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Toyota 22R-E Service Manual

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Table of Contents
IN–1
INTRODUCTION
INTRODUCTION

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Table of Contents

   Summary of Contents for Toyota 22R-E

  • Page 1 IN–1 INTRODUCTION – INTRODUCTION...
  • Page 2: How To Use This Manual, General Description, Repair Procedures

    IN–2 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page.
  • Page 3: Specifications

    IN–3 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: Example: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
  • Page 4: Engine Serial Number

    IN–4 INTRODUCTION – IDENTIFICATION INFORMATION CAUTIONS, NOTICES, HINTS: CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.
  • Page 5 IN–5 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect.
  • Page 6 IN–6 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component illustrations by the ”*”...
  • Page 7 IN–7 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN–9). (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety.
  • Page 8 IN–8 INTRODUCTION – PRECAUTION PRECAUTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1.
  • Page 9 IN–9 INTRODUCTION – VEHICLE LIFT AND SUPPORT LOCATIONS VEHICLE LIFT AND SUPPORT LOCATIONS...
  • Page 10 IN–10 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Automatic Disconnecting Differential Automatic Locking Retractor Automatic Transmission Automatic Transmission Fluid Before Top Dead Center BTDC California Calif. Circuit Breaker Cab and Chassis C&C Dash Pot Double Rear Wheel Electronic Control Unit Emergency Locking Retractor Electronic Spark Advance...
  • Page 11 IN–11 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL Toyota Computer Controlled System TCCS Top Dead Center TEMP. Temperature Transmission Undersize Vacuum Control Valve Vacuum Switching Valve Vacuum Transmitting Valve With Without Two Wheel Drive Vehicles (4 x 2) Four Wheel Drive Vehicles (4 x 4)
  • Page 12 GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS M076–03 This glossary lists all SAE–J 1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. TOYOTA TERMS SAE ABBRE– SAE TERMS ( )––ABBREVIATIONS...
  • Page 13 IN–13 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Idle Speed Control (ISC) Idle Air Control Intake or Inlet Air Temperature Intake Air Temperature I AT Ignition Control Module Indirect injection Indirect Fuel Injection Inertia Fuel–Shutoff Idle Speed Control Knock Sensor...
  • Page 14 IN–14 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetal Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) Three–Way Catalytic Converter CCRO Three–Way + Oxidation Catalytic Converter TWC+OC + CCo Volume Air Flow...
  • Page 15 IN–15 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Class Class Mark Mark 4– Stud bolt Hexagon 5– head bolt 6– 8– 9– 10– 11– No mark Hexagon flange bolt w/ washer No mark hexagon bolt Hexagon head bolt...
  • Page 16 IN–16 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class 1 OT...
  • Page 17 MA–6 MAINTENANCE – MAINTENANCE OPERATIONS MAINTENANCE OPERATIONS ENGINE Cold Engine Operations 1. (3VZ–E ENGINE) REPLACE TIMING BELT (a) Remove the timing belt. (See pages EG–32) (b) Install the timing belt. (See pages EG–41) 2. INSPECT DRIVE BELTS (a) Visually check the belt for excessive wear, frayed cords etc.
  • Page 18 MA–7 MAINTENANCE – MAINTENANCE OPERATIONS HINT: ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After replacing the drive belt, check that it fits properly in the ribbed grooves, especially in the places difficult to see.
  • Page 19 MA–8 MAINTENANCE – MAINTENANCE OPERATIONS 22 R – E w/o Oil filter change 3.8 liters (4.0 US qts, 3.3 Imp. qts) w/ Oil filter change 4.3 liters (4.5 US qts, 3.8 Imp. qts) 3VZ–E w/o Oil filter change 2WD 4.0 liters (4.2 US qts, 3.5 Imp. qts) 4WD 4.2 liters (4.4 US qts, 3.7 Imp.
  • Page 20 MA–9 MAINTENANCE – MAINTENANCE OPERATIONS 8. INSPECT CHARCOAL CANISTER (a) Remove charcoal canister. HINT:Label hoses for correct installation. (b) Visually inspect canister case. (c) Check for clogged filter and stuck check valve. (1) Using low compressed air (4.71 kPa (48 gf/cm2, 0.68 psi), blow into the tank pipe and check that air flows without resistance from the other pipes.
  • Page 21 MA–10 MAINTENANCE – MAINTENANCE OPERATIONS 11. INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes, hangers and connections for severe corrosion, leaks or damage. 12. (3VZ–E ENGINE) ADJUST VALVE CLEARANCE (See page EG–18) 13. (FEDERAL AND CANADA) REPLACE OXYGEN SENSOR (a) Disconnect the oxygen sensor wiring connector.
  • Page 22 MA–11 MAINTENANCE – MAINTENANCE OPERATIONS Hot Engine Operations 14. (22R–E ENGINE) ADJUST VALVE CLEARANCE (a) Warm up the engine to normal operating temperature. (b) Stop the engine and remove the cylinder head cover. (c) Set No.1 cylinder to TDC/compression. Turn the crankshaft with a wrench to align the timing marks at TDC.
  • Page 23 MA–12 MAINTENANCE – MAINTENANCE OPERATIONS Connect all vacuum lines (i.e., EVAP, EGR system, etc.) Make sure all MFI system wiring connectors are fully connected Engine should be at normal operating tempera– ture Switch off accessories Set transmission in neutral (b) Connect a tachometer– to the engine Connect the tachometer–...
  • Page 24 MA–13 MAINTENANCE – MAINTENANCE OPERATIONS Wear Deformation Cracks Corrosion Leaks Bends Twists (b) Check all clamps for tightness and connections for leakage. . (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass thr–...
  • Page 25 MA–14 MAINTENANCE – MAINTENANCE OPERATIONS (c) Check the disc for runout. Minimum disc runout: Ex. C & C 0.09 mm (0.0035 in.) C & C 0.12 mm (0.0047 in.) 18. INSPECT REAR BRAKE LININGS AND DRUMS (See BR section) (a) Check the lining – to – drum contact condition and lining wear.
  • Page 26 MA–15 MAINTENANCE – MAINTENANCE OPERATIONS (b) Check the steering linkage for looseness or damage. Check that: Tie rod ends and relay rod ends do not have excessive play. Dust seals are not damaged. 20. INSPECT STEERING GEAR HOUSING Check the steering gear housing for oil leaks. If leakage is found, check for cause and repair.
  • Page 27 MA–16 MAINTENANCE – MAINTENANCE OPERATIONS 23. (2WD) CHECK OIL LEVEL IN MANUAL TRANSMISSION, AUTOMATIC TRANSMISSION AND DIFFERENTIAL Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
  • Page 28 MA–17 MAINTENANCE – MAINTENANCE OPERATIONS 24. (4WD) CHECK OIL LEVEL IN MANUAL TRANSMISSION, AUTOMATIC TRANSMISSION, TRANSFER AND DIFFERENTIAL Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
  • Page 29 Above –18 _ C (0_F) SAE 90 Below –18 _ C (0 _ F) SAE 80W – 90 or 80W A.D.D. Oil grade: Toyota ’GEAR OIL SUPER’ oil or hypoid gear oil API GL–5 Viscosity: SAE 75W–90 25. REPLACE MANUAL TRANSMISSION. TRANSFER (4...
  • Page 30 MA–19 MAINTENANCE – MAINTENANCE OPERATIONS Oil capacity: Transmission – W55 2.6 liters (2.7 US qts, 2.3 Imp. qts) R150 3.0 liters (3.2 US qts, 2.6 Imp. qts) G58 3.9 liters (4.1 US qts, 3.4 Imp. qts) W56 2.9 liters (3.1 US qts, 2.5 Imp. qts) RI 50F 3.0 liters (3.2 US qts, 2.6 Imp.
  • Page 31 MA–20 MAINTENANCE – MAINTENANCE OPERATIONS Differential – 7.5 in. 1.35 liters (1.4 US qts, 1.2 Imp. qts) 8.0 in. 1.8 liters (1.9 US qts, 1.6 Imp. qts) Front Standard differential 1.6 liters (1.7 US qts, 1.4 Imp. qts) A.D.D. 1.86 liters (2.0 US qts, 1.6 Imp. qts) Rear 2.2 liters 2.3 US qts, 1.9 Imp.
  • Page 32 MA–21 MAINTENANCE – MAINTENANCE OPERATIONS (g) Check that the fluid level is in the ”HOT” range at the normal operating temperature (70 – 80 C or 158 – 176 *F) and add as necessary. NOTICE: Do not overfill. 27. REPACK FRONT WHEEL BEARINGS AND THRUST BUSH (a) Change the front wheel bearing grease.
  • Page 33 MA–22 MAINTENANCE – MAINTENANCE OPERATIONS 29. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts: Seat mounting bolts Torque: 37 N–m (375 kgf–cm, 27 ft–lbf) Strut bar bracket–to –frame mounting bolts (2 Torque: 52 N–m (530 kgf–cm, 38 ft–Ibf) Leaf spring U –...
  • Page 34 MA–23 MAINTENANCE – MAINTENANCE OPERATIONS Suspension system Fuel tank mounts Engine mounts, etc. 30. FINAL INSPECTION (a) Check operation of body parts: Hood Auxiliary catch operates properly Hood locks securely when closed Doors Door locks operate properly Doors close properly Seats Seat adjusts easily and locks securely in any positions...
  • Page 35 EG1–1 ENGINE – 22R–E ENGINE...
  • Page 36 EG1–2 ENGINE – ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 22R–E engine is an in–line 4 cylinder 2.4 liter OHC 8 valve engine.
  • Page 37 EG1–3 ENGINE – ENGINE MECHANICAL The 22R–E engine is in–line 4–cylinder engine with the cylinders numbered 1–2–3–4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearing are made of kelmet. The crankshaft is integrated with 4 weights which are cast with it for balance. Oil holes are made in the center of the crankshaft to supply oil to the connecting rods, bearing, pistons and other components.
  • Page 38 EG1–4 ENGINE – ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 09201–41020 Valve Stem Oil Seal Replacer 09201 –60011 Valve Guide Bushing Remover & Replacer 09202–43013 Valve Spring Compressor 09213–31021 Crankshaft Pulley Puller 09213–36020 Timing Gear Remover 09213–60017 Crankshaft Pulley & Gear Puller (09213–00020) Body With .Bolt (00213–00030) Handle (09213–00060) Bolt Set...
  • Page 39 EG1–5 ENGINE – ENGINE MECHANICAL 09606–35014 Axle Hub & Drive Pinion Bearing Tool Set (09608–06040) Front Hub Inner Bearing Cone Replacer Crankshaft pulley 09330–00021 Companion Flange Holding Tool 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS For suspension engine 09090–04010 Engine Sling Device 09200–00010 Engine Adjust Kit Plug for the vacuum hose, fuel hose etc.
  • Page 40 EG1–6 ENGINE – ENGINE MECHANICAL Dye penetrant Engine tune–up tester Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers SSM (SERVICE SPECIAL MATERIALS) 08826–00080 Seal packing or equivalent...
  • Page 41 EG1–7 ENGINE – ENGINE MECHANICAL TROUBLESHOOTING When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still cannot be confirmed in the basic inspection, then proceed to this step and perform troubleshooting to the numbers in the order given in the table below. See page Suspect area Symptom...
  • Page 42 EG1–8 ENGINE – ENGINE MECHANICAL See page Suspect area Symptom Engine does not crank Starter runs – engine does not crank No initial combustion No complete combustion Engine cranks slowly Under normal condition Cold engine Hot engine Incorrect first idle High engine idle speed Low engine idle speed Rough idling...
  • Page 43 Thermostat EG1–228 Drive Belt section Engine Coolant Temp. Sender Gauge section Oil Pressure Switch section Generator section Cylinder Block EG1–55 EFI Main EG1–206 Relay Circuit Opening EG1–207 Relay Fuel Cut System EG1–219 Fuel Pressure EG1–210 Control System EG1–215 Fuel Quality Fuel Leakage Coolant Leakage EG1–225...
  • Page 44: Air Filter Inspection

    EG1–10 ENGINE – ENGINE MECHANICAL TUNE–UP ENGINE COOLANT INSPECTION (See steps 1 and 2 on page EG1–225) ENGINE OIL INSPECTION (See steps 1 and 2 on page EG1–235) AIR FILTER INSPECTION (See step 4 on page MA–7) BATTERY INSPECTION (See CM section) HIGH–TENSION CORD INSPECTION (See page IG–6) SPARK PLUGS INSPECTION...
  • Page 45 EG1–11 ENGINE – ENGINE MECHANICAL HINT: Adjust idle mixture as necessary.
  • Page 46 EG1–12 ENGINE – ENGINE MECHANICAL IDLE AND OR 2500 RPM CO HC CHECK HINT: This check method is used only to determine whether or not the idle and/or 2,500 rpm CO/HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air intake system connected (d) All accessories switched OFF...
  • Page 47 EG1–13 ENGINE – ENGINE MECHANICAL TROUBLESHOOTING If the HC/CO concentration does not comply with regulations, perform troubleshooting in the order given below. 1. Check oxygen sensor operation (See page EG1–212) 2. See the table below for possible cause, and then inspect and correct the applicable causes if neces–...
  • Page 48 EG1–14 ENGINE – ENGINE MECHANICAL COMPRESSION CHECK HINT: If there is lack of power, excessive oil con– sumption or poor fuel mileage, measure the cylinder compression pressure. 1. WARM UP ENGINE 2. REMOVE SPARK PLUGS 3. DISCONNECT DISTRIBUTOR CONNECTOR 4. DISCONNECT COLD START INJECTOR CONNEC– 5.