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7M-GE
Repair manual
Toyota 7M-GE Repair Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Repair Procedures
Warnings, Cautions, Notes
Replace Drive Shaft Bearing
Specifications
References
Identification Information
General Repair Instructions
Engine Serial Number
Table of Contents
Engine Mechanical
Engine Mechanical Description
Engine Mechanical
Description
Engine Mechanical Troubleshooting
Inspection of Air Filter
Engine Tune-Up
Inspection and Adjustment of Valve Clearance
Remove Air Intake Connector
Measure Valve Clearance
Adjust Valve Clearance
Install Air Intake Connector
Remove ISC Pipe
Remove PCV Pipe with Hoses
Remove Intake Air Connector
Remove Ignition Cover
Remove Cylinder Head Covers
Install Ignition Coil with Bracket
Install Ignition Coil Cover
Install Intake Air Connector
Install PCV Pipe with Hoses
Install ISC Pipe
Adjusting Shim Selection Using Chart
Intake
Exhaust
Inspection and Adjustment of Ignition Timing
Connect Tachometer and Timing Light to Engine
Check Ignition Timing
Further Check Ignition Timing
Inspection and Adjustment of Idle Mixture
Initial Conditions
Inspect and Adjust Idle CO Concentration
Method with CO Meter
Alternative Method
Inspection of Idle HC/CO Concentration
Check Idle Speed
Check Oxygen Sensor Operation
Measure HC/CO Concentration at Idle
Inspection and Adjustment of Dash POT (DP) System
Inspect and Adjust DP Setting Speed
Check Operatoin of VTV
Check Cylinder Compression Pressure
Remove Throttle Body
Compression Check
Removal of Timing Belt
Timing Belt Components
Remove No.3 Timing Belt Cover
Remove Timing Belt from Camshaft Timing Pulleys
Set No.1 Cylinder to Tdc/Compression
Remove Camshaft Timing Pulleys
Remove Crankshaft Pulley
Remove PS Air Pipe
Inspection of Components
Remove Crankshaft Timing Pulley
Remove Oil Pump Drive Pulley
Inspect Idler Pulley
Inspect Tension Spring
Install Crankshaft Timing Pulley
Install Oil Pump Pulley
Installation of Timing Belt
Temporarily Install Timing Belt
Install Camshaft Timing Pulleys
Install Crankshaft Pulley
Check Timing Belt Tension
Install No.3 Timing Belt
Install Timing Belt
Adjust Drive Belts
Install Alternator Drive Belt and Fan
Install Water Outlet
Cylinder Head Components
Removal of Cylinder Head
Remove Air Intake Chamber with Connector
Remove Alternator
Remove Engine Wire
Remove No.2 Fuel Pipe
Remove Exhaust Manifold
Remove Water Outlet Housing
Remove Cylinder Head
Disassembly of Cylinder Head
Remove Bearing Caps and Camshafts
Remove Delivery Pipe with Injectors
Remove Intake Manifold
Inspection, Cleaning and Repair of Cylinder Head Components
Remove Gasket Material
Remove Valve Lifters with Shims
Remove Valves
Clean Combustion Chamber
Clean Cylinder Head
Clean Valve Guide Bushings
Inspect Cylinder Head for Flatiness
Clean Valves
Inspect Cylinder Head for Cracks
Inspect Valve Stems and Guide Bushings
Replace Valve Guide Bushings
Inspect and Grind Valves
Inspect and Clean Valve Seats
Inspect Camshaft and Bearing Caps
Inspect Valve Springs
Inspect Camshaft Oil Clearance
Inspect Camshaft Thrust Clearance
Inspect Valve Lifter Oil Clearance
Maximum Oil Clearance
Standard Oil Clearance
Check Air Control Valve Operation
Check Vacuum Tank by Blowing Air into each Pipe
Inspection of Intake Air Control System
Assembly of Cylinder Head
Install Camshafts and Oil Seals
Install Valve Lifters with Shims
Install Valves
Install Heater Union
Install Intake Manifold
Install Delivery Pipe with Injectors
Install Cylinder Head Covers
Installation of Cylinder Head
Install Exhaust Manifold
Install Water Outlet Housing
Install Air Intake Chamber with Connector
Install Engine Wire
Install No.1 Fuel Pipe and Pulsation Damper
Install No.2 Fuel Pipe
Install Alternator and Adjusting Bar
Install PS Reservoir Tank
Cylinder Block Components
Disassembly of Cylinder Block
Check Connecting Rod Thrust Clearance
Remove Oil Pump
Remove Oil Pump Drive Shaft
Remove Rear Oil Seal Retainer
Check Crankshaft Thrust Clearance
Remove Main Bearing Caps and Check Oil Clearance
Remove Piston and Connecting Rod Assemblies
Remove Crankshaft
Clean Cylinder Block
Inspect Cylinder Bore
Inspect Top of Cylinder Block for Flatness
Inspection of Cylinder Block
Check Fit between Piston and Pin
Disassembly of Piston and Connecting Rod Assemblies
Remove Cylinder Ridges
Remove Piston Rings
Clean Pistons
Inspection of Piston and Connecting Rod Assemblies
Inspect Clearance between Wall of Ring Groove and New Piston Ring
Inspect Piston Diameter and Oil Clearance
Inspect Piston Ring End Gap
Check Piston Pin Fit
Inspect Connecting Rods
Maximum End Gap
Standard End Gap
Bushing Inside Diameter
Maximum Twist
Replace Connecting Rod Bushings
Bore and Hone Cylinders to Calculated Dimensions
Boring of Cylinders
Calculate Amount to Bore Cylinder
Select Oversized Piston
Grind and Hone Main Journals And/Or Crank Pins
Inspect Crankshaft for Runout
Inspect Main Journals and Crank Pins
Inspection of Crankshaft
Inspect Oil Pump Drive Shaft
Replace Oil Pump Drive Shaft Bearing
Inspect Oil Pump Drive Shaft Thrust Clearance
Replace Thrust Plate and Collar
Replace Crankshaft Front Oil Seal
Replacement of Oil Seals
Replace Crankshaft Rear Oil Seal
Replace Pump Drive Shaft Oil Seal
Assembly of Piston and Connecting Rod
Install Piston Rings
Assembly of Cylinder Block
Install Bearings
Install Main Bearings
Install Main Bearing Caps and Lower Thrust
Install Upper Thrust Washers
Place Crankshaft on Cylinder Block
Install Connecting Rod Caps
Install Oil Pump Assembly
Install Piston and Connecting Rod Assemblies
Install Oil Pump Drive Shaft
Install Rear Oil Seal Retainer
Install Timing Belt Case with Water Pump
Install Flywheel or Drive Plate on Crankshaft
Install Oil Hole Cover Plate
Install Oil Regulator
Install Water By-Pass Pipe
Turbocharger System
Turbocharger System Description
Intercooler
Operation of Turbocharger
Waste Gate Valve
Precautions
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
Turbocharger System Troubleshooting
Abnormal Noise
Excessive Oil Consumption or White Exhaust
Inspect Exhaust System
Inspect Intake Air System
Inspect Operation of Actuator and Waste Gate Valve
On-Vehicle Inspection of Turbocharger
Check Turbocharging Pressure
Inspect Impeller Wheel Rotation
Turbocharger System Components
Removal of Turbocharger
Remove Turbo Heat Insulator
Disconnect Front Exhaust Pipe
Remove Oil Dipstick Guide
Inspect Axial Play of Shaft Bearing
Inspection of Turbocharger
Install Turbine Outlet Elbow
Installation of Turbocharger
Install No.1 Turbo Water Pipe
Install Turbocharger
Connect Front Exhaust Pipe
Connect Union Pipe
Install Turbocharger Stay
Install Oil Dipstick Guide
Install Turbo Heat Insulator
EFI System
EFI System System Description
System Description
Air Induction System
Electronic Control System
Fuel System
Idle Speed Control
Inspection Precautions
Maintenance Precautions
If Vehicle Is Equipped with Mobile Radio System
EFI System Troubleshooting
Difficult to Start or no Start
Engine Often Stalls
Engine Sometimes Stalls
Rough Idling And/Or Missing
High Engine Idle Speed (no Drop)
Engine Backfires
Lean Fuel Mixture
Muffler Explosion
Rich Fuel Mixture Misfire
Engine Hesitates And/Or Poor Acceleration
Diagnosis System
Check Engine Warning Light Check
Output of Diagnosis Codes
Malfunction Code Indication
Test Mode
Cancelling out Diagnostic Code
Diagnosis Indication
Inspection of Diagnosis Circuit
Location of Fuses and Fusible Links
Troubleshooting with Volt/Ohmmeter (MA)
EFI System Check Procedure
Terminals of ECU
Voltage at ECU Wiring Connectors
Troubleshooting with Volt/Ohmmeter (Ma
Troubleshooting with Volt/Ohmmeter (MS)
Fuel Pump
Fuel System
Inspect Fuel Pressure
Inspect Fuel Pump Operation
Cold Start Injector
Check Connector Location
Removal of Fuel Pump
Remove Fuel Pump Bracket from Fuel Tank
Remove Fuel Pump from Fuel Pump Bracket
Install Fuel Pump Filter to Fuel Pump
Install Fuel Tank
Installation of Fuel Pump
Remove Fuel Pump Filter from Fuel Pump
Cold Start Injector
Inspect Resistance of Cold Start Injector
Removal of Cold Start Injector
Remove Cold Start Injector Tube
Inspect Injection of Cold Start Injector
Inspection of Cold Start Injector
Remove Cold Start Injector
Inspect Leakage
Install Cold Start Injector Tube
Installation of Cold Start Injector
Disconnect No.2 Fuel Pipe
Pressure Regulator
Removal of Pressure Regulator
Remove Pressure Regulator
Installation of Pressure Regulator
Check Injector Operation
Injectors
Inspect Resistance of Injector
On-Vehicle Inspection
Disconnect Following Connections
Disconnect Following Hoses
Removal of Injector
Remove ISC Valve
Remove No.1 Fuel Pipe
Remove Delivery Pipe
Remove Injectors
Inspection of Injector
Install Injectors into Delivery Pipe
Install Pressure Regulator
Install ISC Valve
Connect Following Connectors
Connect Following Hoses
Air Flow Meter (7M-GE
Inspect Resistance of Air Flow Meter
Air Flow Meter (7M-GTE
Inspection of Air Flow Meter
Installation of Air Flow Meter
Removal of Air Flow Meter
Throttle Body
Inspect Throttle Position Sensor
Removal of Throttle Body
Clean Throttle Body
Inspect Throttle Valve
Inspection of Throttle Body
Installation of Throttle Body
Check for Operating Sound from Isc Valve
Idle Speed Control (ISC) Valve
Removal of ISC Valve
Inspection of Check Valve
Inspection of ISC Valve
Installation of Isc Valve
Electronic Control System
Location of Electronic Control Parts
Location of Electronic Control Parts
EFI Main Relay
Inspect Relay Continuity
Inspect Relay Operation
Inspection of Efi Main Relay
Circuit Opening Relay
Inspection of Circuit Opening Relay
Inspection of Solenoid Resistor
Solenoid Resistor
Cold Start Injector Time Switch
Inspect Resistance of Water Temperature Sensor
Water Temperature Sensor
Fuel Pump Relay and Resistor
Inspect Fuel Pump Relay
Inspection of Pump Relay and Resistor
Inspect Fuel Pump Resistor
High Temperature Line Pressure up System
Inspect VSV for Open Circuit
Inspect VSV for Short Circuit
Inspection of High Temperature Line Pressure up System
High Altitude Compensation System
Inspect Resistance of HAC Sensor
Inspect Feedback Voltage
Inspection of Oxygen Sensor
Oxygen Sensor
Oxygen Sensor
System (7M-GTE
Electronic Controlled Unit (ECU
Inspect Voltage of ECU
Inspection of ECU
Inspect Resistance of ECU
Fuel Cut RPM
Inspection of Fuel Cut Rpm
Radiator
Radiator Cap
Reservoir Tank
Water Pump
Cooling System Troubleshooting
Check and Replacement of Engine Coolant
Check Engine Coolant Level at Reserve Tank
Check Engine Coolant Quality
Replace Engine Coolant
Removal of Water Pump
Water Pump Components
Inspect Water Pump Bearing
Inspect Water Pump Body and Timing Belt Case
Inspection of Water Pump
Installation of Water Pump
Inspection of Thermostat
Install Thermostat and Water Outlet
Removal of Thermostat
Remove Water Outlet and Thermostat
Check Cooling System for Leaks
Check Radiator Cap
Cleaning of Radiator
Inspection of Radiator
Disassembly of Radiator
Remove Tank Plate
Assembly of Radiator
Remove Tank and O-Ring
Install New O-Ring and Tank
Install Oil Cooler to Lower Tank
Install Tank Plate
Stake Claw of Tank Plate
Inspect for Water Leaks
Paint Tank Plates
Lubrication System
Lubrication System Description
Oil Filter
Oil Pressure Regulator
Oil Pump
High Oil Pressure
Low Oil Pressure
Lubrication System Troubleshooting
Oil Leakage
Check Engine Oil Level
Check Engine Oil Quality
Measure Oil Pressure
Oil Pressure Check
Fill with Engine Oil
Recheck Engine Oil Level
Drain Engine Oil
Replace Oil Filter
Replacement of Engine Oil and Oil Filter
Oil Pump Components
Removal of Oil Pump
Remove Oil Pan
Disassembly of Oil Pump
Remove Oil Pump Outlet Pipe
Remove Oil Pump Strainer
Remove Relief Valve
Inspect Body Clearance
Inspect Gear Backlash
Inspect Relief Valve
Inspection of Oil Pump
Assembly and Operation Check of Oil Pump
Check Pump Operation
Install Oil Pump Driven Gear
Install Oil Pump Outlet Pipe
Install Oil Pump Strainer
Installation of Oil Pump
Install Oil Pan
Oil Cooler and Oil Pressure Regulator
Assembly and Installation of Oil Pressure Regulator
Inspection of Oil Pressure Regulator
Removal and Disassembly of Oil Pressure Regulator
Remove Oil Pressure Regulator
Removal and Disassembly of Oil Filter Bracket
Remove Oil Filter Bracket
Assembly and Installation of Oil Filter Bracket
Inspection of Relief Valve
Install Oil Filter Bracket
Ignition System
Ignition System Precautions
Ignition System Troubleshooting
Electronic Spark Advance
Ignition System Circuit
Spark Test
Inspect High-Tension Cord Resistance
Inspection of High-Tension Cords
Install High-Tension Cords
Remove High-Tension Cords
Adjust Electrode Gap
Clean Spark Plugs
Inspection of Spark Plugs
Remove Spark Plugs
Inspect Electrode
Inspect Electrode Gap
Install Spark Plugs
ON-VEHICLE Inspktlon (7M-GE
Visually Inspect Spark Plugs
Inspect Primary Coil Resistance
Inspect Secondary Coil Resistance
Inspection of Ignition Coil
Inspect Air Gaps
Inspect Pickup Coils
Inspection of Distributor
Disconnect Following Cables and Rod
Remove Ignition Coil Cover
Remove Ignition Coil with Bracket
Inspect Ignition Coil Ground
Inspect Power Source Line
Replace Ignition Coil
Check Power Source Line Voltage
Check Power Transistor in Igniter
Inspection of Igniter
Inspect Air Gap
Inspection of Cam Position Sensor
On-Vehicle Inspection (7M-Gte
Removal of Ditributor
Distributor Components
Remove Distributor
Remove O-Ring
Replacement of Distributor Driven Gear
Grind Driven Gear and Pin
Install New Driven Gear and Pin
Installation of Distributor
Removal of Cam Position Sensor
Cam Position Sensor Components
Replacement of Cam Position Sensor Driven Gear
Remove Cam Position Sensor
Installation of Cam Position Sensor
Install Cam Position Sensor
Starting System
Starting System Troubleshooting
Starting System Circuit
Starter Components
Disassembly of Starter
Remove Field Frame with Armature from Magnetic Switch Assembly
Brushes
Inspect Undercut Depth of Segment
Field Frame
Brush Springs
Inspect Brush Spring Load
Brush Holder
Clutch and Gears
Magnetic Switch
Inspect Bearings
Replace Bearings
Assembly of Starter
Install Brush Holder
Install Gears and Clutch Assembly
Install Starter Housing
Install Field Frame with Armature to Magnetic Switch Assembly
Inspect Clutch Pinion Gear Return
Perform Pull-In Test
Perform Hold-In Test
Performance Test of Starter
Starter Relay
Inspection of Starter Relay
Charging System
Charging System Precautions
Charging System Troubleshooting
Charging System Circuit
Check Battery Specific Gravity
Check Battery Terminals, Fusible Links and Fuses
Inspect Drive Belt
Inspect Fuses for Continuity
Check Alternator Wiring and Listen for Abnormal Noises
Check Discharge Warning Light Circuit
Check Charging Circuit Without Load
Check Charging Circuit with Load
Remove Brush Holder
Remove Reara End Cover
Disassembly of Alternator
Alternator Components
Remove IC Regulator
Remove Rectifier Holder
Remove Pulley
Remove Rectifier End Frame
Inspect Slip Rings
Inspect Rotor for Ground
Inspect Rotor for Open Circuit
Inspection and Repair of Alternator
Inspect Exposed Brush Length
Replace Brushes
Inspect Positive Side Rectifier
Inspect Negative Side Rectifier
Replace Front Bearing
Inspect Rear Bearing
Install Rectifier Holder
Assembly of Alternator
Install Pulley
Install Rectifier End Frame
Install Brush Holder and IC Regulator
Install Rear End Cover
Service Specifications
New Car Features
Differential
LSD Construction
Differential Operation
Suspension
Tems
Location of System Components
Function of Components
Wiring Diagram
Slepless Reclining Adjustment
Stepless Reclining Adjuster System
Front Seat
Normal Position
Forward Reclining Position
Power Side Support and Power Lumbar Support
Backward Reclining Lock Position
Power Lumbar Support Adjustment
Power Side Support Adjustment
Construction and Operation
System Circuit
Lumbar and Side Support Switch
Connecter for Lumbar and Side Support Switch
Cruise Control System (CCS)
Major Connectors
Main Switch
Vacuum Pump
Vacuum Switch
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REPAIR MANUAL
Table of
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Table of Contents
Troubleshooting
Engine Mechanical Troubleshooting
11
Turbocharger system troubleshooting
104
EFI System troubleshooting
129
Troubleshooting with Volt/Ohmmeter (MA)
151
TROUBLESHOOTING WITH VOLT/OHMMETER (MA
157
Troubleshooting with volt/ohmmeter (MS)
174
Cooling system troubleshooting
248
Lubrication System Troubleshooting
262
Ignition system troubleshooting
281
Starting system troubleshooting
307
Charging System Precautions
318
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