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Table Of Contents - Toyota 22R-E Service Manual

Table Of Contents

Table of Contents

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Table of Contents

How To Use This Manual2

General Description2

Repair Procedures2

The Procedures Are Presented In A Step–By–Step Format3

Check Piston Stroke Of Overdrive Brake3

Specifications3

Cautions, Notices, Hints4

Identification Information Vehicle Identification Number4

Engine Serial Number4

General Repair Instructions5

Medium Current Fuse And High Current Fuse Equal Amperage Rating6

Observe The Following Precautions To Avoid Damage To The Parts7

For Vehicles Equipped With A Catalytic Converter8

For Vehicles With An Audio System With Built–In Anti–Theft System8

Vehicle Lift And Support Locations9

Abbreviations Used In This Manual10

Glossary Of Sae And Toyota Terms12

Standard Bolt Torque Specifications15

How To Determine Bolt Strength15

Specified Torque For Standard Bolts16

Maintenance Operations Engine17

Cold Engine Operations17

3Vz–E Engine17

Inspect Drive Belts17

Replace Spark Plugs18

Inspect Air Filter18

Replace Air Filter18

Replace Engine Oil And Oil Filter18

Replace Engine Coolant19

Inspect Charcoal Canister20

Replace Gasket In Fuel Tank Cap20

Inspect Fuel Lines And Connections20

Inspect Exhaust Pipes And Mountings21

Adjust Valve Clearance21

Replace Oxygen Sensor (Federal And Canada)21

Hot Engine Operations22

Adjust Valve Clearance (22R-E Engine)22

Adjust Idle Speed22

Inspect Brake Line Pipes And Hoses23

Inspect Brake Line Pipes And Hoses Hint23

Inspect Front Brake Pads And Discs24

Check The Thickness Of The Disc Brake Pad And Check For Irregular Wear24

Check The Disc For Wear24

Minimum Disc Thickness24

Inspect Rear Brake Linings And Drums25

Inspect Steering Linkage25

Inspect Steering Gear Housing26

Inspect Drive Shaft Boots (4Wd)26

Inspect Ball Joints And Dust Covers26

Check Oil Level In Manual Transmission, Automatic Transmission And Differential (2Wd)27

Check Oil Level In Manual Transmission, Automatic Transmission, Transfer And Differential (4Wd)28

Replace Manual Transmission. Transfer (4Wd) And Differential Oil29

Replace Automatic Transmission Fluid31

Repack Front Wheel Bearings And Thrust Bush32

Lubricate Propeller Shaft (4Wd)32

Tighten Bolts And Nuts On Chassis And Body33

Final Inspection34

22R–E Engine35

Engine Mechanical36

Sst (Special Service Tools)38

Recommended Tools39

Ssm (Service Special Materials)40

Troubleshooting41

Air Filter Inspection44

Idle And Or 2500 Rpm Co Hc Check46

Compression Check48

Measure Cylinder Compression Pressure48

Install Spark Plugs48

Cylinder Head49

Preparation For Removal50

Disconnect Accelerator Cable50

Disconnect Throttle Cable (A/T)50

Disconnect Following Parts50

Disconnect Following Wires51

Remove Chamber With Throttle Body51

Disconnect Fuel Hose From Delivery Pipe51

Remove Ps Belt (W/Ps)51

Disconnect Ps Bracket From Cylinder Head52

Cylinder Head Removal52

Remove Cam Sprocket Bolt52

Remove Distributor Drive Gear And Camshaft Thrust Plate52

Remove Cam Sprocket53

Remove Chary Cover Bolt53

Remove Cylinder Head Bolts53

Cylinder Head Disassembly53

Remove Intake Manifold With Delivery Pipe And Injectors54

Remove Egr Valve54

Remove Exhaust Manifold With No. 2 Secondary Air Injection Manifold54

Remove Two Engine Hangers And Ground Strap54

Measure Camshaft Thrust Clearance55

Remove Valves55

Inspection, Cleaning And Repair Of Cylinder Head Components55

Clean Top Of Pistons And Top Of Cylinder Block55

Clean Combustion Chambers56

Clean Valve Guide Bushings56

Clean Cylinder Head56

Inspect Cylinder Head For Flatness56

Inspect Cylinder Head For Cracks57

Inspect Valve Stems And Guide Bushings57

If Necessary, Replace Valve Guide Bushings58

Bore Intake And Exhaust58

Inspect And Grind Valves59

Inspect And Clean Valve Seats60

Inspect Valve Springs61

Inspect Camshaft And Bearing Caps62

Inspect Camshaft Oil Clearance62

Inspect Rocker Arms63

Inspect Intake, Exhaust Manifolds And Air Intake Chamber64

Cylinder Head Assembly64

Install Valves65

Install Camshaft65

Install Cylinder Head Rear Cover65

Install Rh Engine Hanger65

Install Plug Pate66

Install Exhaust Manifold66

Install Egr Valve66

Install Intake Manifold67

Install No. 1 Secondary Air Injection Manifold67

Cylinder Head Installation67

Apply Seal Packing To Cylinder Block67

Install Rocker Arm Assembly68

Install Chain Cover Bolt68

Install Distributor Drive Gear And Camshaft Thrust Plate68

Install Half–Circular Plugs69

Install Head Cover70

Post Installation70

Connect Ps Bracket To Cylinder Head (W/Ps)70

Connect By–Pass Hose To Intake Manifold70

Connect Fuel Return Hose71

Install Chamber With Throttle Body71

Connect Following Wires71

Connect Following Parts71

Connect Throttle Cable (A/T)72

Connect Exhaust Pipe To Exhaust Manifold72

Timing Chain Components73

Preparation Of Removal73

Remove Oil Pan73

Timing Chain Removal74

Remove Fluid Coupling With Fan And Water Pump Pulley74

Remove Crankshaft Pulley74

Remove No. 1 Water By–Pass Pipe75

Remove Fan Belt Adjusting Bar75

Disconnect Heater Water Outlet Pipe75

Remove Chain Cover Assembly75

Remove Pump Drive Spline And Crankshaft Sprocket76

Components Inspection76

Measure Chain And Sprocket Wear76

Measure Chain Tensioner & Dampers76

Timing Chain Installation77

Install Crankshaft Sprocket And Chain77

Place Chain On Camshaft Sprocket77

Install Timing Chain Cover Assembly77

Install Heater Water Outlet Pipe78

Install No.1 Water By–Pass Pipe78

Install Crankshaft Pulley78

Install Water Pump Pulley And Fluid Coupling With Fan78

Engine Removal81

Disconnect Following Wires And Connectors81

Disconnect Following Hoses81

Disconnect Following Cable81

Remove Ps Pump From Bracket82

Remove Compressor From Bracket82

Disconnect Transfer Shift Linkage82

Remove Front Exhaust Pipe83

Remove Clutch Release Cylinder With Bracket From Transmission (M/T)83

Remove No.1 Front Floor Heat Insulator And Brake Tube Heat Insulator (4Wd)83

Remove Engine Rear Mounting And Bracket (2Wd)83

Remove No.2 Frame Crossmember From Side Frame (4Wd)84

Remove Engine With Transmission For Vehicle84

Remove Transmission From Engine (A/T)84

Cylinder Block Disassembly84

Remove Oil Strainer85

Remove Rear Oil Seal Retainer85

Measure Connecting Rod Thrust Clearance85

Measure Connecting Rod Oil Clearance85

Push Out Piston And Connecting Rod Assembly87

Measure Crankshaft Thrust Clearance87

Measure Crankshaft Oil Clearance88

Remove Crankshaft89

Cylinder Block Inspection89

Remove Gasket Material89

Clean Cylinder Block89

Inspect Cylinder Block Warpage90

Measure Cylinder Bore90

Remove Cylinder Ridge91

Disassembly Of Piston And Connecting Rod Assembly91

Check Fit Between Piston And Pin91

Remove Piston Rings91

Disconnect Connecting Rod From Piston92

Inspection Of Piston And Connecting Rod92

Inspect Piston Diameter And Oil Clearance93

Measure Clearance Between Piston Groove And Piston Ring94

Piston Diameter94

Measure Ring End Gap95

Inspect Piston Pin Fit95

Inspect Connecting Rods95

Rod Bushing Replacement96

Remove Rod Bushing96

Install New Rod Bushing96

Hone New Bushing And Check Pin Fit In Connecting Rod97

Crankshaft Inspection And Repair97

Measure Crankshaft For Runout97

Inspect Main Journals And Crank Pins97

Oil Seals Replacement98

If Timing Chain Cover Is Removed From Cylinder Block (Replacement Of Front Oil Seal)98

If Timing Chain Cover Is Installed On Cylinder Block (Replacement Of Front Oil Seal)98

If Rear Oil Seal Retainer Is Removed From Cylinder Block (Replacement Of Rear Oil Seal)99

If Rear Oil Seal Retainer Is Installed On Cylinder Block (Replacement Of Rear Oil Seal)99

Cylinders Boring100

Select Oversized Piston100

Calculate Dimension To Bore Cylinders100

Piston And Connecting Rod Assembly100

Place Rings On Piston101

Install Bearings101

Installation Of Crankshaft, Piston And Connecting Rod Assembly102

Install Main Bearings102

Install Upper Thrust Washers102

Install Main Bearing Caps With Lower Thrust Washers102

Install Piston And Connecting Rod Assembly103

Install Connecting Rod Caps103

Cylinder Block Assembly104

Install Rear Oil Seal Retainer104

Install Oil Strainer104

Install Flywheel Or Drive Plate104

Engine Installation105

Place Engine With Transmission In Vehicle105

Install Engine Mounting To Frame Bracket105

Install Engine Rear Mounting And Bracket (2Wd)105

Install No.2 Frame Crossmember106

Install Brake Tube Heat Insulator And No.1 Front Floor Heat Insulator106

Install Clutch Release Cylinder With Bracket To Transmission106

Install Exhaust Pipe106

Connect Transfer Shift Linkage (4Wd A/T)107

Install Shift Lever (M/T)107

Install Compressor To Bracket (With A/C)107

Install Ps Pump With Ps Pump Bracket (W/Ps)107

Connect Following Hoses108

Connect Following Wires And Connectors108

Install Ps Pump And Belt108

Exhaust System Components110

Service Specifications111

Service Data111

Torque Specifications114

Emission Control Systems115

System Purpose115

Layout And Schematic Drawing (Federal And Canada)116

Layout And Schematic Drawing (Calif.)117

Positive Crankcase Ventilation (Pcv) System118

Pcv Valve Inspection119

Blow Air From Cylinder Head Side119

Blow Air From Intake Manifold Side119

Pcv Hoses And Connections Inspection119

Evaporative Emission (Evap) Control System120

Inspection Of Fuel Vapor Lines, Fuel Tank And Tank Cap120

Visually Inspect Lines And Connections120

Visually Inspect Fuel Tank120

Visually Inspect Fuel Tank Cap121

Charcoal Canister Inspection121

Check For Clogged Filter And Stuck Check Valve121

Clean Filter In Canister121

Exhaust Gas Recirculation (Egr) System (Federal And Canada)122

Egr System Inspection123

Check And Clean Filter In Egr Vacuum Modulator123

Check Tvv With Cold Engine123

Check Tvv And Egr Vacuum Modulator With Hot Engine123

Check Egr Valve124

Tvv Inspection124

Check Tvv By Blowing Air Into Pipe124

Check Egr Vacuum Modulator Operation124

Egr Valve Inspection125

Exhaust Gas Recirculation (Egr) System (Calif.)126

Check Seating Of Egr Valve127

Check Vsv With A Cold Engine127

Check Vsv And Egr Vacuum Modulator With Hot Engine127

Egr Vacuum Modulator Inspection128

Vsv Inspection128

Check Vacuum Circuit Continuity In The Vsv By Blowing Air Into Pipe128

Check For Short Circuit129

Check For Open Circuit129

Pulsed Secondary Air Injection (Pair) System130

Pair System Inspection131

Pair Valve Inspection131

Check Pair System With Cold Engine131

Check Pair System With Warm Engine131

Check Valve Inspection132

Check Vacuum Circuit Continuity In Vsv By Blowing Air Into Pipe132

Check For Short & Open Circuit132

Three–Way Catalytic Converter (Twc) System133

Exhaust Pipe Assembly Inspection133

Catalytic Converter Inspection133

Heat Insulator Inspection134

Catalytic Converter Replacement134

Remove Converter134

Install Converter134

Mfi System Description135

Electronic Control System136

Maintenance Precautions139

Precaution When Connecting Gauge139

In Event Of Engine Misfire, The Following Precautions Should Be Taken139

Precautions When Handling Oxygen Sensor139

If Vehicle Equipped With A Mobile Radio System (Ham, Cb, Etc.)140

Air Induction System140

Union Bolt Type142

Flare Nut Type142

Diagnosis System Description144

Malfunction Indicator Lamp144

Diagnostic Trouble Codes Output144

Normal System Operation145

Malfunction Code Indication145

Diagnostic Trouble Codes Cancellation146

2 Trip Detection Logic146

Diagnosis Indication147

Diagnostic Trouble Codes148

Diagnostic Trouble Code Detection Driving Pattern150

Main Oxygen Sensor Circuit150

Air–Fuel Ratio Lean Malfunction151

Air–Fuel Ratio Lean Malfunction (California)152

Air–Fuel Ratio Rich Malfunction (California)152

Sub–Oxygen Sensor Circuit153

Egr System Malfunction154

Inspection Of Diagnosis Circuit155

Troubleshooting With Volt Ohmmeter156

Fuses, H–Fuses And Fusible Link Location156

System Check Procedure (2Wd)157

Terminals Of Ecm (2Wd)157

Voltage At Ecm Wiring Connectors (2Wd)158

There Is No Voltage Between Ecm Terminals Batt And E1159

+B (+B1 )–E1160

There Is No Voltage Between Ecm Terminals + B (+B1) And E1 (Ig Sw On)160

Idl–E2 (E21)161

There Is No Voltage Between Ecm Terminals Idl And E2 (E21) (Ig Sw On) (Throttle Valve Open)161

Vcc–E2 (E21)162

Vta–E2 (E21)162

Here Is No Voltage Between Ecm Terminals Vcc And E2 (E21) (Ig Sw On)162

There Is No Voltage Between Ecm Terminals Vta And E2 (E21 ) (Ig Sw On)162

Vc–E2 (E21)163

There Is No Voltage Between Ecm Terminals Vc And E2 (E21) (Ig Sw On)163

Vs–E2 (E21)164

Tha–E2 (E21)164

There Is No Voltage Between Ecm Terminals Vs And E2 (E21) (Ig Sw On)164

There Is No Voltage Between Ecm Terminals Tha And E2 (E21) (Ig Sw On)164

There Is No Voltage Between Ecm Terminals Thw And E2 (E21) (Ig Sw On)165

There Is No Voltage Between Ecm Terminals Sta And E1 (Ig Sw Start)166

There Is No Voltage Between Ecm Terminals No. 10 And/Or No. 20 And E01, And/Or E02 (Ig Sw On)167

There Is No Voltage Between Ecm Terminals Igt And E1 (Idling)168

There Is No Voltage Between Ecm Terminals W And E1 (Idling)169

There Is No Voltage Between Ecm Terminals Stj And E1 (Ig Sw Start)170

There Is No Voltage Between Ecm Terminals Stp And E1171

California Vehicles Only172

There Is No Voltage Between Ecm Terminals Vf And E1172

There Is No Voltage Between Ecm Terminals Thg And E2 (E21) (Engine Running At 2,000 Rpm)174

Mfi System Check Procedure (4Wd M/T)175

Terminals Of Ecm Kwd M/T175

Voltage At Ecm Wiring Connectors (4Wd M/T)176

There Is No Voltage Between Ecm Terminals + B (+ B1) And E1 (Ig Sw On)178

There Is No Voltage Between Ecm Terminals Idl And E2 (E21) (Ig Sw On)179

There Is No Voltage Between Ecm Terminals Vcc And E2 (E21) (Ig Sw On)180

There Is No Specified Voltage Between Ecm Terminals Vta And E2 (E21) (Ig Sw On)180

There Is No Voltage Between Ecm Terminals No. 10 And/Or No. 20 And E01, And/Or E02–(Ig Sw On)185

There Is No Voltage Between Ecm Terminals Stj And E1 (Ig Sw On)188

Mfi System Check Procedure (4Wd A/T)193

Terminals Of Ecm (4Wd A/T)193

Voltage At Ecm Connectors (4Wd A/T)194

+B (B+)–E1196

There Is No Voltage Between Ecm Terminals +B (+B1) And E1 (Ig Sw On)196

Throttle Position Sensor197

There Is No Voltage Between Ecm Terminals Vcc And E2 (Ig Sw On)198

There Is No Voltage Between Ecm Terminals Vta And E2 (E21) (Ig Sw On)198

There Is No Voltage Between Ecm Terminals W And E1 (Ldling)205

On–Vehicle Inspection212

Check Fuel Pump Operation212

Fuel Pump Removal214

Drain Fuel From Fuel Tank214

Remove Fuel Pump Bracket214

Fuel Pump Installation215

Remove Fuel Pump Filter215

Install Fuel Pump Filter215

Measure Resistance Of Cold Start Injector217

Cold Start Injector Removal217

Remove Cold Start Injector217

Cold Start Injector Inspection218

Cold Start Injector Installation219

Fuel Pressure Regulator220

Pressure Regulator Removal & Installation220

Check Injector Operation221

Injectors Removal & Inspection222

Remove Delivery Pipe With Injectors222

Test Injection Of Injector222

Check Leakage223

Install Injectors Into Delivery Pipe224

Install Delivery Pipe With Injectors224

Connect Fuel Hose To Delivery Pipe225

Connect Wires225

Fuel Tank And Line Components226

Fuel Lines And Connections Inspection227

Measure Resistance Of Volume Air Flow Meter228

Vaf Meter Removal, Inspection And Installation229

Remove Air Cleaner Cap With Volume Air Flow Meter229

Remove Volume Air Flow Meter229

Measure Resistance Of Vaf Meter229

Inspect Throttle Body231

Inspect Throttle Position Sensor231

Inspect Dash Pot (Dp) (M/T)232

Inspect Throttle Opener (A/T)233

Throttle Body Removal234

Disconnect Throttle Sensor Connector234

Remove Throttle Body234

Clean Throttle Body Before Inspection235

Check Throttle Valve235

If Necessary, Adjust Throttle Position Sensor235

Throttle Body Disassembly, Assembly And Installation236

Remove Throttle Position Sensor236

Remove Auxiliary Air Valve236

Install Throttle Position Sensor236

Check Operation Of Auxiliary Air Valve238

Electronic Parts Location239

Efi Main Relay Inspection240

Inspect Relay Continuity240

Inspect Relay Operation240

Circuit Opening Relay Inspection241

Cold Start Injector Time Switch242

Start Injector Time Switch Inspection242

Measure Resistance Of Start Injector Time Switch242

Engine Coolant Temperature (Ect) Sensor Inspection243

Fuel Pressure Control System244

Oxygen Sensor Inspection246

Inspect Heater Resistance Of Oxygen Sensor246

Inspection Of Feedback Voltage (Vf1)246

Egr Gas Temp. Sensor Inspection248

Engine Control Module (Ecm)249

Inspect Voltage Of Ecm249

Voltage At Ecm Wiring Connectors250

Inspect Resistance Of Ecm251

Resistance Of Ecm Wiring Connectors252

Fuel Cut Rpm Inspection253

Warm Up Engine253

Connect Tachometer253

Inspect Fuel Cut Operation253

Cooling System Description257

Radiator Cap257

Coolant Check And Replacement259

Check Engine Coolant Level In Reservoir Tank259

Check Engine Coolant Quality259

Water Pump Components260

Water Pump Removal260

Water Pump Inspection And Installation261

Remove Water Pump261

Inspect Water Pump Bearing261

Inspect Fluid Coupling261

Thermostat Removal, Inspection And Installation262

Remove Thermostat262

Place Thermostat In Intake Manifold262

Radiator Cleaning263

Radiator Inspection263

Check Radiator Cap263

Radiator Removal264

Check Cooling System For Leaks264

Lubrication System Description266

Oil Pressure Regulator (Relief Valve)267

Oil Pressure Check269

Check Oil Quality And Level269

Measure Oil Pressure269

Oil And Filter Replacement270

Drain Engine Oil270

Replace Oil Filter270

Fill With Engine Oil270

Recheck Engine Oil Level271

Oil Capacity271

Oil Pump Components272

Oil Pump Removal272

Oil Pump Disassembly273

Oil Pump Inspection273

Remove Oil Pump Assembly273

Remove Oil Pump Drive Spline273

Pressure Regulator Inspection274

Front Oil Seal Replacement274

Measure Tip Clearance274

Measure Side Clearance274

Oil Pump Assembly And Installation275

Install Oil Seal275

Install Oil Pump Drive Spline And O–Ring275

Install Oil Pump275

Engine Mechanical Description279

Check Engine Coolant Level At Reservoir Tank289

Engine Oil Inspection290

Check Oil Quality290

Check Engine Oil Level290

Battery Inspection291

Check Battery Specific Gravity And Electrolyte Level291

Check Hydrometer291

Check Battery Terminals, Fusible Link And Fuses291

High–Tension Cords Inspection292

Disconnect High–Tension Cords From Spark Plugs292

Inspect High–Tension Cord Terminals292

Inspect High–Tension Cord Resistance292

Spark Plugs Inspection293

Clean Spark Plugs293

Adjust Electrode Gap293

Reconnect High–Tension Cords To Sparkplugs294

Generator Drive Belt Inspection294

Valve Clearance Inspection And Adjustment295

Remove Spark Plugs295

Remove Engine Wire295

Set No.1 Cylinder To Tdc/Compression296

Inspect Valve Clearance296

Remove The Adjusting Shim297

Determine The Replacement Adjusting Shim Size Byfollowing–The Formula Or Chart298

Adjusting Shim Selection Chart (Intake)299

New Shim Thickness299

Intake Valve Clearance (Cold)299

Adjusting Shim Selection Chart (Exhaust)300

Instill Cylinder Head Covers301

Install Engine Wire301

Install Air Intake Chamber301

Ignition Timing Inspection And Adjustment302

Connect Tachometer And Timing Light To Engine302

Adjust Ignition Timing302

Further Check Ignition Timing303

Idle Speed Inspection And Adjustment304

Initial Conditions304

Insert Co/Hc Meter Testing Probe Into Tailpipe At Least 40 Cm (1.3 Ft) During Idling305

Immediately Check Co/Hc Concentration At Idle And/Or 2,500 Rpm305

Check Cylinder Compression Pressure307

Reinstall Spark Plugs308

Timing Belt Components309

Timing Belt Removal309

Remove Engine Under Cover309

Remove Radiator309

Disconnect No.2 And No.3 Air Hoses From Air Pipe310

Remove Cooling Fan310

Remove Water Outlet311

Remove No.2 Timing Belt Cover311

If Re–Using Timing Belt, Check Installation Marks On Timing Belt311

Set No.1 Cylinder At Tdc/Compression312

Remove Timing Belt Tensioner312

Remove Fan Bracket312

Disconnect Timing Belt From Camshaft Timing Pulleys312

Remove Camshaft Timing Pulleys313

Remove No.1 Timing Belt Cover Hint314

Remove Timing Belt Guide314

Remove No.1 Idler Pulley315

Remove Crankshaft Timing Pulley315

Timing Belt Components Inspection315

Inspect Timing Belt315

Inspect Idler Pulleys316

Inspect Timing Belt Tensioner317

Install Crankshaft Timing Pulley318

Install No.1 Idler Pulley318

Temporarily Install Timing Belt318

Install Timing Belt Guide318

Timing Belt Installation318

Install No.1 Timing Belt Cover319

Install Lh Camshaft Timing Pulley319

Crankshaft Position320

Rh Camshaft Pulley Position320

Lh Camshaft Pulley Position320

Connect Timing Belt To Lh Camshaft Timing Pulley320

Install Rh Camshaft Timing Pulley And Timing Belt321

Install Fan Bracket322

Set Timing Belt Tensioner322

Install Timing Belt Tensioner322

Check Valve Timing323

Install No.2 Timing Belt Cover323

Install Water Outlet324

Install Generator Drive Belt324

Install Cooling Fan324

Install A/C Drive Belt324

Install Ps Pump Pulley And Drive Belt325

Install Radiator325

Recheck Engine Coolant Level325

Cylinder Head Components326

Cylinder Heads Removal328

Disconnect Clutch Release Cylinder Hose (M/T Only)328

Remove A/C Drive Belt328

Remove Generator Drive Belt329

Disconnect Strap, Wires, Connectors329

Disconnect Heater Hoses329

Remove Timing Belt330

Remove Air Intake Chamber330

Remove No.2 And No.3 Fuel Pipes333

Remove No.4 Timing Belt Cover333

Remove No.2 Idler Pulley333

Remove No.3 Timing Belt Cover334

Remove Delivery Pipes And Injectors334

Remove Water By–Pass Outlet334

Remove Intake Manifold334

Remove Exhaust Crossover Pipe335

Disconnect Water By–Pass Pipe From Rh Cylinder Head335

Remove No.2 Engine Hanger From Lh Cylinder Head335

Remove Cylinder Head Covers335

Remove Camshafts336

Remove Cylinder Heads336

Remove Generator Bracket337

Remove Exhaust Manifold From Rh Cylinder Head337

Remove Exhaust Manifold From Lh Cylinder Head338

Cylinder Heads Disassembly338

Remove Camshaft Housing Plugs338

Remove Valve Lifters And Shims338

Cylinder Head Components Inspection And Repair340

Clean Top Surfaces Of Pistons And Cylinder Block340

Inspect Cylinder Head341

Inspect Camshafts And Bearings347

Inspect Valve Lifters And Lifter Bores348

Inspect Air Intake Chamber349

Inspect Intake Manifold349

Cylinder Head Side349

Air Intake Chamber Side349

Inspect Exhaust Manifold350

Cylinder Heads Assembly351

Install Valve Lifters And Shims352

Install Camshaft Housing Plugs352

Cylinder Heads Installation353

Install Rh Exhaust Manifold To Rh & Lh Cylinder Head353

Install Generator Bracket353

Install Cylinder Heads353

Install Cylinder Head (12 Pointed Head) Bolts354

Install Cylinder Head (6 Pointed Head) Bolts355

Install Camshafts355

Check And Adjust Valve Clearance356

Install Cylinder Head Covers357

Install Water By–Pass Pipe To Rh Cylinder Head357

Install No.2 Engine Hanger358

Install Oil Dipstick Guide And Dipstick358

Install Exhaust Crossover Pipe358

Install Water By–Pass Outlet358

Install Injectors And Delivery Pipe359

Install Pair Reed Valve And No.1 Injection Manifold360

Install Vsv Bracket And Vsv To Pair Reed Valve360

Install No.3 Timing Belt Cover360

Install No.2 Idler Pulley360

Install No.4 Timing Belt Cover361

Install No.2 And No.3 Fuel Pipes361

Connect High–Tension Cords To Spark Plugs364

Install Front Exhaust Pipe364

Connect Fuel Inlet And Outlet Hoses364

Connect Heater Hoses364

Connect Cables, Hoses, Connectors, Strap And Wires365

Connect Clutch Release Cylinder Hose (M/T Only)366

Install Air Cleaner And Hose366

Perform Road Test366

Cylinder Block Components367

Disconnect Clutch Release Cylinder Hose368

Remove Ps Drive Belt And Pump Pulley368

Disconnect Strap, Wires369

Remove Engine Rear Mounting Bracket370

Remove No.2 Frame Crossmember371

Remove Engine And Transmission Assembly From Vehicle371

Preparation For Disassembly372

Remove Flywheel Or Drive Plate372

Remove Rear End Plate372

Remove Rh And Lh Engine Mounting Brackets372

Remove No.1 Water By–Pass Pipe373

Remove Oil Pressure Sender Gauge373

Remove Knock Sensor373

Remove Oil Cooler And Bracket Assembly (2Wd)373

Remove Oil Cooler (4Wd)374

Remove Oil Filter Union374

Remove Oil Pan Baffle Plate375

Remove Oil Pump375

Check Connecting Rod Thrust Clearance376

Remove Connecting Rod Caps And Check Oil Clearance376

Remove Piston And Connecting Rod Assemblies378

Check Crankshaft Thrust Clearance379

Remove Main Bearing Cap And Check Oil Clearance379

Inspect Top Surface Of Cylinder Block For Flatness383

Inspect Cylinder For Vertical Scratches383

Inspect Cylinder Bore Diameter383

Piston And Connecting Rod Disassembly384

Check Fit Between Piston And Piston Pin384

Piston And Connecting Rod Inspection385

Inspect Piston Oil Clearance386

Inspect Piston Ring Groove Clearance387

Inspect Piston Ring End Gap387

Inspect Connecting Rod Alignment388

Inspect Connecting Rod Bolts388

Cylinder Boring389

Keep Oversized Pistons389

Calculate Amount To Bore Cylinders389

Bore And Hone Cylinder To Calculated Dimensions389

Inspect Crankshaft For Runout390

If Necessary, Grind And Hone Main Journals And/Or Crank Pins390

Crankshaft Oil Seals Replacement391

Replace Crankshaft Front Oil Seal391

If Oil Pump Is Removed From Cylinder Block391

If Oil Pump Is Installed To The Cylinder Block391

Replace Crankshaft Rear Oil Seal392

If Rear Oil Seal Retainer Is Removed From Cylinder Block392

If Rear Oil Seal Retainer Is Installed To Cylinder Block392

Pistons And Connecting Rods Assembly393

Assemble Piston And Connecting Rod393

Install Piston Rings393

Install Main Bearing Cap And Lower Thrust Washers395

Place Main Bearing Cap And Lower Thrust Washers On Cylinder Block395

Install Main Bearing Cap Bolts395

Install Piston And Connecting Rod Assemblies396

Place Connecting Rod Cap On Connecting Rod397

Post Assembly399

Install Oil Pan Baffle Plate400

Install Oil Pan401

Install Oil Filter Union401

Install Knock Sensor402

Install Oil Cooler And Bracket Assembly (2Wd)402

Install Oil Cooler403

Install Engine Coolant Drain Plugs403

Install Lh And Rh Engine Mounting Brackets403

Install Oil Filter403

Install Oil Pressure Sender Gauge404

Install Generator Adjusting Bar404

Install Water Pump404

Install Thermostat And Water Inlet405

Install No.1 Water By-Pass Pipe405

Install Rear End Plate406

Insert Engine And Transmission Assembly In Vehicle407

Install Engine Rear Mounting Bracket (2Wd)407

Install No.2 Frame Crossmember (4Wd)407

Tighten Rh And Lh Engine Mounting Insulator Bolts408

Connect Clutch Release Cylinder Hose408

Install A/C Compressor408

Connect Strap, Wires, Connectors, Hoses And Cables409

Exhaust System411

Layout And Schematic Drawing419

Evaporative (Evap) Emission Control System422

Fuel Vapor Lines, Fuel Tank And Tank Cap Inspection423

Exhaust Gas Recirculation (Egr) System425

Check Vsv With Cold Engine426

Check Vsv And Egr Vacuum Modulator With Warm Engine426

Check Pair System With Cold & Warm Engine430

Pair Reed Valve Inspection430

Check Reed Valve By Blowing Air Into Pipe430

Check Valve By Blowing Air Into Each Pipe431

Check For Dents Or Damage432

Description System Circuit435

Operation Fuel System437

Precautions When Connecting Gauge442

Precautions When Handling Heated Oxygen Sensor442

If Vehicle Is Equipped With Mobile Radio System (Ham, Cb, Etc)443

When Disconnecting The Connection Of The High Fuel Pressure Line, A Large Amount Of Gasoline May Come Out So Observe The Following Procedure445

When Connecting The Flare Nut Or Union Bolt On The High Pressure Pipe Union, Observe The Following Procedure445

Observe The Following Precautions When Removing And Installing The Injectors446

Install The Injector To The Delivery Pipe And Intake Manifold As Shown In The Illustration446

Confirm That There Are No Fuel Leaks After Performing Any Maintenance On The Fuel System446

Malfunction Indicator Lamp Check448

Diagnostic Trouble Codes Output (Normal Mode)448

Normal System Operation (No Malfunction)449

Diagnostic Trouble Code Cancellation452

Dtc 12 Heated Oxygen Sensor Circuit455

Air–Fuel Ratio Lean Malfunction (California, C & C)457

Air–Fuel Ratio Rich Malfunction (California, C & C)457

Diagnosis Circuit Inspection459

Fuses And Fusible Link Location460

Mfi System Check Procedure461

Engine Control Module (Ecm) Terminals461

Engine Control Module (Ecm) Wiring Connectors Voltage462

Idl-E2 (E21)465

Vta-E2 (E21)466

Tha-E2 (E21)468

There Is No Voltage Between Ecm Terminals #10 And/Or #20 And E01 And/Or E02 (Ig Sw On)471

There Is No Voltage Between Ecm Terminals Igt And Ei (Idling)472

There Is No Voltage Between Ecm Terminals W And Ei (Idling)473

There Is No Voltage Between Ecm Terminals 11F And E1477

System Circuit479

On-Vehicle Inspection479

Check Fuel Pressure480

Components For Removal And Installation482

Remove Fuel Pump From Fuel Pump Bracket483

Remove Fuel Pump Filter From Fuel Pump483

Install Fuel Pump Filter To Fuel Pump483

Install Fuel Pump To Fuel Pump Bracket483

Install Fuel Pump Bracket484

Install Fuel Tank484

Cold Start Injector On-Vehicle Inspection485

Inspect Resistance Of Cold Start Injector485

Check Injection Of Cold Start Injector486

Inspect Leakage487

Install Cold Start Injector487

Install Cold Start Injector Tube488

Check For Fuel Leakage488

Fuel Pressure Regulator On-Vehicle Inspection489

Fuel Pressure Regulator Removal489

Disconnect Following Cables490

Disconnect Vacuum Sensing Hose490

Disconnect Fuel Return Hose490

Remove Fuel Pressure Regulator492

Fuel Pressure Regulator Installation493

Install Fuel Pressure Regulator493

Connect Vacuum Sensing Hose496

Connect Air Cleaner Hose496

Connect Following Cables496

Injector Components For Removal And Installation497

Injectors Removal498

Injectors Inspection501

Measure Resistance Of Injector501

Injectors Installation503

Install Injectors And Delivery Pipes503

Volume Air Flow (Vaf) Meter On-Vehicle Inspection510

Volume Air Flow Meter Removal511

Disconnect Resonator Bracket511

Remove Volume Air Flow Meter From Air Cleaner Cap511

Volume Air Flow Meter Inspection511

Volume Air Flow Meter Installation512

Install Volume Air Flow Meter To Air Cleaner Cap512

Install Resonator Bracket512

Throttle Body On-Vehicle Inspection513

Inspect Dashpot (Dp)514

Inspect Throttle Opener515

Inspect Air Valve Operation516

Disconnect Air Cleaner Hose517

Throttle Body Inspection518

Throttle Body Installation520

Connect Throttle Position Sensor Connector520

Install Accelerator Cable Bracket520

Efi Main Relay522

Circuit Opening Relay523

Cold Start Injector Time Switch Inspection524

Measure Resistance Of Cold Start Injector Time Switch524

Engine Coolant Temp. Sensor Inspection525

Measure Resistance Of Engine Coolant Temp. Sensor525

Fuel Pressure Vsv Inspection526

Check Vsv Operation526

Measure Resistance Of Egr Gas Temp. Sensor528

Heated Oxygen Sensor Inspection529

Inspect Heater Resistance Of Heated Oxygen Sensor529

Engine Control Module (Ecm) Inspection531

Inspect Voltage Of Engine Control Module (Ecm)531

Inspect Resistance Of Engine Control Module (Ecm)533

Engine Control Module (Ecm) Wiring Connectors Resistance533

Fuel Cut Rpm534

Cooling System538

Reservoir Tank539

Engine Coolant540

Inspect Fan Pulley Bracket543

Water Pump Installation543

Thermostat Removal545

Thermostat Inspection545

Thermostat Installation545

Radiator Installation547

Lubrication System549

Ssm (Special Service Materials)552

Check Oil Level553

Remove Oil Pressure Sender553

Recheck Engine Level556

Remove Driven And Drive Rotors558

Remove Relief Valve558

Inspect Body Clearance559

Inspect Tip Clearance559

Inspect Side Clearance559

Inspect Relief Valve559

Crankshaft Front Oil Seal Replacement560

Install Drive And Driven Rotors561

Install Pump Body Cover561

Install Relief Valve561

Clean Oil Pan Baffle Plate And Oil Pan562

Oil Cooler Components565

Oil Cooler Removal565

Disconnect Oil Cooler Hoses565

Remove Oil Cooler (2Wd)566

Oil Cooler Inspection566

Oil Cooler Installation566

Connect Oil Cooler Hoses567

Ignition System569

Electronic Spark Advance (Esa)571

High–Tension Cord Inspection574

Inspect High–Tension Cord Resistance & Terminals574

Clean And Inspect Spark Plugs574

Ignition Coil Inspection575

Measure Primary Coil Resistance575

Measure Secondary Coil Resistance575

Distributor Inspection575

Check Signal Generator (Pickup Coil)576

Distributor Components577

Distributor Removal577

Distributor Installation577

Install Distributor And Set577

Connect High–Tension Cords And Wiring Connector578

Disconnect Tachometer And Timing Light From Engine579

Ignition Coil582

Pickup Coils582

Check That Spark Occurs586

Disconnect High-Tension Cords From Spark Plugs587

Disconnect High–Tension Cords From Distributor Cap And Ignition Coil587

Reconnect High–Tension Cords To Distributor Cap And Ignition Coil587

Reconnect High-Tension Cords To Spark Plugs588

Visually Inspect Spark Plugs589

Clean Coil And Check Following590

Inspect Primary Coil Resistance590

Inspect Secondary Coil Resistance590

Inspect Air Gaps591

Inspect Signal Generator (Pickup Coil)591

Disconnect High–Tension Cords From Distributor Cap592

Remove Distributor593

Remove O–Ring593

Check No.1 Cylinder To Tdc/Compression593

Install Dust Proof Packing And Distributor Cap594

Connect High–Tension Cords To Distributor Cap594

Connect Distributor Connector594

Starting System596

Starter Components597

Removal Of Starter598

Disconnect Two Wires From Starter598

Remove Starter Motor598

Disassembly Of Starter598

Remove Clutch Assembly And Gears From Starter Housing599

Remove Steel Ball And Spring599

Remove Brushes And Brush Holder599

Remove Armature From Field Frame599

Inspection Of Starter600

Armature Coil600

Inspect Commutator Circle Runout600

Inspect Commutator Diameter600

Inspect Undercut Depth Of Segment601

Inspect Field Coil For Open Circuit601

Inspect That Field Coil Is Not Grounded601

Inspect Brush Length601

Inspect Brush Spring Load602

Inspect Insulation Of Brush Holder602

Clutch And Gears602

Inspect Bearings602

If Necessary, Replace Bearings603

Magnetic Switch603

Perform Pull–In Coil Open Circuit Test603

Perform Hold–In Coil Circuit Test603

Assembly Of Starter604

Install Brush Holder604

Insert Steel Ball Into Clutch Shaft Hole604

Install Gears And Clutch Assembly604

Install Starter Housing605

Install Field Frame With Armature To Magnetic Switch Assembly605

Performance Test Of Starter606

Perform Pull–In And Hold–In Test606

Inspect Clutch Pinion Gear Return606

Perform No–Load Performance Test606

Installation Of Starter607

Install Starter Motor On Transaxle607

Connect Two Wires To Starter607

Connect Cable To Negative Terminal Of Battery607

Inspection Of Starter Relay608

Charging System609

Inspect Battery Specific Gravity And Electrolyte Level610

Check Battery Terminals And Fusible Links610

Inspect Drive Belt610

Inspect Fuses For Continuity611

Visually Check Generator Wiring And Listen For Abnormal Noises611

Inspect Discharge Warning Light Circuit611

Check Charging Circuit Without Load612

Inspect Charging Circuit With Load612

Generator Components613

Removal Of Generator614

Disconnect Wiring From Generator614

Remove Water Inlet Hose (W/Ps)614

Remove Generator614

Disassembly Of Generator616

Remove Ic Regulator616

Remove Rectifier Holder616

Remove Pulley616

Remove Rear End Frame617

Inspection And Repair Of Generator618

Inspect Exposed Brush Length619

If Necessary, Replace Brushes619

Inspect Positive Side Rectifier619

Inspect Negative Side Rectifier620

Inspect Front Bearing620

If Necessary, Replace Front Bearing620

Inspect Rear Bearing621

If Necessary, Replace Rear Bearing621

Assembly Of Generator622

Install Rear End Frame622

Install Pulley622

Install Rectifier Holder622

Install Brush Holder And Ic Regulator623

Install Rear End Cover623

Make Sure Rotor Rotates Smoothly623

Install Generator624

Install Water Inlet Hose624

Connect Wiring To Generator624

Fill With Coolant624

Installation Of Generator625

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Troubleshooting

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