with demineralized water or distilled wate...

Page 126: ...completed make sure the cock is closed securely Add coolant and repeat steps c to f When the coolant level stops dropping install the filler cap on the refill inlet Remove the EFI fuse 15 A frorn the R B No 2 for 10 seconds or more then reinsert the fuse to erase the diagnostic code from the ECU HINT I Cancellation can also be done by removing the negative terminal cable from the battery but in th...

Page 127: ......

Page 128: ...he radiator core and cleaner nozzle ON VEHICLE INSPECTION r O 9Q 1 CHECK ENGINE WARNING LIGHT OPERATION a Turn the ignition switch ON Yn é P13663 CHECK Engine Warning Light P07 NOTICE Do not start the engine b Check that the warning light comes on c When the engine is started check that the warning light goes out d Disconnect the intercooler coolant level warning I W I S Lave ammg ens sensor conne...

Page 129: ...hat there is no continuity between terminals 1 and 2 If continuity is not as specified replace the relay Inspect relay operation Apply battery voltage across terminals 3 and 5 Using an ohmmeter check that there is no continuity between terminals 2 and 4 Check that there is continuity between terminals 1 and 2 If operation is not as specified replace the relay INSPECT INTERCOOLER RELAY See page EG ...

Page 130: ...ck the reading on the ammeter Standard amperage 5 6 A or lass NOTICE Do not operate the pump for more than 30 seconds Reconnect the intercooler water pump connector INSPECT ENGINE ECU FOR CIRCUIT Disconnect the connectors from ECU Check the connectors on the wiring harness side as shown in the chart below Continuity E2 Ground Continuity M Ground I if Voltage Ignition SW ON 9 14 V M Ground G d Leve...

Page 131: ...l IIIIIIIII IIIIIII IIIIIII IIIIIII g I 4 1 I I Q WQ _ r I _ n I Radiator Water Hose Cg I Q I 1 Jig _ Reservoir Tank Radiator Water Pipe 8 Q r 1 1 i 1 lntercooler Water Pump e I ____ lntercooler Coolant Level Warning Sensor _ i lntercooler Coolant Filler Cap lntercooler _ _ 1 _ _ k 3 via T T I x le I I I l I wl k 5 vs 5 5 g M W Radiator Water Hose J __r _ I 1 O I W1 Y H8389 ...

Page 132: ...ening pressure 59 kPa 0 6 kgf cm 0 5 psi If the opening pressure is less than minimum replace the filler cap INSPECT INTERCOOLER COOLING SYSTEM FOR LEAKS Fill the cooling system with coolant and attach a radiator cap tester Warm up the engine Pump it to 118 kPa 1 2 kgf cm 17 1 psi and check that the pressure does not drop If the pressure drops check the hoses radiator or water pump INSPECT INTERCO...

Page 133: ...b 2 3 INSPECT INTERCOOLER RELAY Inspect relay continuity Using an ohmmeter check that there is no continuity between terminals 1 and 2 Check that there is continuity between terminals 3 and 4 If continuity is not as specified replace the relay Inspect relay operation Apply battery voltage across terminals 3 and 4 Using an ohmmeter check that there is continuity between terminals 1 and 2 If operati...

Page 134: ...OURCE VOLTAGE OF TURBO PRESSURE SENSOR a Disconnect the turbo pressure sensor connector i sz Y b Turn the ignition switch ON voltmeter c Using a voltmeter measure the voltage between con nector terminals VC and E2 of the wiring harness side Voltage EB 4 5 _ 5 5 V d Turn the ignition switch to LOCK o FPU 8 F0 1 g in 1 P136611 e Reconnect the turbo pressure sensor connector ...

Page 135: ...he ECU Voltmeter V é ilk ECU and measure the output voltage under ambient atmospheric pressure d Apply vacuum to the turbo pressure sensor in 13 3 0 kPa 100 mmHg 3 94 in Hg segments to 66 7 kPa 500 mmHg 19 69 in Hg e Measure the voltage drop from step c above for each r segment Applied Vacuum 3 3 26 7 40 0 53 3 Voltage drop i 1 66 7 23 5 33 32 13951 1 935 12929 in Hg 0103 03 OSJOS 07 07 09 0911 Vo...

Page 136: ... 8 kPa 0 10 kgf cm 1 4 psi segments to 49 0 kPa 0 50 kgf cm 7 1 psi SST 09992 00241 g Measure the voltage up from step c above for each segment Voltage up 19 6 29 4 39 2 49 l 3 f l 3 1 51 Voltage 0 05 0 20 0 35 0 50 0 65 up V 0 20 0 35 0 50 0 65 0 80 I _ mom _ ham Pressure kPa z I Applied VO55Cl8 h Reconnect the vacuum hose to the turbo pressure sensor jet s Ki 2 9 1 r r s_ ...

Page 137: ... continuity replace the VSV I Ii Fri Ohmmeter Inspect VSV for ground No Conﬁnuny Usin an ohmmeter check that there is no continui 9 TY between each terminal and the body If there is continuity replace the VSV EHer gm Li Inspect VSV operation Check that air does not flow from port E to F Air Apply battery voltage across the terminals Check that air flows from port E to F If operation is not as spec...

Page 138: ...water pump 5 6 A or less VSV for turbo charging DFBSSUTB Resistance at 20 C 68 F 22 261 TORQUE SPECIFICATIONS Part tightened N m kgf cm ft lbf Side bearing housing plate x Turbocharger 1 1 5 120 9 Turbo water pipe x Turbocharger Nut 11 5 120 9 Turbo oil pipe x Turbocharger 17 175 13 Turbocharger x Exhaust manifold 64 650 47 Turbo oil pipe x Cylinder block Bolt Union bolt 37 380 27 39 400 29 Turbo ...

Page 139: ... Light A C Idle Up Valve Y hi _ Knock Sans Fuel Pump Relay 0 Ignition Switch Check Connector Stop Light Switch I A C Arnplilier 1 r__ _ I 4 4 I _ _j N I Ii I I _ _ I _ _ _ I 1 I 1 l v _ O T 1 I i i T __ _ _I mt 1 l _ _ _ e ennui Q un _ r ISC Valve 9 _ l I 1 Intake Air Temp Sensor _ F 9 k Fuel Filter _ _ ___ I J ll i 4 T 2 5 5 v l I 1 Water Temp Vacuum Sensor Sensor GR Valve ECU Dellogger Ftelay TO...

Page 140: ...tion timing under all operating conditions Using data provided by sensors which monitor various engine functions rpm coolant tempera ture etc the microcomputer ECU triggers the spark at precisely the right instant 3 Idle Speed Control ISC The ECU is programmed with target idling speed values to respond to different engine conditions coolant temperature air conditioning ON OFF etc Sensors transmit ...

Page 141: ...d is distributed to each injector at a set pressure maintained by the fuel pressure regulator The fuel pressure regulator adjusts the pressure of the fuel from the fuel line high pressure side to a pressure 250 kPa 2 55 kgf cm 36 psi higher than the pressure inside the intake manifold and excess fuel is returned to the fuel tank through the return pipe Fuel is injected into the intake manifold acc...

Page 142: ...controlled by the throttle valve opening is distributed from the air intake chamber to the manifold of each cylinder and is drawn into the combustion chamber At low temperatures the ISC valve opens and air flows through the ISC valve and the throttle body into the air intake chamber During engine warming up even if the throttle valve is completely closed air flows to the air intake chamber thereby...

Page 143: ......

Page 144: ... an ECU which determines the injection volume timing based on the signals from the sensors The various sensors detect the intake air pressure engine speed oxygen density in the exhaust gas engine coolant temperature intake air temperature and atmospheric pressure etc and convert the information into an electrical signal which is sent to the ECU Based on these signals the ECU calculates the optimum...

Page 145: ......

Page 146: ...ire E EFI Inspection Injector 09843 18020 1 Diagnosis Check Wire RECOMMENDED TOOLS 09002 00050 TOYOTA Electrical Tester Sat 09200 00010 __ I Engine Adjust Kit 09258 00030 y 92 Hose Plug Set Plug for vacuum hose fuel hose QQC EOUIPMEMT Carburetor cleaner Throttle body Graduated cylinder Injector Soft brush Throttle body Sound scope Injector Tachometer Thermometer f 1 t 45i l i iE iii3E51 s iil4 i5 ...

Page 147: ...E6416 ENGINE EFI SYSTEM Torque wrench i r SSM SERVICE SPECIAL MATERIALS KCG l 08826 00080 Seal Packing Black or equivalent Cylinder head cover FIPG 5 _ Q 5 Z j ...

Page 148: ...rning light when TE1 and E1 terminals on the check connector are connected When 2 or more codes are indicated the lowest number code will appear first If a malfunction is detected when in the test mode the ECU lights up the check engine warning light to inform the technician of the occurrence of malfunction except for code Nos 42 43 and 51 In this case TE2 and E1 terminals on the check connector s...

Page 149: ...c or more lH l l Open or short in heater circuit or oxygen sensor Oxygen sensor heater ECU ON At normal driving speed lbelow I00 ltmlh I60 mph and engine speed is above 1 500 rpml amplitude of oxygen sensor signal lOX ll is reduced to between 0 35 0 70 V continuously for 00 secs or more l2 trip detection logic Open or short in oxygen sensor circuit Oxygen sensor Open or short in vacuum sensor circ...

Page 150: ...ot input to ECU for 2 revoiutiona IKNKI Open or short in ltnocl sensor circuit Knock sensor llooaeneaa etc ECU 53 H1619 Knock Control Sig nel ON NA Engine speed is between 700 rpm and 7 300 rpm and ECU lfor lrnocl control malfunction il detected ECU 54 P036130 lntercooler System Malfunction ON N A lntercooler water pump motor is locked or intercooler coolant level is low lntercooler water pump lnt...

Page 151: ...ake a simple check of the fuses fusible link and the condition of the connectors 0 The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit within the computer 0 If engine trouble occurs even though proper operating voltage is detected in the computer connector then it can be assumed that the ECU is faulty and should be replaced ...

Page 152: ...to sections A and B in the illustration which can be easily broken Reconnect the connectors to the ECU cl HINT ecu U unuouunnnuoo uouooo uouunnuee DUDDDUUUDOD UDDDDIJ I _ g _ 1 voltmeter V 5 E1 M8294 0 Perform all voltage measurements with the con nectors connected 0 Verify that the battery voltage is 11 V or more when the ignition switch is in the ON position Using a voltmeter with high impedance...

Page 153: ...THW WATER TEMP SENSOR STP I STOP LIGHT SWTICH IGT IGNITER l IDL THROTTLE POSITION SENSOR INTERCOOLER COOLANT I EV LEVEL SENSOR EGR EGR VSV THA INTAKE AIR TEMP SENSOR FOR AIR CLEANER CASE M INTERCOOLER WATER PUMP VTA THROTTLE POSITION SENSOR FC CIRCUIT OPENING G2 DISTRIBUTOR PIM TURBO PRESSURE SENSOR RE LAY TAILLIGHT RELAY EL5 DEFOGGER RELAY G1 DISTRIBUTOR I THAM INTAKE AIR TEMP SENSOR FOR INTAKE M...

Page 154: ... 9 14 EG 129 6 THA E2 7 THAM E2 8 THW E2 i i Intake air temp 20 C 68 Fl I IG SW ON 0 5 3 4 EG 130 EG 131 Coolant temp 80 C l176 Fl 0 2 1 0 EG 132 We STA E1 I Cranking 6 or more EG 133 10 GT E1 Cranking or idling Pulse generation EG I34 RSC 11 RSO E1 IG SW ON ECU connectors disconnected 9 14 EG 135 12 W E1 No trouble Check engine warning light off and engine running 9 14 EG 136 ECU Terminals H l _ ...

Page 155: ... 51 Check that there is voltage between ECU termin DOB3DDDODDDDDD and E1 al 8 and body I 8 I ground IIG sw om IE N0 I o Check wiring between ECU terminal E1 mam ground and body Voltmeter i I ECU u DOCIDDC DO OK I I DD DCICICIDU ODD SC D8 OD OODODDODODDO BAD Repair or replace IL Checkfuses fusible links and ignition BAD switch Repair or replace P18295 OK Check EFI main relay Replace ll ECU Check wi...

Page 156: ...age between ECU terminal BATT and body ground NO Iok err xa Voltmeter III ECU 7 7 __ _ i i I 5A9 A ___ F I Check fuse and fusible link H Replace OK W Check wiring between ECU terminal BAD I I and battery Repair or replace FI2754 Ecu_ 1 L _ If 5 1 I 1 u v a c a 1 I In I uu n n I Ohmmeter I I AH I W MEI I I There is no voltage between ECU terminals BATT and E1 Check wiring between ECU terminal E1 an...

Page 157: ...there is voltage between ECU terminal 8 and body Vonmeterl _ _ _ T 7 IDL E 2 i ground IIG SW ONI NO I OK F I2782 ground Check wiring between ECU terminal E1 and body a a DCIU I CIOOODD 1 IJDDGDCIDDD DOD I I DOCIOCID I I CIDDDDGDOD I gaDDDDDD DD CIDODDOOD I ecu OK WV 8 I _ P1B295 Ohmmeter BAD Check throttle position sensor See page EG 161 BAD BAD Try another ECU Repair or replace Refer to B E1 trou...

Page 158: ...ge EG 124 1 BAD 1 OK I H4757 Check wiring between ECU and throttle position sensor Throttle Position Sensor Repair 0 ep ace_ b to I OK BAD 1 1 i Try another ECU I Flepair or replace 0 VTA E2 ECU No specified voltage at ECU terminals VTA and E2 G SW I E5 no sw om FIZ763 Voltmeter T ion l I I ox Refer to VC E2 troubleshooting section 2 O OK ECU Ch k th ttl t BAD _ _ _ I ___ _ _ __ 6C YO 8 pOSl ION S...

Page 159: ...ck that there is voltage between ECU terminal 8 and body ground IIG SW ON l OK NO ecu 3 Q Q I Q Q Q Q Q Q Q u DDDDDDDDDDD CIODDDO UDCIDDUO IILlI L ml Voltmeter ii U M U 8 mazes Refer to 8 E1 troubleshooting section N0 ll See page EG 124 I Check wiring between ECU terminal E1 and body ground OK K BAD 1 Check vacuum sensor Repair or replace BAD Y Replace vacuum Check wiring between ECU and vacuum se...

Page 160: ...D voltage 9 14 V H5314 Solenoid Resistor II a 9 1 Voltmeter Oo_e O i l 0 1ﬁ ti Fl 20 30 Oh mmeter k I I I iz i _ _ r i P1845 Check fusible links wiring BAD Repair or 0 In 30 u 1 s m i x t r 1 ll voltmeter R ___ E Ch k h h iﬁ d olt b t ol Id resistor l v r I 5 7 i l 2 i J51 K 7 and ignition switch replace Check that there is specified voltage between resistor terminals 10 20 30 or 40 and body groun...

Page 161: ...s THA and E2 _ THA p E2 Check that there is voltage between ECU terminal B and body I _ I ground ilG SW ONl ECU OK NO Refer to 8 E1 troubleshooting section lNo 1l See page EG 124 I _ 0 0 0 DDIJDCIDDUDUD DCIDUDD DD DDDDDUD DDOODDDUDDD DODODD CIDDDDDD Voltmeter Check wiring between ECU terminal E1 and body ground OK BAD Check intake air temp sensor N V BAD L OK 4ﬂ 5 _ I Ohmmeter ll i K Repair intake...

Page 162: ...i Vonmeter L 177 7 I_r t THAME Check that there is voltage between ECU terminal B and body 1 ground us sw om Refer to B E1 mazo troubleshooting section No 1 See page EG 124 ecu _ Y Check wiring between ECU terminal E1 and body ground of ql Ilnnr iiiiiiF III I 8 Voltmeter BAD Ch k t k t e S p _ 6 P Repairorreplace BAD 10K Y F A mm Repair intake air Check wiring between ECU and intake T temp sensor ...

Page 163: ...G SW ONI i i 1 eck that there is voltage between ECU te i I 1 _ E2 I ground IG SW ON O e l_v __o Ch rminal B and body l OK ECU Voltmeter 00 00 _ on onOD _ ta 4 W F I A P182535 D DDDODDDODDO D I DD DCIDUDD _ ODDDOD JODDCI H2766 NO Flefer to 8 E1 troubleshooting section iNo 1l See page EG 124 I Check wiring between ECU terminal E1 and body ground I OK Y Check BAD water temp sensor I Repair or replac...

Page 164: ... I 1 11 _ e_ Repair or replace F1218 a ECU I ground Check wiring between ECU terminal E1 and body Ohmmeter I l_ iT_ I f e r i Q r r IQK BAD _ 4rE1 E 5 I Try another ECU I Repair or replace I Check fusible links battery and ignition BAD Re air or re lace switch p p Voltmeter QBI r_ Terminal 50 Starter V OK I N0 rmss QK l Check that there is voltage at terminal 50 of starter IG SW START STD voltage ...

Page 165: ...7 7I I I _ 3 H2770 i 9 v ground Ildlingl 00 1 0 8 I Vmmeter VIA A Check that there is volta e between ECU terminal IGT and bod Iii v IGT I E1 t I _ 5 NO IOK U Check wiring between ECU BAD Repair or terminal El and body ground replace OK ECU H I W Try another ECU _ _ _L _ A _ _ _ A 1 I v It t V1 r _v_ IGT Check fusible links and ignition switch I IBAD Repair or replace O I V OK 5 FI2755 Check distr...

Page 166: ... I P03472 EC U EIODDOUDDDDDDCIDDDCIDOOCI DDDCDDGDDDD DDDODO EIDDDOODDD Ki Liitl Voltmeter ll I 5 ii 4 P5225 Ohmmeter if RSO I Y mass There is no voltage between ECU terminals RSC or RSO and E1 I IIG sw ONI Check that there is voltage between E ground IIG SW ON CU terminal B and body NO Reier to 8 E1 troubleshooting section lNo ll See page EG 124 Check resistance between ISC valve terminals 8 and R...

Page 167: ...rminals w and E1 _ __ é Z _ Ildlingl l7 1 1 12 l 1 Iriilti Z 2 _1I e Voltmeter V Iii Check thatthere is voltage between ECU terminal Wand body I62 ground ii er N0 IOK FI2772 Voltmeter O i O ECU Try another ECU Repair or replace Check wiring between ECU terminal E1 and body ground OK BAD A _ _ _ Y V WI cn ckGAUGE fLlSBi1U A and CHECK I e engine warning light OK I BAD I I Repair or replace I rmrzi O...

Page 168: ...ck Connector W IOK Check fuel pressure _a N l t_ 43 1 wt E TE1 iiL ii E I I 0i Voltmeter CIIGCK IHIBCIZOTS See page EG 148 I oi Check vacuum sensor l_I SST 5 5 ii Check Connector fg _ ll e I F1 I BAD Check wiring between oxygen sensor BAD II n gm E1 P06331 and ECU Ii I Repair wiring IOK Replace oxygen sensor I P06326 T no I OK I Check wiring between ECU terminal E1 and body ground I I oi BAD BAD R...

Page 169: ... To ecu FPR e e 0 I O FC 0 To ECU iFCl STA Negative Terminal Cable _I_I _I S O Q _ 121 an gt 9 iti ON VEHlCLE INSPECTION FUEL PUMP INSPECTION B I CD D T Fuel Pump it ii 0 I e e EIEIIB Check Connector I e e 1 DISCONNECT NEGATIVE TE FROM BATTERY RMINAL CABLE 2 DISCONNECT FUEL PUMP CONNECTOR a Remove the wire protector b Disconnect the fuel pump protector ...

Page 170: ...ositive lead from the battery to terminal 1 of the connector and the negative lead to terminal 2 Check that the fuel pump operates If operation is not as specified replace the fuel pump NOTICE 0 These tests must be performed quickly within 10 seconds to prevent the coil from burning out I Keep the fuel pump as fer away from the battery as possible I Always perform switching at the battery side ﬁe ...

Page 171: ...tive Terminal Cable __l _ 5 _ 2 iéé AO9902 2132111 Y P18 453 IGIl lII FUEL PUMP REMOVAL See Components for Removal and Installation CAUTION Do not smoke or work near an open flame when working on the fuel pump 1 DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY 2 DRAIN GASOLINE FROM FUEL TANK 3 REMOVE FUEL TANK REMOVE FUEL PUMP BRACKET FROM FUEL TANK Remove the 4 screws and 7 bolts Pull out the evap...

Page 172: ...er i 0 crap Rubber Cushion Y P181154 As904 y _ 4é _ Zl D7 Y Pl 197 bl FUEL PUMP DISASSEMBLY 1 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET a Disconnect the lead wire connector from the fuel pump Pull out the lower side of the fuel pump from the bracket Disconnect the fuel hose from the fuel u c p mp and remove the fuel pump dl Remove the rubber cushion ...

Page 173: ...ly and Assembly 1 INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip INSTALL FUEL PUMP T0 FUEL PUMP BRACKET Insert the outlet port of the fuel pump into the fuel hose Install the rubber cushion to the lower side of the fuel pump Push the lower side of the fuel pump together with the rubber cushion into the fuel pump bracket 2 8 b cl aIr_ r 1 5 A9904 212201 d Connect the ...

Page 174: ...BRACKET a Place the fuel pump bracket and evaporation tube with 2 new gaskets on the fuel tank b Install and torque the 7 bolts and 4 screws Torque Bracket 2 9 N m 30 kgf cm 26 in lbf Bent tube 3 4 N m 35 kgf cm 30 in lbf 2 INSTALL FUEL TANK 3 REFILL GASOLINE 4 CONNECT NEGATIVE TERMINAL CABLE TO BATTERY 5 CHECK FOR FUEL LEAKAGE ...

Page 175: ...EG 144 ENGINE EFI SYSTEM PRESSURE REGULATOR Vacuum Sensing Hose Fuel Pressure Regulator II I Fuel inlet Hose T l 2 is M l_x1 _ ta e4 r l I 7 Delivery Pipg Fuel Return Hose ml14 qi__ Y P1809 ...

Page 176: ... _ 4 Engine Wire 1 _ e 0 I 1 LJ Gasket Accelerator Cable Bracket _ ell L Gasket CIBITIP fl Spacer A Seal Washer 1 tame No 1 ose O O Ring A Spac Q Insulator a 6 1 2 Pl Air Connector _ 5 5 sis Cylinder Head Cover u t Fuel Hose Gasket Delivery Pipe Gasket 1 PCV H S _ Air H No Fuel Pressure Regulator _ V N03 water Bypass Hose 0 er 3 e i t F5 fqwlt EGR Vacuum Modulator EGR VSV Connector Gaske Vacuum Ho...

Page 177: ...sure regulator IﬂIW1 5I New Ming FUEL PRESSURE REGULATOR INSTALLATION INSTALL FUEL PRESSURE REGULATOR Fully loosen the lock nut of the pressure regulator Apply a light coat of gasoline to a new O ring and install it to the pressure regulator Thrust the pressure regulator completely into the de livery pipe by hand Turn the pressure regulator counterclockwise until the fuel return pipe faces in the ...

Page 178: ...322 Fuel Pressure R89U 6 t0r r a fay i 1 I MAIN 60A ll I MAIN Fl I Battery E O 3 Q t t Delivery Pipe Ignition Switch ECU AM2 30A AM2 G2 8 Solenoid Resistor Injector o o 10 20 30 Nofto No 20 No 30 4 40 Fuel Return Hose 213203 injector Fuel Inlet Hose 1 Fmzr ...

Page 179: ... proportion to engine rpm If you have no sound scope you can check the injec tor transmission operation with a screwdriver If no sound or unusual sound is heard check the wiring connector injector or injection signal from the ECU INSPECT INJECTOR RESISTANCE Remove the throttle body See page EG l63 Disconnect the 4 injector connectors Using an ohmmeter measure the resistance between the terminals R...

Page 180: ...igh Tension Cord Cylinder Head Cover No 1 PCV Hose Engine Wire m Fuel Hose Q0 Fling J 5 w 9 No 3 Fuel Tube A s Injector Cover r O Insulator O Insulator Spa Accelerator Cable Bracket 6 9 P r 5 Q p Clamp Fuel Hose at t trt 1 8 si A K _ Q lntercooler 4 SeaIWasher No 1 PCV Case I t J Z Gasket No 1 Air Hose é Fuel Hose O Gasket Delivery Pipe Q Insulator 5 gqkthtie 6 J Specified torque Q Non reusable pa...

Page 181: ... bracket bl 0 f I __ i t I J T 2 T L 1 Y Pl845S 3 REMOVE VSV AND EGR VACUUM MODULATOR Disconnect the VSV connector Remove the following hoses from the EGR vacuum modulator I Vacuum hose from EGR valve 2 EGR hose from EGR valve ta bi T Re 4 1 I V i l _ _3 i _ 1 kt _ _ T7 c Remove the 2 bolts VSV and EGR vacuum modulator i assembly II _ A A 7 _ 1 A09749 Zi32l4 4 REMOVE COOL AIR INLET Remove the 2 bo...

Page 182: ... ﬁlo if W F l8 73 l r r j k 7 REMOVE NO 1 PCV HOSE A09752 r 5 5 t ii ea nn Q o k __ Zl32l 8 DISCONNECT ENGINE WIRE th d d th Disconnect e 2 bolts an sconnect e engine B wire from the No 4 timing belt cover 9 DISCONNECT VACUUM SENSING HOSE FROM PRESSURE REGULATOR g Q 5 41 10 REMOVE CYLINDER HEAD COVER WITH NO 4 TIMING BELT COVER a Remove the gasket and spacer b Remove the 10 bolts cylinder head cov...

Page 183: ...Cover the cylinder head with a clean shop rag to prevent damage to the cylinder head and camshafts REMOVE DELIVERY PIPE ASSEMBLY Disconnect the 4 injector connectors Remove the union bolt and 2 gaskets and disconnect the fuel inlet hose from the delivery pipe Loosen the 3 bolts holding the delivery pipe to the cylinder head Remove the delivery pipe and 3 spacers ...

Page 184: ...ng a spanner a umon Bolt SST SST Wnronlﬁ New Hose Gasket __ Fuel Filter _ P151523 b Connect SST union and hose to the fuel filter outlet with 2 new gaskets and union bolt SST 09268 41045 90405 0901 5 Torque 29 N m 300 kgf cm 22 ft Ibf Union Bolt W SST New Gasket Union I 31o Pressure K Re ulator 91 Fuel Return Hose SST Hose Y F l853I Connect the fuel return hose to the fuel outlet of the No 3 fuel ...

Page 185: ...jection volume with a graduated cylinder Test each injector 2 or 3 times SST 09842 30060 Volume 120 150 cm 7 3 9 2 cu in per 15 seconds Difference between each injector 5 cm 0 3 cu in or less If the injection volume is not as specified replace the injector INSPECT LEAKAGE In the condition above disconnect the tester probes of SST wire from the battery and check for fuel leakage from the injector S...

Page 186: ...MOVE INJECTOR COVER e __ _ a Disconnect the fuel hose from the fuel pressure regu 4 5 W lator b Remove the 4 bolts N 3 o fuel tube and injector cover c Remove the 4 insulators from th pi l _ vxewwwﬁgn ES SW I K 2 _ Gasoline e injectors P1 ui __ 2 REMOVEINJECTORS Gasoline a Apply gasoline between the delivery pipe and injec tors FI54 _ er ssr IQ J 1 r i C I bi jectors E SST O926B 74010 O9268 04020 ...

Page 187: ...light coat of gasoline to 2 new O rings b Install the 2 O rings and new insulator to each injec IIO c Push in the 4 injectors so that the injector connectors are positioned as shown in the illustration 4 INSTALL INJECTOR COVER a Install a new insulator on each injector b Install the injector cover and No 3 fuel tube with the 4 bolts Torque 7 8 N m 80 kgf cm 69 in Ibf c Connect the fuel hose to the...

Page 188: ...orque 29 N m 300 kgf cm 22 ft Ibf e 4 7 ﬁ5 j l 2 Km 11 Zliﬂa Connect the fuel inlet hose to the delivery pipe with 2 new gaskets and union bolt Torque 32 N m 325 kgf cm 24 ft Ibf Connect the 4 injector connectors HINT No 1 and No 3 injector connectors are brown No 2 and No 4 injector connectors are black id Bl t p_ 1L_ Mn _r r aTyjo1 _ nine Inn _Ky _ i IIIIIIIIIIEIIIIIEI J _ _jo O 0 i i ilo_0 AO99...

Page 189: ...O FUEL PRESSURE REGULATOR Id 3 AO9752 5 Z7 J one m Q F ab Zl l 4 INSTALL ENGINE WIRE Install the 2 bolts and connect the engine wire to the No 4 timing belt cover TI 9 as K E ﬂa F Pl84T3 5 INSTALL NO 1 PCV HOSE 1 X b Q Install the following hoses 1 2 water bypass hoses to No 1 air tube A0975I 213216 V 6 INSTALL no 3 WATER BYPASS HOSE AND NO 1 4 AIR HOSE In M19750 K _ l E 9 9 sq H3215 2 No 1 air ho...

Page 190: ... MODULATOR la Install the VSV and vacuum modulator assembly with the 2 bolts 9 of Q K v I E Z P181158 _ f 4 1 _4 ﬁgs C 5 g I 1 t it 5 Install the following hoses to the vacuum modulator 1 EGR hose from EGR valve 2 Vacuum hose from EGR valve Connect the VSV connector lb C _ 1 nil 4 l 0 _ _ L ti D Y PN3503 INSTALL NO 1 PCV CASE Install the PCV case to the backet Connect the No 3 water bypass hose to...

Page 191: ...GINE EFI SYSTEM THROTTLE BODY P181383 FH356 Thmme Body Throttle Position Sensor r 0 0 k _ 0 Ll A _____ Throttle Opener Throttle Position Sensor E2 ISC Valve IDL VTA _ vc ECU B E2 IDL VTA VC E1 7 7W pun an 213204 ...

Page 192: ...isconnect the throttle position sensor connector b Disconnect the vacuum hose from the throttle opener Apply vacuum to the throttle opener d Insert a feeler gauge between the throttle stop screw and stop lever e Using an ohmmeter measure the resistance between each terminal 0 _ Z Clearance between lever and stop screw Between terminals Resistance 0 mm D in VTA E2 0 2 5 7 RQ __ F y 0 50 mm 0 020 in...

Page 193: ...om the throttle opener and plug the hose end la 900 1 900 rpm 0 C R P M Tachometer P021160 1 7g Check the throttle opener setting speed Throttle opener setting speed 900 1 900 rpm w Cooling fen OFF If the throttle opener setting is not as specified replace the throttle body assembly Stop the engine bl V _ 7 a 1 Z X CORHB if rl Y P181167 d Reconnect the vacuum hose to the throttle opener P02463 700...

Page 194: ... L Air Connector St at at ISC Valve i Intake Air Connector ﬂl9r 00 Br Connector ii Accelerator Cable Bracket Gasket l Air Connector 3 4 No 1 Air Hose I No 3 Water Bypass Hose Y PIBSOT 3 i ii _ 4 A P 1 W _ P_ Y H3202 Q t IGT 0 THROTTLE BODY REMOVAL See Components for Removal Installation 1 DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY 2 DRAIN ENGINE COOLANT 3 REMOVE INTERCOOLER a Loosen the 3 cla...

Page 195: ...ort E of throttle body 3 Vacuum hose from throttle opener la lb Remove the 6 bolts and air connector stay and dis connect the throttle body from the intake manifold Remove the throttle body gasket Remove the No 3 cylinder head gasket 0 id B f Disconnect the following hoses and connector from the throttle body and remove the throttle body I No 3 water bypass hose 2 No 1 air hose 3 ISC valve connect...

Page 196: ...er gauge between the throttle stop screw E2 and stop lever c Using an ohmmeter measure the resistance between lever and stop screw Resistance VTA E2 0 2 5 7 kQ 0 50 mm 0 020 in IDL E2 2 3 kQ or lass 0 90 mm 0 035 in IDL E2 Infinity Throttle valve fully open VTA E2 Clearance between _ Between terminals VC E2 2 5 5 9 kQ I sire 5 I Y P181170 SENSOR 4 IF NECESSARY ADJUST THROTTLE POSITION Loosen the 2...

Page 197: ...H Q T e Components for Removal and Installation Q fl lb i 1 I AD9739 _ E13 l 1 P1847 M W ll X N4 A 1 J INSTALL THROTTLE BODY Connect the following connector and hoses to the throttle body I ISC valve connector 2 No 3 water bypass hose 3 No 1 air hose Install the No 3 cylinder head gasket to the spacer Install a new gasket on the throttle body facing the protrusion upward Install the throttle body ...

Page 198: ...r connector 2 INSTALL INTAKE AIR CONNECTOR K Install the intake air connector and accelerator cable bracket with the 4 bolts 1 7 Torque 21 N m 210 kgf cm 15 ft Ibf ii as its 91l i __ 3 INSTALL INTERCOOLER A0 rt a J1 3 a Install the intercooler with the 3 bolts a 2 L I 1 lb T X P1320 Connect the air connector to the intercooler and tighten the 3 clamps 4 CONNECT NEGATIVE TERMINAL CABLE Tl BATTERY 5...

Page 199: ...r 1 rT u 20 0 20 40 60 B0 I00 l 4l I32 l68ll104Il140Il176I 212l Temperature C Fl PI83l9 H4741 Z1325 3 INTAKE AIR TEMPERATURE SENSOR INSPECTION for INTAKE MANIFOLD 1 REMOVE INTAKE AIR TEMPERATURE SENSOR 2 INSPECT INTAKE AIR TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the terminals Resistance Refer to the graph If the resistance is not as specified replace the intake air temp...

Page 200: ... 20 10 E01 E02 i m22 Z illlml r No 20 N0 30 I No 10 8 No 4g83 _ SOLENOID RESISTOR INSPECTION 1 2 DISCONNECT SOLENOID RESISTOR CONNECTOR INSPECT SOLENOID RESISTOR Using an ohmmeter measure the resistance between terminals B and other terminals Resistance 4 6 Q at 20 C 68 F If the resistance is not as specified replace the resis tor 3 RECONNECT SOLENOID RESISTOR CONNECTOR ...

Page 201: ...LAY INSPECT FUEL PUMP RELAY Inspect relay continuity Using an ohmmeter check that there is continuity between terminals 1 and 3 Check that there is continuity between terminals 2 and 4 Check that there is no continuity between terminals 4 and 5 If continuity is not as specified replace the relay Inspect relay operation Apply battery voltage across terminals 1 and 3 Using an ohmmeter check that the...

Page 202: ...NSPECTION 1 DISCONNECT FUEL PUMP RESISTOR CONNECTOR INSPECT FUEL PUMP RESISTOR Using an ohmmeter measure the resistance between the terminal Resistance Approx 0 73 Q at 20 C 68 F If the resistance is not as specified replace the resis tor 3 RECONNECT FUEL PUMP RESISTOR CONNECTOR ...

Page 203: ...inity 2 0 10 2 kQ 2 5 5 9 ItQ ISC valve Resistance B RSC or RSO 81 2030 68 Fl 19 3 22 3 Q VSV for EG R Resistance 33 39Q A C idle up valve Resistance et 20 C 68 F 30 349 Water Temp sensor Resistance at 2o c 4 F at o c 32 F at 2o c 68 F at 4o c 104 F at eo c 140 F at eo c 176 F IO 20 llQ 4 7kQ 2 3kQ 0 9 1 3kQ 0 4 0 7 kQ 0 2 0 4 ltQ Intake Air Temp sensor for Air Cleaner case Resistance at 2o c i 4 ...

Page 204: ...erminals TE1 E1 not connected IG SW ON Check connector terminals TE1 E1 connected Resistance IDL E2 at throttle valve open at throttle valve fully closed VTA E2 at throttle valve fully open at throttle valve fully closed VC E2 THA E2 at intake air temp 20 C 68 F THW E2 at coolant temp 80 C 176 F G1 or G2 G at cold I0 C 14 F to 50 C 1 22 F at hot 50 C 1 22 F to 100 C 21 2 Fl NE G at cold l0 C I4 F ...

Page 205: ...ure regulator x Delivery pipe 29 300 22 Fuel return pipe x Fuel pressure regulator 29 300 22 Delivery pipe x Cylinder head 29 300 22 Fuel inlet hose x Delivery pipe 32 325 24 Cylinder head cover x Cylinder head 16 60 12 Throttle body x Intake manifold 21 210 I5 I Air connector stay x Cylinder head 21 210 15 Air connector x Throttle body 21 210 15 Knock sensor x Cylinder block 44 450 33 Oxygen sens...

Page 206: ... OPERATION lSC Valve Pi p 3 Water lnlet 1 E I n L d Water Pum Throttle Body O _ K Qt on1 I t 599 119 t W F FROM HEATE x ﬁr i Q 51 7 Oil Cooler hermostat Turbooharger Water Bypass Pipe FROM F1ADlATOR O N TO HEATER Water Outlet RADlATOR Pissez l_ ...

Page 207: ...ternator Bracket II k E2 _______T _ Alternator Wire Alternator 5 __ 1 BeltGuide Exhaust Camshaft Timing Pulley Engine Wire Protector Timing Belt Tensioner 1 5 K re 59lG00 43 W i 4 II Y 11420 30l 1 T Hr 1 _ Plate Washer No 1 Idler Pulley it Precoated part For use with SST N m kgf cm ft lbf Specified torque No 2 Idler Pulley _ 1 I _ ___ V _ ___ ____ I l I I 4 II Q _____5 ___ A O _ 0 XJ i vs e LUTI 1...

Page 208: ... Bracket Q E Water Pump Cover O Gasket 5 61 3 WasherPum cl P w I l Il Q0 Q 0 a _ r O w J O O Non reusable part Pl 3f 9 CR _ H O T Z ix I O O Ring K16 __ 6 Gasket r5 H IIlJ _ i i I 1 Tq Q _ _ _ rf I e L77 I W I I I f P V Z I1 _ f_J o 1 I tﬂfb I 0 A K I 1 J T I K 2 I I WY vpﬂ A _ ti i K 3 Q _l___ Oil Dipstick Guide P 0 oTRing Oil Dipstick ...

Page 209: ...t lbf Cylinder block x Drain plug 2 5 250 18 Water pump x Water pump cover 8 8 90 78 in lbf Water pump x Cylinder block 7 5 76 66 in lbf Water bypass pipe x Water pump cover I0 100 7 Idler pulley bracket for alternator drive belt x Cylinder block Water pump aide Cylinder block side 23 230 19 190 17 14 No 3 timing belt cover x Cylinder head 8 0 82 71 in lbf No 2 idler pulley x Cylinder block 4 4 45...

Page 210: ... 23 I 5r 4 q i Ila _ 1 PI8583 VALVE LIFTERS _ _ at VALVE stems 1 1 PISTONS CAMS 1 1 CONNECTING CAMSHAFT r noos JOURNALS 1 CRANKSHAFT OIL NOZZLES CYLINDER HEAD 1 MAIN OIL HOLE l l r 1 lruneoci mac isi i RELIEFVALVE OILCOOLER i RELIEFVALVE I OILFILTER I P nzuer VALVE I i OIL STFIAINER I 1 I I OIL PAN Zl l ...

Page 211: ...V9 lam __ Connector 1 v IvVf W rming Be RH Front Engine Hanger Gasket Alternator Bracket Alternator Wire 7 xi we g RH Engine I __ 4 6_ ii Y itii I 5Q I i Y ii iiit _ 1 5 _____eu r Ox en Sensor _ __ I Alternator Engine Wire Protector Connector Knock Pin 59 I600 43 41 I420 30 Oil Pump Pulley No2 Idler Pulley I For use with SST Crankshaft Pulley I N m lkgf cm ft Ibf Specified torque 1 f 1 La _ y 7 I ...

Page 212: ...a2 11 inulbll Q _ _ I 10mmHeadBoIt 1 1 _ 12 121150 315 It l I l l OI O O Gasket 21 1210 151 i I e Oil Strainer I _ fa 1 1 1 6 _____I Oil Pressure 7 T 1 1 i I Regulator _4 1 i 1 _ O O Ring 45 Engine Wire X r i l CI C Bracket 1 TKQ _ _ Q _ No 10i Pan A _ ié f O Gasket 0 Ring Oil Level 7 L at __ Sensor Y _ _ ti Connector q No 2 Oil Pan 1 lg il _ J in p ug is easier N m kgf cm ft Ibf Specified torque ...

Page 213: ... V I W Fe in Alternator Wife I I 1 _ 1 Nim kgf cm ft Ibf Specified torque 0 Non reusable part Y Pl r i R i 1 Alternator Connector I I I I I I I 7 _ _ _ ___I Water Bypass Hose Oil Cooler Oil Dlpstick Guide E I I I Alternator Q __ Ti Q0 Ring T ﬁ T e Relief Valve il tt I I _ _ O Seal Washer T s Oil Dipstick Q Gasket II s PK Water Inlet G O O Ring ...

Page 214: ...lt 9 0 8 0 92 82 80 in lbf 71 in lbf Oil strainer x Oil pump 9 0 92 80 in lbf Oil strainer x Cylinder block 6 5 66 58 in lbf Oil pan baffle plate x Cylinder block 6 5 66 58 in lbf No 1 oil pan x Oil pump 9 0 92 80 in lbf No 1 oil pan x Rear oil seal retainer 9 0 92 80 in lbf No 1 oil pan x Cylinder block 20 mm 0 79 in long bolt for 10 mm head 25 mm 0 98 in long bolt for I2 mm head Nut 12 21 14 120...

Page 215: ......

Page 216: ...ST 1 STARTING SYSTEM SERVICE SPECIFICATIONS ST Z REFER TO 3S GE ENGINE REPAIR MANUAL Pub No RM396EI NOTE The above pages contain only the points which differ from the above listed manual ...

Page 217: ...imit STD Limit Limit 12 V 1 2 kW 90AorIeseat11 5V 3 000 rpm or more 15 0 mm 0 591 in 8 0 mm 0 315 in 10 I6 N 1 0 1 6 kgf 2 2 3 6 30 mm 1 18 in 29 mm 1 14 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 10 0020 in TORQUE SPECIFICATIONS I101 N Part tightened ft Ibf End cover x Brush holder 1 5 15 13 in lbf Starter housing x Magnetic switch 5 9 60 52 in lbf End cover x Starter housing 5 9 60 52 in lbf Lea...

Page 218: ...CH 1 CHARGING SYSTEM ALTERNATOR CH_ 2 SERWCE pEC p CAT 0N3 CH_ 3 REFER TO 3S GE ENGINE REPAIR MANUAL Pub No nmassei NOTE The above pages contain only the points which differ from the above listed manual ...

Page 219: ... j ROtU CH Q Rear Bearing 5 J Alternator Washer r Wt cf __ J L A C Rubber Insulator Bearing CW9 w 5 r 11 Front Bearing q f T ff arm L 4 4 Ae J_ é Bearing Cover IC Regulator f Brush Holder I _ J J _ l if gr o Rectifier Holder T t t Cord Cup __ x Seal Plate Terminal Insulator Brush Home Cove ﬁ ﬁr G Plate Terminal 0D I I I r I ____q______I J Lead Wire 4 We 1 ET Air Duct I T T w e F4857 ...

Page 220: ... 2 14 4 mm 0 559 0 567 in 12 8 mm 0 504 in 10 5 mm 0 413 in 1 5 mm 0 059 in IC regulator Regulating voltage at 25 C 77 F at 115 C 239 F 13 9 15 1 V 13 5 14 3V TORQUE SPECIFICATIONS GJIIIO I Part tightened N m kgf cm ft Ibf Bearing retainer x Drive end frame 2 6 27 23 in lbf Rectifier end frame x Drive end frame 4 5 46 40 in lbf Cord clip x Rectifier end frame 5 4 55 47 in lbf I Alternator pulley x...

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