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3S-GE
Repair manual
Toyota 3S-GE Repair Manual
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Repair manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Introduction
How to Use this Manual
Repair Procedures
Identification Information Engine Serial Number
General Repair Instructions
Precautions for Vehicles Equipped with a Catalytic Converter
Abbreviations Used in this Manual
Engine Mechanical
Description (5S-FE)
Description (3S-GE and 3S-GTE)
Troubleshooting
Engine Overheating
Hard Starting
Rough Idling
Engine Hesitates/Poor Acceleration
Engine Dieseling
After Fire, Backfire
Excessive Oil Consumption
Excessive Fuel Consumption
Unpleasant Odor
Engine Tune-Up
Inspection of Air Filter
Inspection of High-Tension Cords
Inspection and Adjustment of Spark Plugs (Conventional Type Only)
Inspection and Adjustment of Alternator Drive Belt (5S-FE)
Inspection and Adjustment of Alternator Drive Belt (3S-GE and 3S-GTE)
Inspection and Adjustment of Valve Clearance (5S-FE)
Adjusting Shim Selection Using Chart
Intake
Exhaust
Inspection and Adjustment of Valve Clearance (3S-GE and 3S-GTE)
Adjust Valve Clearance
Inspection and Adjustment of Ignition Timing (5S-FE)
Warm up Engine
Connect Tachometer
Further Check Ignition Timing
Inspection and Adjustment of Ignition Timing (3S-GE and 3S-GTE)
Inspection and Adjustment of Idle Speed (5S-FE)
Initial Conditions
Adjust Idle Speed
Further Check Idle Speed
Inspection of Idle Speed (3S-GE and 3S-GTE)
Inspection of Acoustic Control Induction System (ACIS) (3S-GE)
Inspection of TOYOTA-Variable Induction System (T-VIS) (3S-GTE)
Connect Vacuum Gauge
Inspect T-VIS Operation
Idle HC/CO Concentration Check Method (W/Twc)
Check Oxygen Sensor Operation
Check HC/CO Concentration at Idle
Idle Co Concentration Check and Adjustment Method (W/O TWC)
Compression Check
Check Cylinder Compression Pressure
Timing Belt (5S-FE)
Components
Removal of Timing Belt
Remote No.2 Timing Belt Cover
Set No.1 Cylinder to Tdc/Compression
Remove Timing Belt from Camshaft Timing Pulley
Remove Camshaft Timing Pulley
Remove Crankshaft Pulley
Remove No.1 Timing Belt Cover
Remove Timing Belt Guide
Remove No.1 Idler Pulley and Tension Spring
Remove No.2 Idler Pulley
Remove Crankshaft Timing Pulley
Remote Oil Pump Pulley
Inspection of Timing Belt Components
Inspect Idler Pulleys
Inspect Tension Spring
Install Oil Pump Pulley
Install Crankshaft Timing Pulley
Temporarily Install No.1 Idler Pulley and Tension Spring
Temporarily Install Timing Belt
Install Timing Belt Guide
Install No.1 Timing Belt Cover
Install Crankshaft Pulley
Install Camshaft Timing Pulley
Install Timing Belt
Check Valve Timing
Install No.2 Timing Belt Cover
Install Engine Wire to Alternator Bracket and Adjusting Bar
Install Spark Plugs
Install RH Engine Mounting Bracket
Timing Belt (3S-GE and 3S-GTE) Components
Remove Timing Belt from Camshaft Timing Pulleys
Remove Camshaft Timing Pulleys
Remove No.1 Timing Belt Covers
Remove Timing Belt
Remove No.1 Idler Pulley
Remove Oil Pump Pulley
Inspect Timing Belt
Inspect Timing Belt Tensioner
Installation of Timing Belt
Install Camshaft Timing Pulleys
Install Timing Belt Tensioner
Adjustment of Valve Timing
Check Camshaft Timing Pulley Marks
Adjust Camshaft Timing Pulley Timing Marks
Adjust Valve Timing
Reinstall Spark Plugs
Cylinder Head (5S-FE) Components
Removal of Cylinder Head
Remove Alternator
Remove Distributor
Remove Exhaust Manifold and Catalytic Converter Assembly
Separate Exhaust Manifold and Catalytic Converter
Remove Water Outlet
Remove Water By-Pass Pipe
Remove EGR Valve and Vacuum Modulator
Remove Air Tube
Disconnect Engine Wire Ground Strap from Intake Manifold
Remove EGR VSV
Remove Intake Manifold
Remove No.3 Timing Belt Cover
Remove Engine Hangers
Remove Alternator Bracket
Remove Oil Pressure Switch
Remove Cylinder Head Cover
Remove Exhaust Camshaft
Remove Intake Camshaft
Disassemble Exhaust Camshaft
Remove Cylinder Head
Disassembly of Cylinder Head
Remove Valve Lifters and Shims
Remove Valves
Inspection, Cleaning and Repair of Cylinder Head Components
Clean Top Surfaces of Pistons and Cylinder Block
Remove Gasket Material
Inspect Cylinder Head
Clean Valves
Inspect Valve Stems and Guide Bushings
If Necessary, Replace Valve Guide Bushings
Inspect and Grind Valves
Inspect and Clean Valve Seats
Inspect Valve Springs
Inspect Camshaft for Runout
Inspect Cam Lobes
Inspect Camshaft Bearings
Inspect Camshaft Gear Spring
Inspect Camshaft Journal Oil Clearance
Inspect Camshaft Thrust Clearance
Inspect Camshaft Gear Backlash
Inspect Valve Lifters and Lifter Bores
Inspect Intake and Exhaust Manifolds
Assembly of Cylinder Head
Install Valves
Install Valve Lifters and Shims
Installation of Cylinder Head
Place Cylinder Head on Cylinder Block
Install Cylinder Head Bolts
Install Spark Plug Tubes
Assemble Exhaust Camshaft
Install Intake Camshaft
Install Exhaust Camshaft
Install Semi-Circular Plugs
Install Cylinder Head Cover
Install Oil Pressure Switch
Install Alternator Bracket
Install No.3 Timing Belt Cover
Install Intake Manifold
Install EGR VSV
Install Engine Wire Ground Strap to Intake Manifold
Install Air Tube
Install EGR Valve and Vacuum Modulator
Install Water Outlet
Assemble Exhaust Manifold and Catalytic Converter
Install Exhaust Manifold and Catalytic Converter Assembly
Install Alternator
Cylinder Head (3S-GE and 3S-GTE) Components (3S-GE)
Components (3S-GTE)
Cylinder Head (3S-GTE) Components
Removal of Cylinder Head (3S-GE)
Drain Engine Coolant
Remove RH Front Engine Hanger and No.1 Alternator Bracket
Remove Exhaust Manifold
Remove Intake Manifold Stay
Remove ACIS Vacuum Tank, ACIS VSV, Fuel Pressure VSV and Bracket
Remove Cold Start Injector
Remove Air Intake Chamber
Remove LH Engine Hanger
Remove ACIS Valve
Remove RH Rear Engine Hanger
Disconnect Engine Wire from Cylinder Head Cover
Remove Catalytic Converter
Remove No.2 Air Tube
Remove EGR Vacuum Modulator and VSV
Remove EGR Valve and Pipe
Remove Vacuum Pipe
Remove Intake Manifold Stays
Remove No.1 Air Tube
Remove T-VIS Vacuum Tank, T-VIS VSV, Turbocharging Pressure VSV and Bracket
Remove Intake Manifold and T-VIS Valve
Remove Camshafts
Clean Combustion Chambers
Clean Valve Guide Bushings
Clean Cylinder Head
Inspect for Flatness
Inspect for Cracks
Inspect Camshafts and Bearings
Inspect Camshaft Journals
Intake Manifold (3S-GE)
Intake Manifold (3S-GTE)
Exhaust Manifold
Inspect Air Intake Chamber (3S-GE)
Inspection of Acoustic Control Induction System (ACIS) (3S-GE)
Inspect ACIS Valve
Inspect Vacuum Tank
Inspection of TOYOTA-Variable
Induction System (T-VIS) (3S-GTE)
Inspect T-VIS Valve
Installation of Cylinder Head (3S-GE)
Install Cylinder Head Covers
Install Engine Wire to Cylinder Head Cover
Install RH Rear Engine Hanger
Install ACIS Valve
Install LH Engine Hanger
Install Air Intake Chamber
Install ACIS Vacuum Tank, ACIS VSV, Fuel Pressure VSV and Bracket
Install Intake Manifold Stay
Install Water By-Pass Pipe
Install Exhaust Manifold
Install No.1 Alternator Bracket and RH Front Engine Hanger
Installation of Cylinder Head (3S-GTE)
Install Camshafts
Install T-VIS Valve and Intake Manifold
Install T-VIS Vacuum Tank, T-VIS VSV, Turbocharging Pressure VSV and Bracket
Install No.1 Air Tube
Install Intake Manifold Stays
Install Vacuum Pipe
Install EGR Valve and Pipe
Install EGR Vacuum Modulator and VSV
Install No.2 Air Tube
Install Catalytic Converter
Cylinder Block (5S-FE)
Preparation for Disassembly
Disassembly of Cylinder Block
Remove Rear Oil Seal Retainer
Check Connecting Rod Thrust Clearance
Remove Connecting Rod Caps and Check Oil Clearance
Remove Piston and Connecting Rod Assemblies
Check Crankshaft Thrust Clearance
Remove Main Bearing Caps and Check Oil Clearance
Cylinder Block Main Journal Bore Diameter
Crankshaft Journal Diameter
Standard Sized Bearing Center Wall Thickness
Remove Crankshaft
Inspection of Cylinder Block
Inspect Top Surface of Cylinder Block for Flatness
Inspect Cylinder for Vertical Scratches
Inspect Cylinder Bore Diameter
Remove Cylinder Ridge
Disassembly of Piston and Connecting Rod Assemblies
Remove Piston Rings
Disconnect Connecting Rod from Piston
Inspection of Piston and Connecting Rod Assemblies
Clean Piston
Inspect Piston Oil Clearance
Inspect Piston Ring Groove Clearance
Inspect Piston Ring End Gap
Inspect Piston Pin Fit
Inspect Connecting Rod Alignment
Inspect Piston Pin Oil Clearance
If Necessary, Replace Connecting Rod Bushing
Inspect Connecting Rod Bolts
Inspection and Repair of Crankshaft
Inspect Crankshaft for Runout
Inspect Main Journals and Crank Pins
If Necessary, Grind and Hone Main Journals And/Or Crank Pins
Replacement of Crankshaft Oil Seals
Replace Crankshaft Front Oil Seal
Replace Crankshaft Rear Oil Seal
Assembly of Piston and Connecting Rod Assemblies
Install Piston Rings
Install Bearings
Assembly of Cylinder Block
Install Main Bearings
Install Upper Thrust Washers
Place Crankshaft on Cylinder Block
Install Main Bearing Caps and Lower Thrust Washers
Install Piston and Connecting Rod Assemblies
Install Connecting Rod Caps
Install Rear Oil Seal Retainer
Post Assembly
Install PS Pump Bracket
Install Rear End Plate
Install Flywheel (M/T)
Install Clutch Disc and Cover (M/T)
Cylinder Block (3S-GE and 3S-GTE)
Remove Rear End Plate
Remove RH Engine Mounting Bracket
Remove PS Pump Bracket
Remove Knock Sensor
Clean Cylinder Block
Check Fit between Piston and Piston Pin
Standard Oil Clearance
Maximum Oil Clearance
Ring Groove Clearance
Standard End Gap
Maximum End Gap
Assemble Piston and Connecting Rod
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Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting
16
Troubleshooting hints
238
Troubleshooting procedures
239
Troubleshooting with volt/ohmmeter
265
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