Page 1 EM-1 ENGINE MECHANICAL – Description, Operation ENGINE MECHANICAL...
Page 2 EM-2 ENGINE MECHANICAL – Description, Operation DESCRIPTION The 2VZ–FE engine is a V–6, 2.5 liter, DOHC 24–valve engine. OPERATION...
Page 3 EM-2 ENGINE MECHANICAL – Description, Operation DESCRIPTION The 2VZ–FE engine is a V–6, 2.5 liter, DOHC 24–valve engine. OPERATION...
Page 4 EM-3 ENGINE MECHANICAL – Operation The 2VZ–FE engine has 6 cylinder in a V arrangement at a bank angle of 60°. From the front of the RH bank cylinders are numbered 1 – 3 – 5, and from the front of the LH bank cylinders are numbered 2 – 4 – 6. The crank- shaft is supported by 4 bearings inside the crankcase.
Page 5 EM-4 ENGINE MECHANICAL – Preparation PREPARATION SST (SPECIAL SERVICE TOOLS) Illustration Part No. Part Name Note Connecting rod bolts 12 mm Socket Wrench 09011–38121 for 12 Pointed Head Valve Stem Oil Seal 09201–41020 Replacer Valve Guide Bushing 09201–70010 Remover & Replacer Valve Spring 09202–70010 Compressor...
Page 6 EM-5 ENGINE MECHANICAL – Preparation SST (SPECIAL SERVICE TOOLS) (Cont’d) Illustration Part No. Part Name Note (09221–00200) (Guide “L”) Crankshaft oil seal Crankshaft Front Oil 09223–4601 1 Seal Replacer Crankshaft Rear Oil 09223–56010 Seal Replacer Valve Clearance Adjust 09248–55010 Tool Set 09249–63010 Torque Wrench Adapter Camshaft timing pulley...
Page 7 EM-6 ENGINE MECHANICAL – Preparation EQUIPMENT Part Name Note Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Engine tune–up tester Feeler gauge Micrometer Precision straight edge Spring tester Valve spring Steel square Valve spring Torque wrench Vernier calipers SSM (SERVICE SPECIAL MATERIALS) Part Name...
Page 8 EM-7 ENGINE MECHANICAL – Engine Tune–Up ENGINE TUNE–UP INSPECTION OF ENGINE COOLANT (See steps 1 and 2 on page CO–5) INSPECTION OF ENGINE OIL (See steps 1 and 2 on page LU–5) INSPECTION OF BATTERY (See pages 1 and 2 on page CH–5) Standard specific gravity: 1.25–1.27 when fully charged at 20°C (68°F) INSPECTION OF AIR FILTER...
Page 9 EM-8 ENGINE MECHANICAL – Engine Tune–Up INSPECTION AND ADJUSTMENT OF VALVE CLEARANCE HINT: Adjust the valve clearance while the engine is cold. REMOVE AIR INTAKE CHAMBER (See steps 1 to 14 pages FI–28 and 29) REMOVE CYLINDER HEAD COVERS (See step 32 on page EM–34) SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark “0”...
Page 10 EM-9 ENGINE MECHANICAL – Engine Tune–Up (d) Remove the adjusting shim. Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. Press down the valve lifter with SST (A), and place SST (B) between the camshaft and valve lifter. Remove SST (A).
Page 11 EM-10 ENGINE MECHANICAL – Engine Tune–Up Adjusting Shim Selection Using Chart INTAKE Intake valve clearance (Cold): 0.13–0.23 mm (0.005–0.009 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a No.22 shim.
Page 12 EM-11 ENGINE MECHANICAL – Engine Tune–Up Adjusting Shim Selection Using Chart EXHAUST Exhaust valve clearance: 0.27–0.37 mm (0.011–0.015 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a No.18 shim.
Page 13 EM-12 ENGINE MECHANICAL – Engine Tune–Up, Idle and/or 2,500 rpm HC/CO Concentration Check Method INSPECTION AND ADJUSTMENT OF IGNITION TIMING (See page IG–13) Ignition timing: 10° BTDC @ idle (w/ Terminals TE1 and E1 connected) INSPECTION OF IDLE SPEED Idle speed: 700 50 rpm IDLE AND/OR 2,500 RPM HC/CO CONCENTRATION CHECK METHOD...
Page 14 EM-12 ENGINE MECHANICAL – Engine Tune–Up, Idle and/or 2,500 rpm HC/CO Concentration Check Method INSPECTION AND ADJUSTMENT OF IGNITION TIMING (See page IG–13) Ignition timing: 10° BTDC @ idle (w/ Terminals TE1 and E1 connected) INSPECTION OF IDLE SPEED Idle speed: 700 50 rpm IDLE AND/OR 2,500 RPM HC/CO CONCENTRATION CHECK METHOD...
Page 15 EM-13 ENGINE MECHANICAL – Idle and/or 2,500 rpm HC/CO Concentration Check Method Troubleshooting If the HC/CO concentration does not comply with regulations, perform troubleshooting in the order given below. (a) Check oxygen sensor operation. (See page FI–54) (b) See the table below for possible causes, and then inspect and correct the applicable causes if necessary.
Page 16 EM-14 ENGINE MECHANICAL – Compression Check COMPRESSION CHECK HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating tempera- ture.
Page 17 EM-15 ENGINE MECHANICAL – Timing Belt TIMING BELT COMPONENTS REMOVAL OF TIMING BELT DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 18 EM-16 ENGINE MECHANICAL – Timing Belt REMOVE RH ENGINE MOUNTING STAYS (a) Remove the three bolts and No.1 mounting stay. (b) Remove the bolt, nut and No.2 mounting stay. 10. SLIGHTLY JACK UP ENGINE Raise the engine enough to remove the weight from the en- gine mounting on the right side.
Page 19 EM-17 ENGINE MECHANICAL – Timing Belt 17. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with the timing mark “0” of the No.1 timing belt cover. (b) Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
Page 20 EM-18 ENGINE MECHANICAL – Timing Belt (b) Remove the timing belt from the camshaft timing pulleys. HINT (Re–using timing belt): If the installation marks have disappeared, after removing the timing belt from the cam- shaft timing pulleys, place new installation mark on the timing belt to match the end of the No.1 timing belt cover.
Page 21 EM-19 ENGINE MECHANICAL – Timing Belt 22. REMOVE CRANKSHAFT PULLEY (a) Using SST, remove the pulley bolt. SST 09213–54014 (Body), 90213–70010 (90105–08076 (Bolt)) and 09330–00021 HINT (Re–using timing belt): When the crankshaft pulley bolt is loosened, the position of the timing mark of the crankshaft pulley and also the installation mark may slip, so check and align them again.
Page 22 EM-20 ENGINE MECHANICAL – Timing Belt 25. REMOVE TIMING BELT HINT (Re–using timing belt): If the installation marks have disappeared, place a new installation mark on the timing belt to match the drilled mark of the crankshaft timing pulley. 26. REMOVE NO.1 IDLER PULLEY Using a 8 mm hexagon wrench, remove the bolt, idler pulley and plate washer.
Page 23 EM-21 ENGINE MECHANICAL – Timing Belt INSPECTION OF TIMING BELT COMPONENTS INSPECT TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.
Page 24 EM-22 ENGINE MECHANICAL – Timing Belt (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check to correct gasket installation and for foreign material on the pulley teeth. If necessary, replace the timing belt. INSPECT IDLER PULLEYS Check the turning smoothness of the idler pulley.
Page 25 EM-23 ENGINE MECHANICAL – Timing Belt INSTALLATION OF TIMING BELT (See page EM–15) INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. INSTALL NO.1 IDLER PULLEY (a) Apply adhesive to two or three threads of the mount bolt end.
Page 26 EM-24 ENGINE MECHANICAL – Timing Belt INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, slide the pulley. (b) Using SST, install and torque the bolt. SST09213–54014 (Body), 09213–70010 (90105–08076 (Bolt)) and 09330–00021 Torque: 2,500 kg–cm (181 ft–lb, 245 N m) INSTALL NO.2 IDLER PULLEY (a) Install the idler pulley with the bolt.
Page 27 EM-25 ENGINE MECHANICAL – Timing Belt 10. INSTALL TIMING BELT TO LH CAMSHAFT TIMING PULLEY (a) Check that the installation mark on the timing belt matches the end of the No.1 timing belt cover. If the installation mark do not align, shift the meshing of the timing belt and crankshaft timing pulley until they align.
Page 28 EM-26 ENGINE MECHANICAL – Timing Belt Using SST, align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. SST 09278–54012 (g) Using SST, install and torque the bolt. SST 09249–63010 and 09278–54012 Torque: 760 kg–cm (55 ft–lb, 75 N m) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).
Page 29 EM-27 ENGINE MECHANICAL – Timing Belt (b) Remove the 1.27 mm hexagon wrench from the tensioner. 14. CHECK VALVE TIMING (a) Turn the crankshaft pulley two revolutions from TDC to TDC. HINT: Always turn the crankshaft clockwise. (b) Check that each pulley aligns with the timing marks as shown in the figure.
Page 30 EM-28 ENGINE MECHANICAL – Timing Belt 19. INSTALL RH ENGINE MOUNTING INSULATOR (a) Attach the mounting insulator to the mounting bracket and body, temporarily install the mounting insulator four nuts, bolt the mounting stay bolt (A). (b) Torque the mounting insulator with four nuts and bolt. Do not torque the mounting stay bolt (A) yet.
Page 31 EM-29 ENGINE MECHANICAL – Cylinder Heads CYLINDER HEADS COMPONENTS...
Page 32 EM-30 ENGINE MECHANICAL – Cylinder Heads REMOVAL OF CYLINDER HEADS (See page EM–29) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 33 EM-31 ENGINE MECHANICAL – Cylinder Heads 16. REMOVE VACUUM PIPE (a) Disconnect the following hoses: (1) Four BVSV vacuum hoses (2) Fuel pressure VSV hose (3) A/C control valve vacuum hose (b) Remove the two bolts and vacuum pipe. 17. REMOVE DISTRIBUTOR (See page IG–10) 18.
Page 34 EM-32 ENGINE MECHANICAL – Cylinder Heads 24. REMOVE WATER BY–PASS OUTLET (a) Disconnect the following connectors and hose: (1) Cold start injector time switch connector (2) Water temperature sensor connector (3) Heater water by–pass hose (b) Remove the three nuts, water by–pass outlet and gasket.
Page 35 EM-33 ENGINE MECHANICAL – Cylinder Heads (c) Remove the six nuts, exhaust manifold and gasket. (d) Remove the bolt and inside heat insulator. 28. REMOVE LH EXHAUST MANIFOLD (a) Remove the two nuts and heat insulator. (b) Remove the six nuts, exhaust manifold and gasket. 29.
Page 36 EM-34 ENGINE MECHANICAL – Cylinder Heads 32. REMOVE CYLINDER HEAD COVERS Remove the six nuts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers. 33. REMOVE SPARK PLUG TUBE GASKETS Remove the six tube gaskets. 34. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed.
Page 37 EM-35 ENGINE MECHANICAL – Cylinder Heads Remove intake camshaft of RH cylinder head (a) Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown. (b) Remove the five bearing caps, oil seal and intake camshaft.
Page 38 EM-36 ENGINE MECHANICAL – Cylinder Heads HINT: Arrange the bearing caps incorrect order. 35. DISASSEMBLE EXHAUST CAMSHAFTS (a) Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Insert a service bolt (A) into the service hole of the camshaft sub–gear.
Page 39 EM-37 ENGINE MECHANICAL – Cylinder Heads 36. REMOVE CYLINDER HEADS (a) Using a 8 mm hexagon wrench, remove the cylinder head (recessed head) bolts. (b) Uniformly loosen and remove the cylinder head (12 pointed head) bolts in several passes in the sequence shown.
Page 40 EM-38 ENGINE MECHANICAL – Cylinder Heads DISASSEMBLY OF CYLINDER HEADS (See page EM–29) REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. REMOVE VALVES (a) Using SST, compress the valve spring and remove the two keepers.
Page 41 EM-39 ENGINE MECHANICAL – Cylinder Heads INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS CLEAN TOP OF PISTONS AND TOP OF BLOCK (a) Turn the crankshaft and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surfaces.
Page 42 EM-40 ENGINE MECHANICAL – Cylinder Heads INSPECT CYLINDER HEADS FOR FLATNESS Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head.
Page 43 EM-41 ENGINE MECHANICAL – Cylinder Heads (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.970–5.985 mm (0.2350–0.2356 in.) Exhaust 5.965–5.980 mm (0.2348–0.2354 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025–0.060 mm...
Page 44 EM-42 ENGINE MECHANICAL – Cylinder Heads (d) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. (e) Select a new guide bushing (STD size or O/S 0.05). Both intake and exhaust If the bushing bore diameter of the cylinder head is greater Bushing bore diameter mm (in.) Bushing size than 11.027 mm (0.4341 in.), machine the bushing bore to...
Page 45 EM-43 ENGINE MECHANICAL – Cylinder Heads (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. (d) Check the valve overall length. Standard overall length: Intake 96.1 mm (3.783 in.)
Page 46 EM-44 ENGINE MECHANICAL – Cylinder Heads If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. (2) If the seating is too low on the valve face, use 60° and 45°...
Page 47 EM-45 ENGINE MECHANICAL – Cylinder Heads (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 18.6–21.4 kg (41.0–47.2 lb, 182–210 N) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring.
Page 48 EM-46 ENGINE MECHANICAL – Cylinder Heads Inspect camshaft gear spring Using vernier calipers, measure the free distance between the spring end. Free distance: 18.2–18.8 mm (0.712–0.740 in.) If the free distance is not as specified, replace the gear spring. Inspect camshaft journal oil clearance (a) Clean the bearing caps and camshaft journals.
Page 49 EM-47 ENGINE MECHANICAL – Cylinder Heads Inspect camshaft gear backlash (a) Install the camshafts without installing the exhaust camshaft sub–gear. (See step 4 on pages EM–52 to 55) (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020–0.200 mm (0.0008–0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.)
Page 50 EM-48 ENGINE MECHANICAL – Cylinder Heads ASSEMBLY OF CYLINDER HEADS (See page EM–29) HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, spark plug tubes must be installed.
Page 51 EM-49 ENGINE MECHANICAL – Cylinder Heads (c) Using a plastic–faced hammer, lightly tap the valve stem tip to assure proper fit. INSTALL VALVE LIFTERS AND SHIMS Check the valve lifter rotates smoothly by hand.
Page 52 EM-50 ENGINE MECHANICAL – Cylinder Heads INSTALLATION OF CYLINDER HEADS (See page EM–29) INSTALL CYLINDER HEADS A. Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the cylinder head in position on the cylinder head gasket.
Page 53 EM-51 ENGINE MECHANICAL – Cylinder Heads C. Install cylinder head (recessed head) bolts (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Using a 8 mm hexagon wrench, install the cylinder head bolts.
Page 54 EM-52 ENGINE MECHANICAL – Cylinder Heads (d) Insert a service bolt (A) into the service hole of the camshaft sub–gear. (e) Using a screwdriver, align the holes of the camshaft driven gear and sub–gear by turning camshaft subgear clockwise, and install a service bolt (B). NOTICE: Be careful not to damage the camshaft.
Page 55 EM-53 ENGINE MECHANICAL – Cylinder Heads (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown. Torque: 160 kg–cm (12 ft–lb, 16 N m) Install exhaust camshaft of RH cylinder head...
Page 56 EM-54 ENGINE MECHANICAL – Cylinder Heads (c) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent (d) Install the five bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
Page 57 EM-55 ENGINE MECHANICAL – Cylinder Heads (e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts. Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown. Torque: 160 kg–cm (12 ft–lb, 16 N m) (g) Remove the service bolt (B).
Page 58 EM-56 ENGINE MECHANICAL – Cylinder Heads INSTALL CYLINDER HEAD COVERS (a) Apply seal packing to the cylinder heads as shown in the figure. Seal packing: Part No. 08826–00080 or equivalent (b) Install the gasket to the cylinder head cover. (c) Install the cylinder head cover with the six seal washers and nuts.
Page 59 EM-57 ENGINE MECHANICAL – Cylinder Heads (b) Install a new gasket and the exhaust manifold with six new nuts, Uniformly tighten the nuts in several passes. Torque: 400 kg–cm (29 ft–lb, 39 N m) (c) Install the outside heat insulator with the three nuts. (d) Connect the oxygen sensor connector.
Page 60 EM-58 ENGINE MECHANICAL – Cylinder Heads (b) Install the No.2 idler pulley bracket stay with the two bolts. Torque: 185 kg–cm (13 ft–lb, 18 N m) 15. INSTALL CYLINDER HEAD REAR PLATE Install the rear plate with the two bolts. 16.
Page 61 EM-59 ENGINE MECHANICAL – Cylinder Heads 19. INSTALL AIR INTAKE CHAMBER (a) Install two new gaskets and the intake chamber with the two bolts and two nuts. Torque: 440 kg–cm (32 ft–lb, 43 N m) (b) Install the two intake chamber stays with the four bolts. Torque: 380 kg–cm (27 ft–lb, 37 N m) (c) Connect the following hoses:...
Page 62 EM-60 ENGINE MECHANICAL – Cylinder Heads 26. INSTALL EGR PIPE Install a new gasket and the EGR pipe with the two bolts and union nut. Torque: Bolt 185 kg–cm (13 ft–lb, 18 N m) 800 kg–cm (58 ft–lb, 78 N m) 27.
Page 63 EM-61 ENGINE MECHANICAL – Cylinder Block CYLINDER BLOCK REMOVAL OF ENGINE...
Page 64 EM-62 ENGINE MECHANICAL – Cylinder Block...
Page 65 EM-63 ENGINE MECHANICAL – Cylinder Block DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 66 EM-64 ENGINE MECHANICAL – Cylinder Block REMOVE RADIATOR (See pages CO–12 and 13) 10. REMOVE ALTERNATOR (See page CH–8) 11. REMOVE ALTERNATOR BELT ADJUSTING BAR 12. REMOVE RADIATOR RESERVOIR TANK 13. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 14. (A/T) DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 15.
Page 67 EM-65 ENGINE MECHANICAL – Cylinder Block 18. DISCONNECT VACUUM HOSES (a) Brake booster vacuum hose from air intake chamber (b) A/C control valve vacuum hose from air intake chamber (c) A/C control valve vacuum hose from vacuum pipe (on air intake chamber) (d) Charcoal canister vacuum hose from vacuum pipe (on air intake chamber)
Page 68 EM-66 ENGINE MECHANICAL – Cylinder Block 28. REMOVE FRONT EXHAUST PIPE (a) Remove the two pipe stay bolts. (b) Remove the two bolts and nuts, and disconnect the front pipe from the center pipe. Remove the gasket. (c) Remove the three nuts, front pipe and gasket. 29.
Page 69 EM-67 ENGINE MECHANICAL – Cylinder Block 35. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET (a) Remove the nut, through bolt and mounting insulator. (b) Remove the three bolts and mounting bracket. 36. REMOVE PS OIL RESERVOIR TANK WITHOUT DISCONNECTING HOSES Remove the two bolts and reservoir tank.
Page 70 EM-68 ENGINE MECHANICAL – Cylinder Block 39. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Attach the engine chain hoist to the engine hangers. (b) Remove the clamp bolts of the PS oil cooler pipes. (c) Remove the four nuts, bolt and RH mounting insulator. (d) Remove the through bolt, nut, four bolts and LH mounting insulator.
Page 71 EM-69 ENGINE MECHANICAL – Cylinder Block COMPONENTS...
Page 72 EM-70 ENGINE MECHANICAL – Cylinder Block PREPARATION FOR DISASSEMBLY (M/T) REMOVE CLUTCH COVER AND DISC (M/T) REMOVE FLYWHEEL (A/T) REMOVE DRIVE PLATE REMOVE REAR END PLATE Remove the bolt and end plate. INSTALL ENGINE ENGINE STAND DISASSEMBLY REMOVE DISTRIBUTOR (See page IG–9) REMOVE TIMING BELT AND PULLEYS (See pages EM–16...
Page 73 EM-71 ENGINE MECHANICAL – Cylinder Block DISASSEMBLY OF CYLINDER BLOCK (See page EM–69) REMOVE REAR OIL SEAL RETAINER Remove the six bolts and retainer. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.150–0.330 mm (0.0059–0.0130 in.) Maximum thrust clearance: 0.38 mm (0.0150 in.)
Page 74 EM-72 ENGINE MECHANICAL – Cylinder Block (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings.
Page 75 EM-73 ENGINE MECHANICAL – Cylinder Block Measure the Plastigage at its widest point. Standard oil clearance: 0.028–0.065 mm (0.0011–0.0026 in.) 0.25 0.027–0.080 mm (0.0011–0.0031 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings.
Page 76 EM-74 ENGINE MECHANICAL – Cylinder Block REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the main bearing cap bolts in several passes in the sequence shown. (b) Using a screwdriver, pry up the main bearing cap, and remove the main bearing cap, lower main bearings and lower thrust washers (No.2 journal position of main bearing cap only).
Page 77 EM-75 ENGINE MECHANICAL – Cylinder Block Remove the eight bolts and main bearing cap. (See procedure (a) and (b) above) Measure the Plastigage at its widest point. Standard clearance: 0.029–0.056 mm (0.0011–0.0022 in.) 0.25 0.028–0.080 mm (0.0011–0.0031 in.) Maximum clearance: 0.08 mm (0.0031 in.) HINT: If replacing the cylinder block subassembly, the bear- ing standard clearance will be: 0.031–0.067 mm (0.0012–0.0026 in.)
Page 78 EM-76 ENGINE MECHANICAL – Cylinder Block (Reference) (Cont’d) Standard sized bearing center wall thickness: Mark “1” 1.989–1.992 mm (0.0783–0.0784 in.) Mark “2” 1.992–1.995 mm (0.0784–0.0785 in.) Mark “3” 1.995–1.998 mm (0.0785–0.0787 in.) Mark “4” 1.998–2.001 mm (0.0787–0.0788 in.) Mark “5” 2.001–2.004 mm (0.0788–0.0789 in.) (k) Completely remove the Plastigage.
Page 79 EM-77 ENGINE MECHANICAL – Cylinder Block INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the six cylinders or replace the cylinder block. INSPECT CYLINDER BORE DIAMETER HINT: There are three sizes of the standard cylinder bore di- ameter, marked “1”, “2”...
Page 80 EM-78 ENGINE MECHANICAL – Cylinder Block DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the two compression rings.
Page 81 EM-79 ENGINE MECHANICAL – Cylinder Block INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning or broken ring, clean the piston ring grooves. (c) Using solvent and a brush, thoroughly clean the piston.
Page 82 EM-80 ENGINE MECHANICAL – Cylinder Block HINT (Use new cylinder block): Use a piston with the same number mark as the standard bore diameter marked on the cylinder block. INSPECT CLEARANCE BETWEEN WALL OF RING GROOVE AND NEW PISTON RING Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove.
Page 83 EM-81 ENGINE MECHANICAL – Cylinder Block INSPECT CONNECTING ROD Using a rod aligner, check the connecting rod alignment. Check for bending. Maximum bending: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly.
Page 84 EM-82 ENGINE MECHANICAL – Cylinder Block BORING OF CYLINDERS HINT: Bore all the six cylinders for the oversized piston outside diameter. Replace the piston rings with ones to match the oversized pistons. KEEP OVERSIZED PISTONS Oversized piston diameter: O/S 0.50 87.945–87.975 mm (3.4624–3.4636 in.) CALCULATE AMOUNT TO BORE CYLINDER...
Page 85 EM-83 ENGINE MECHANICAL – Cylinder Block INSPECTION AND REPAIR OF CRANKSHAFT INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V–blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft.
Page 86 EM-84 ENGINE MECHANICAL – Cylinder Block REPLACEMENT OF CRANKSHAFT OIL SEALS HINT: There are two methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL If oil pump is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal.
Page 87 EM-85 ENGINE MECHANICAL – Cylinder Block REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal retainer is removed from cylinder block: (a) Using screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge.
Page 88 EM-86 ENGINE MECHANICAL – Cylinder Block ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES ASSEMBLE PISTON AND CONNECTING ROD (a) Align the front marks of the piston and connecting rod. Connecting rod front (mold) mark: B6, 1B, 8A, C3 or etc. (b) Coat the piston pin and piston hole of the piston with engine oil.
Page 89 EM-87 ENGINE MECHANICAL – Cylinder Block INSTALL BEARINGS (a) Align the bearing claw with the groove of the connecting rod or connecting cap. (b) Install the bearings in the connecting rod and connecting rod cap. ASSEMBLY OF CYLINDER BLOCK (See page EM–69) HINT: Thoroughly clean all parts to be assembled.
Page 90 EM-88 ENGINE MECHANICAL – Cylinder Block INSTALL MAIN BEARING CAP AND LOWER THRUST WASHERS Place main bearing cap and lower thrust washers on cyl- inder block (a) Install the thrust washers on the No.2 journal position of the bearing cap with the grooves facing outward. (b) Install the main bearing cap with the front mark facing forward.
Page 91 EM-89 ENGINE MECHANICAL – Cylinder Block INSTALL PISTON AND CONNECTING ROD ASSEMBLIES (a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
Page 92 EM-90 ENGINE MECHANICAL – Cylinder Block (d) Retighten the connecting rod cap nuts 90° in the numerical order shown. (e) Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. (g) Check the connecting rod thrust clearance.
Page 93 EM-91 ENGINE MECHANICAL – Cylinder Block POST ASSEMBLY INSTALL NO.2 IDLER PULLEY BRACKET Install the pulley bracket with the three bolts. Torque the bolts. Torque: 380 kg–cm (27 ft–lb, 37 N m) INSTALL WATER BY–PASS PIPE (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the by–pass pipe and cylinder block.
Page 94 EM-92 ENGINE MECHANICAL – Cylinder Block INSTALL OIL FILTER (See page LU–6) INSTALL OIL PUMP AND OIL PAN (See page LU–11) INSTALL WATER PUMP (See page CO–7) INSTALL CYLINDER HEADS (See pages EM–50 to 60) INSTALL PULLEYS AND TIMING BELT (See pages EM–23 to 28)
Page 95 EM-93 ENGINE MECHANICAL – Cylinder Block INSTALLATION OF ENGINE (See page EM–61 to 63) ASSEMBLE ENGINE AND TRANSAXLE (See page MT–8 or AT–15) (A/T) INSTALL STARTER (See page ST–5) INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Attach the engine chain hoist to the engine hangers. (b) Lower the engine into the engine compartment.
Page 96 EM-94 ENGINE MECHANICAL – Cylinder Block (h) Torque the four nuts and bolt of the RH mounting insulator. Do not torque the bolt (A) yet. Torque: Bolt 650 kg–cm (47 ft–lb, 64 N m) To bracket 530 kg–cm (38 ft–lb, 52 N m) To body 900 kg–cm (65 ft–lb, 88 N m) Remove the engine hoist chain from the engine.
Page 97 EM-95 ENGINE MECHANICAL – Cylinder Block INSTALL FRONT ENGINE MOUNTING BRACKET AND INSULATOR (a) Install the mounting bracket with the three bolts. Torque the bolts. Torque: 790 kg–cm (57 ft–lb, 77 N m) (b) Temporarily install the mounting insulator with the through bolt and a new nut.
Page 98 EM-96 ENGINE MECHANICAL – Cylinder Block 14. INSTALL FRONT EXHAUST PIPE (a) Place two new gaskets on the front pipe. (b) Install the front pipe with the two bolts and five new nuts. Torque the nuts. Torque: To manifold 630 kg–cm (46 ft–lb, 62 N m) To converter 440 kg–cm (32 ft–lb, 43 N m) (c) Install the two pipe stay bolts.
Page 99 EM-97 ENGINE MECHANICAL – Cylinder Block 24. CONNECT VACUUM HOSES (a) Brake booster vacuum hose to air intake chamber (b) A/C idle–up vacuum hose to air intake chamber (c) A/C idle–up vacuum hose to vacuum pipe (on air intake chamber) (d) Charcoal canister vacuum hose to vacuum pipe (on air intake chamber) 25.
Page 100 EM-98 ENGINE MECHANICAL – Cylinder Block 28. (A/T) INSTALL THROTTLE CABLE, AND ADJUST IT 29. INSTALL ACCELERATOR CABLE, AND ADJUST IT 30. INSTALL RADIATOR RESERVOIR TANK 31. INSTALL ALTERNATOR BELT ADJUSTING BAR 32. INSTALL ALTERNATOR (See page CH–8) 33. INSTALL RADIATOR (See page CO–13) 34.
Page 101 EM-99 ENGINE MECHANICAL – Cylinder Block (c) Adjust the ignition timing. (See page IG–12) Ignition timing: 10° BTDC @ idle (w/ Terminals TE1 and E1 connected) 41. INSTALL ENGINE UNDER COVERS 42. INSTALL HOOD 43. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
Page 102 EM-100 ENGINE MECHANICAL – Service Specifications SERVICE SPECIFICATIONS SPECIFICATIONS Idle speed 50 rpm Intake manifold at Idle speed 440 mmHg (17.32 in. Hg, 58.6 kPa) or vacuum more at 250 rpm 12.5 kg/cm (178 psi, 1,226 kPa) or more Compression pressure Limit 10.0 kg/cm...
Page 103 EM-101 ENGINE MECHANICAL – Service Specifications SPECIFICATIONS (Cont’d) Cam lobe height Intake 39.510–39.610 mm 1.5555–1.5594 in. Camshaft (cont’d) ’d) Exhaust 38.960–39.060 mm 1.5339–1.5378 in. Limit Intake 39.36 mm 1.5496 in. Exhaust 38.81 mm 1.5279 in. Camshaft gear backlash 0.020–0.200 mm 0.0008–0.0079 in.
Page 104 EM-102 ENGINE MECHANICAL – Service Specifications SPECIFICATIONS (Cont’d) Main journal oil clearance 0.029–0.056 mm 0.0011–0.0022 in. Crankshaft (cont’d) ’d) U/S 0.25 0.028–0.080 mm 0.0011–0.0031 in. Limit 0.08 mm 0.0031 in. Main journal diameter 63.985–64.000 mm 2.5191–2.5197 in. U/S 0.25 63.745–63.755 mm 2.5096–2.5100 in.
Page 105 EM-103 ENGINE MECHANICAL – Service Specifications TORQUE SPECIFICATIONS (Cont’d) Part tightened kg–cm ft–lb EGR pipe X EGR valve EGR pipe X RH exhaust manifold Main bearing cap X Cylinder block Turn 90° Connecting rod cap X Connecting rod Turn 90° Rear oil seal retainer X Cylinder block 69.in.–lb No.
Page 106 FI–1 EFI SYSTEM...
Page 107 FI–2 EFI SYSTEM – Description DESCRIPTION...
Page 108 FI–3 EFI SYSTEM – Description The EFI system is composed of three basic sub–systems: Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake manifold in a accordance with signals from the ECU (Electronic Control Unit).
Page 109 Hose Nut 14 x 17 mm Wrench Set Wiring “A” 09842–30050 EFI Inspection Wiring “F” 09842–30070 EFI Inspection Diagnosis Check 09843–18020 Wiring RECOMMENDED TOOLS TOYOTA Electrical 09082–00015 Tester Engine Adjust 09200–00010 Plug for vacuum hose, fuel hose etc. 09258–00030 Hose Plug Set...
Page 110 FI–9 EFI SYSTEM – Preparation EQUIPMENT Part Name Note Graduated cylinder Injector Ohmmeter Sound scope Injector Tachometer Torque wrench Voltmeter...
Page 111 FI–4 EFI SYSTEM – Operation (System Circuit) OPERATION System Circuit...
Page 112 FI–5 EFI SYSTEM – Description System Operation FUEL SYSTEM Fuel is pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector and cold start injector at a set pressure maintained by the pressure regulator. The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side) to a pres- sure 2.9 kg/cm (41 psi, 284 kPa) higher than the pressure inside the intake manifold, and excess fuel is returned...
Page 113 FI–6 EFI SYSTEM – Operation (System Operation) AIR INDUCTION SYSTEM Air filtered through the air cleaner passes through the air flow meter and the amount flowing to the air intake chamber is determined according to the throttle valve opening in the throttle body and the engine rpm. The air flow meter measures the intake air flow by the opening of the measuring plate in response to the volume of intake air to the engine.
Page 114 FI–7 EFI SYSTEM – Operation (System Operation) ELECTRONIC CONTROL SYSTEM The control system consists of sensors which detect various engine conditions, and a ECU which determines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air volume, engine rpm, oxygen density in the exhaust gas, coolant temperature, intake air temperature and atmospheric pressure etc.
Page 115 FI–10 EFI SYSTEM – Precautions, Inspection Precautions PRECAUTIONS Before working on the fuel system, disconnect the cable from negative (–) terminal of the battery. HINT: Any diagnostic code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the battery terminal.
Page 116 FI–10 EFI SYSTEM – Precautions, Inspection Precautions PRECAUTIONS Before working on the fuel system, disconnect the cable from negative (–) terminal of the battery. HINT: Any diagnostic code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the battery terminal.
Page 117 FI–11 EFI SYSTEM – Inspection Precautions IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) The ECU has been designed so that it will not be affected by out- side interference. However, if your vehicle is equipped with a CB radio transceiver, etc.
Page 118 FI–12 EFI SYSTEM – Inspection Precautions Care is required when pulling out and inserting wiring connectors. (a) Release the lock and pull out the connector, pulling on the connectors. (b) Fully insert the connector and check that it is locked. When inspecting a connector with a volt/ohmmeter.
Page 119 FI–13 EFI SYSTEM – Inspection Precautions FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (a) Put a container under the connection. (b) Slowly loosen the connection. (c) Disconnect the connection.
Page 120 FI–14 EFI SYSTEM – Inspection Precautions Check that there are no fuel leaks after performing any maintenance on the fuel system. (a) Using SST, connect terminals +B and FP of the check connector. SST 09843–18020 (b) With engine stopped, turn the ignition switch ON. (c) When the fuel return hose is pinched, the pressure within high pressure line will rise to approx.
Page 121 FI–15 EFI SYSTEM – Fuel System (Fuel Pump) FUEL SYSTEM Fuel Pump...
Page 122 FI–16 EFI SYSTEM – Fuel System (Fuel Pump) ON–VEHICLE INSPECTION CHECK FUEL PUMP OPERATION (a) Using SST, connect terminals +B and FP of the check connector. SST 09843–18020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine. (c) Check that there is pressure in the hose from the fuel filter.
Page 123 FI–17 EFI SYSTEM – Fuel System (Fuel Pump) (c) Disconnect the cold start injector connector. (d) Put a suitable container or shop towel under the cold start injector tube. (e) Remove the union bolt and two gaskets, and disconnect the cold start injector tube from the LH delivery pipe. HINT: Slowly loosen the union bolt.
Page 124 FI–18 EFI SYSTEM – Fuel System (Fuel Pump) (m) Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. (o) Measure the fuel pressure at idling. Fuel pressure: 2.7 – 3.1 kg/cm (38–44 psi, 265–304 kPa) (p) Reconnect the vacuum sensing hose to the fuel pressure regulator.
Page 125 FI–19 EFI SYSTEM – Fuel System (Fuel Pump) REMOVAL OF FUEL PUMP CAUTION: Do not smoke or work near an open flame when working on the fuel pump. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the “LOCK”...
Page 126 FI–20 EFI SYSTEM – Fuel System (Fuel Pump) INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 1 of the connector, and the negative (–) lead to terminal 2. Check that the fuel pump operates. NOTICE: These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out.
Page 127 FI–21 EFI SYSTEM – Fuel System (Fuel Pump) INSTALL FUEL PUMP BRACKET TO FUEL TANK (a) Install a new gasket and the pump bracket with the seven screws. Torque: 40 kg–cm (35 in.–lb, 3.9 N m) (b) Install the bolt of the bracket. INSTALL FUEL TANK When installing the fuel tank, refer to FI–35...
Page 128 FI–22 EFI SYSTEM – Fuel System (Cold Start Injector) Cold Start Injector ON–VEHICLE INSPECTION INSPECT RESISTANCE OF COLD START INJECTOR (a) Disconnect the cold start injector connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 2 – 4 If the resistance is not as specified, replace the cold start injector.
Page 129 FI–23 EFI SYSTEM – Fuel System (Cold Start Injector) INSPECTION OF COLD START INJECTOR INSPECT INJECTION OF COLD START INJECTOR CAUTION: Keep clear of sparks during the test. (a) Install SST (two unions) to the injector and delivery pipe with new gaskets and the union bolts. SST 09268–41045 (09268–41080) (b) Connect SST (hose) to the unions.
Page 130 FI–24 EFI SYSTEM – Fuel System (Cold Injector) INSTALLATION OF COLD START INJECTOR INSTALL COLD START INJECTOR Install a new gasket and the injector with the two bolts. Torque: 55 kg–cm (48 in.–lb, 5.4 N m) CONNECT COLD START INJECTOR TUBE (a) Connect the injector tube to clamp.
Page 131 FI–25 EFI SYSTEM – Fuel System (Fuel Pressure Regulator) Fuel Pressure Regulator ON–VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page FI–16) REMOVAL OF FUEL PRESSURE REGULATOR DISCONNECT VACUUM SENSING HOSE DISCONNECT FUEL RETURN HOSE (a) Put a suitable container or shop towel under the pressure regulator.
Page 132 FI–26 EFI SYSTEM – Fuel System (Fuel Pressure Regulator) INSTALLATION OF FUEL PRESSURE REGULATOR INSTALL FUEL PRESSURE REGULATOR (a) Fully loosen the lock nut of the pressure regulator. (b) Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator.
Page 133 FI–27 EFI SYSTEM – Fuel System (Injectors) Injectors ON–VEHICLE INSPECTION INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm. (b) If you have no sound scope, you can check the injector transmission operation with your finger.
Page 134 FI–28 EFI SYSTEM – Fuel System (Injectors) REMOVAL OF INJECTORS DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 135 FI–29 EFI SYSTEM – Fuel System (Injectors) 10. DISCONNECT HOSES AND PARTS (a) Brake booster vacuum hose (b) PS vacuum and air hoses (c) Cruise control vacuum hose (d) Ground strap connector (e) Wire harness clamp Remove the nut, and disconnect the wire harness clamp.
Page 136 FI–30 EFI SYSTEM – Fuel System (Injectors) 19. REMOVE DELIVERY PIPES AND INJECTORS (a) Remove the two bolts and LH delivery pipe together with three injectors. NOTICE: Be careful not to drop the injectors, when re- moving the delivery pipe. (b) Remove the three bolts and RH delivery pipe with the No.1 fuel pipe and three injectors.
Page 137 FI–31 EFI SYSTEM – Fuel System (Injectors) (e) Install a new O–ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41045 (g) Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.
Page 138 FI–32 EFI SYSTEM – Fuesl System (Injectors) INSTALLATION OF INJECTORS INSTALL INJECTORS AND DELIVERY PIPES (a) Install a new grommet to the injector. (b) Apply a light coat of gasoline to a new O–ring and install it to the injector. (c) While turning the injector left and right, install it to the delivery pipes.
Page 139 FI–33 EFI SYSTEM – Fuel System (Injectors) INSTALL NO.2 FUEL PIPE Install the No.2 fuel pipe with four new gaskets and the union bolts as shown in the illustration. Torque: 330 kg–cm (24 ft–lb, 32 N m) CONNECT FUEL INLET AND RETURN HOSES (a) Connect the inlet hose to the fuel filter with two new gaskets and union bolt.
Page 140 FI–34 EFI SYSTEM – Fuel System (Injectors) 11. CONNECT COLD START INJECTOR TUBE (See step 2 on page FI–24) 12. CONNECT COLD START INJECTOR CONNECTOR 13. INSTALL NO.1 RH ENGINE MOUNTING STAY Install the mounting stay with the three bolts. Torque: 530 kg–cm (38 ft–lb, 52 N m) 14.
Page 141 FI–35 EFI SYSTEM – Fuel System (Fuel Tank and Lines) Fuel Tank and Lines COMPONENTS...
Page 142 FI–36 EFI SYSTEM – Fuel System (Fuel Tank and Lines) PRECAUTIONS Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened. INSPECT FUEL LINES AND CONNECTIONS (a) Check the fuel lines for cracks or leakage, and all connections for deformation.
Page 143 FI–37 EFI SYSTEM – Air Induction System (Air Flow Meter) AIR INDUCTION SYSTEM Air Flow Meter ON–VEHICLE INSPECTION INSPECT RESISTANCE OF AIR FLOW METER (a) Disconnect the air flow meter connector. (b) Using an ohmmeter, measure the resistance between each terminal. Between Temp.
Page 144 FI–38 EFI SYSTEM – Air Induction System (Air Flow Meter) DISCONNECT AIR FLOW METER CONNECTOR DISCONNECT AIR CLEANER HOSE REMOVE AIR CLEANER CAP AND AIR FLOW METER ASSEMBLY REMOVE AIR FLOW METER FROM AIR CLEANER CAP (a) Remove the two bolts and resonator. (b) Pry off the lock plate, and remove the bolt, four nuts, four plates washers, air flow meter and gasket.
Page 145 FI–39 EFI SYSTEM – Air Induction System (Throttle Body) Throttle Body ON–VEHICLE INSPECTION INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. Start the engine. Check the vacuum with your finger. Port name At idling Other than idling...
Page 146 FI–40 EFI SYSTEM – Air Induciton System (Throttle Body) Clearance between Between Resistance lever and stop screw terminals 0 mm (0 in). VTA – E2 0.3 – 6.3 k 0.30 mm (0.012 in.) IDL – E2 2.3 k or less 0.70 mm (0.028 in.) IDL –...
Page 147 FI–41 EFI SYSTEM – Air Induction System (Throttle Body) F. Check VTV operation Race the engine at 2,500 rpm for a few seconds, release the throttle valve and check that the engine returns to idle in a few seconds. REMOVAL OF THROTTLE BODY DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx.
Page 148 FI–42 EFI SYSTEM – Air Induction System (Throttle Body) INSPECTION OF THROTTLE BODY CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor.
Page 149 FI–43 EFI SYSTEM – Air Induction System (Throttle Body) INSTALLATION OF THROTTLE BODY INSTALL THROTTLE BODY (a) Install a new gasket and the throttle body with the four (M/T) or three (A/T) bolts. Torque: 130 kg–cm (9 ft–lb, 13 N m) (b) (A/T) Install the throttle cable bracket with the two bolts.
Page 150 FI–44 EFI SYSTEM – Air Induction System (Idle Speed Control (ISC) Valve) Idle Speed Control (ISC) Valve ON–VEHICLE INSPECTION CHECK FOR OPERATING SOUND FROM ISC VALVE Check that there is a clicking sound immediately stopping the engine. INSPECT ISC VALVE RESISTANCE (a) Disconnect the ISC valve connector.
Page 151 FI–45 EFI SYSTEM – Air Induction System (Idle Speed Control (ISC) Valve) DISCONNECT ISC VALVE CONNECTOR DISCONNECT AIR HOSE AND TWO WATER BY–PASS HOSES REMOVE ISC VALVE (a) Remove the nut, and disconnect the wire harness clamp. (b) Remove the two bolts, ISC valve and gasket. INSPECTION OF ISC VALVE INSPECT ISC VALVE OPERATION (a) Apply battery voltage to terminals B1 and B2, and while...
Page 152 FI–46 EFI SYSTEM – Electronic Control System (Location of Electronic Control Parts) ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts...
Page 153 FI–47 EFI SYSTEM – Electronic Control System (EFI Main Relay) EFI Main Relay INSPECTION OF EFI MAIN RELAY INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is no continuity between terminals 2 and 4.
Page 154 FI–48 EFI SYSTEM – Electronic Control System (Circuit Opening Relay) Circuit Opening Relay INSPECTION OF CIRCUIT OPENING RELAY INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals STA and E1. (b) Check that there is continuity between terminals +B and (c) Check that there is no continuity between terminals +B and FP.
Page 155 FI–49 EFI SYSTEM – Electronic Control System (Cold Start Injector Time Switch) Cold Start Injector Time Switch INSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT RESISTANCE OF COLD START INJECTOR TIME SWITCH Using an ohmmeter, measure the resistance between each terminal.
Page 156 FI–50 EFI SYSTEM – Electronic Control System (Water Temperature Sensor) Water Temperature Sensor INSPECTION OF WATER TEMPERATURE SENSOR INSPECT RESISTANCE OF WATER TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the ter- minals. Resistance: Refer to the chart If the resistance is not as specified, replace the sensor.
Page 157 FI–51 EFI SYSTEM Electronic Control System (EGR Gas Temperature Sensor (CALIF. only)) – EGR Gas Temperature Sensor (CALIF. only) INSPECTION OF EGR GAS TEMPERATURE SENSOR INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the ter- minals. Resistance: 69.40 –...
Page 158 FI–52 EFI SYSTEM – Electronic Control System (Fuel Pressure Control System) Fuel Pressure Control System INSPECTION OF FUEL PRESSURE COTROL SYSTEM INSPECT WATER TEMPERATURE SENSOR (See page FI–50) INSPECT INTAKE AIR TEMPERATURE SENSOR (See page FI–37) INSPECT FUEL PRESSURE VSV A.
Page 159 FI–53 EFI SYSTEM – Electronic Control System (Fuel Pressure Control System) C. Inspect VSV operation (a) Check that air flows from ports E to G. (b) Apply battery voltage across the terminals (c) Check that air flows from port E to filter. If operation is not as specified, replace the VSV.
Page 160 FI–54 EFI SYSTEM – Electronic Control System (Oxygen Sensor (Main)) Oxygen Sensor (Main) INSPECTION OF OXYGEN SENSOR WARM UP ENGINE Allow the engine to warm up to normal operating tempera- ture. INSPECT FEEDBACK VOLTAGE Connect the positive (+) probe of a voltmeter to terminal VF1 of the check connector, and negative (–) probe to terminal E1.
Page 161 FI–55 EFI SYSTEM – Electronic Control System (Oxygen Sensor (Main)) CONTINUED FROM PAGE FI–54 Repair the relevant diagnostic code. Malfunction code(s) (Ex. code Nos. 21, 25 and 26) Rear record diagnostic codes. (See page TR–9 or TR–10) Normal code, code Nos. 21, 25 and 26 Disconnect terminals TE1 and E1 of the check connector.
Page 162 FI–56 EFI SYSTEM Electronic Control System (Oxygen Sensor (Main), Sub–Oxygen Sensor (CALIF. only)) – INSPECT HEATER RESISTANCE OF OXYGEN SENSOR Using an ohmmeter, measure the resistance between termi- nals +B and HT. Resistance (Cold): 5.1–6.3 at 20 C (68 F) If the resistance is not as specified, replace the sensor.
Page 163 FI–56 EFI SYSTEM Electronic Control System (Oxygen Sensor (Main), Sub–Oxygen Sensor (CALIF. only)) – INSPECT HEATER RESISTANCE OF OXYGEN SENSOR Using an ohmmeter, measure the resistance between termi- nals +B and HT. Resistance (Cold): 5.1–6.3 at 20 C (68 F) If the resistance is not as specified, replace the sensor.
Page 164 FI–57 EFI SYSTEM Electronic Control System (Electronic Control Unit (ECU)) – Electronic Control Unit (ECU) TERMINALS OF ECU Symbol Terminal name Symbol Terminal name POWER GROUND SUB–OXYGEN SENSOR POWER GROUND STOP LIGHT SWITCH No. 10 INJECTOR (No. 1 and No. 6) WATER TEMPERATURE SENSOR No.
Page 165 FI–58 EFI SYSTEM – Electronic Control System (Electronic Control Unit (ECU)) INSPECTION OF ECU HINT: The EFI circuit can be checked by measuring the resis- tance and voltage at the wiring connectors of the ECU. PREPARATION (a) Disconnect the connectors from the ECU. (b) Remove the locks as shown in the illustration so that the test probe(s) can easily come in.
Page 166 FI–59 EFI SYSTEM – Electronic Control System (Electronic Control Unit (ECU)) Voltage at ECU Wiring Connectors Terminals Condition STD voltage (V) BATT – E1 – IG SW – E1 10 – 14 M-REL – E1 IG SW ON IG SW ON –...
Page 167 FI–60 EFI SYSTEM – Electronic Control System (Electronic Control Unit (ECU) INSPECT RESISTANCE OF ECU NOTICE: Do not touch the ECU terminals. The tester probe should be inserted into the wiring connector from the wiring side. Check the resistance between each terminal of the wiring connectors.
Page 168 FI–61 EFI SYSTEM – Electronic Control System (Fuel Cut RPM) Fuel Cut RPM INSPECTION OF FUEL CUT RPM WARM UP ENGINE Allow the engine to warm up to normal operating tempera- ture. INSPECT FUEL CUT RPM (a) Disconnect the connector from the throttle position sensor.
Page 169 FI–62 EFI SYSTEM – Service Specifications SERVICE SPECIFICATIONS SPECIFICATIONS Fuel pressure Fuel pressure at no vacuum 2.7 – 3.1 kg/cm regulator (38 – 44 psi, 265 – 304 kPa) Cold start Resistance 2 – 4 injector Fuel leakage One drop or less per minute Resistance Approx.
Page 170 FI–63 EFI SYSTEM – Service Specifications SPECIFICATIONS (Cont’d) HINT: HINT: Perform all voltage and resistance measurements with the ECU connected. Verify that the battery voltage is 11 V or above with the ignition switch is ON. Voltage Terminals Condition STD voltage (V) BATT –...
Page 171 FI–64 EFI SYSTEM – Service Specifications SPECIFICATIONS (Cont’d) ECU (cont’d) Resistance Terminals Condition STD resistance ( ) Throttle valve open Infinity IDL – E2 Throttle valve fully closed 2,300 or less Throttle valve fully open 3,500 – 10,300 VTA – E2 Throttle valve fully closed 300 –...
Page 172 EX–1 EXHAUST SYSTEM – REPAIR INSTRUCTIONS EXHAUST SYSTEM...
Page 173 EX–2 EXHAUST SYSTEM – Exhaust Pipes and Heat Insulators EXHAUST PIPES AND HEAT INSULATORS COMPONENTS...
Page 174 EC–1 EMISSION CONTROL SYSTEMS...
Page 175 EC–2 EMISSION CONTROL SYSTEMS – System Purpose SYSTEM PURPOSE System Abbreviation Purpose Positive Crankcase ventilation Reduces blow–by gas (HC) Fuel evaporative emission control EVAP Reduces evaporative HC Exhaust gas recirculation Reduces NOx Three–way catalyst Reduces HC, CO and NOx Electronic fuel injection* Regulates all engine conditions for reduction of exhaust emissions.
Page 176 EC–3 EMISSION CONTROL SYSTEMS – Component Layout and Schematic Drawing COMPONENT LAYOUT AND SCHEMATIC DRAWING...
Page 177 EC–4 EMISSION CONTROL SYSTEMS – Positive Crankcase Ventilation (PCV) System POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM To reduce HC emission, crankcase blow–by gas (HC) is routed through the PCV valve to the air intake chamber for combustion in the cylinders...
Page 178 EC–5 EMISSION CONTROL SYSTEMS – Positive Crankcase Ventilation (PCV) System INSPECTION OF PCV VALVE REMOVE PCV VALVE INSTALL CLEAN HOSE TO PCV VALVE BLOW AIR FROM CYLINDER HEAD SIDE Check that air passes through easily. NOTICE: Do not suck air through the valve. Petroleum substances inside the valve are harmful.
Page 179 EC–6 EMISSION CONTROL SYSTEMS – Fuel Evaporative Emission Control (EVAP) System FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM To reduce HC emissions, evaporated fuel from the fuel tank is routed through the charcoal canister to the intake manifold for combustion in the cylinders. Check Canister Check Valve Coolant...
Page 180 EC–7 EMISSION CONTROL SYSTEMS – Fuel Evaporative Emission Control (EVAP) System INSPECTION OF CHARCOAL CANISTER REMOVE CHARCOAL CANISTER REMOVE DUST COVER FROM CHARCOAL CANISTER VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. CHECK FOR CLOGGED FILTER AND STUCK CHECK VALVE (a) Using low pressure compressed air, blow into port A and check that air flows without resistance from the other...
Page 181 EC–8 EMISSION CONTROL SYSTEMS – Exhaust Gas Recirculation (EGR) System EXHAUST GAS RECIRCULATION (EGR) SYSTEM To reduce NOx emissions, part of the exhaust gasses are recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature. Coolant Throttle Valve Pressure in the EGR...
Page 182 EC–9 EMISSION CONTROL SYSTEMS – Exhaust Gas Recirculation (EGR) System INSPECTION OF EGR SYSTEM CHECK AND CLEAN FILTERS IN EGR VACUUM MODULATOR (a) Check the filters for contamination or damage. (b) Using compressed air, clean the filters. HINT: Install the filters with the coarser surface facing the at- mospheric side (outward).
Page 183 EC–10 EMISSION CONTROL SYSTEMS – Exhaust Gas Recirculation (EGR) System CHECK EGR VALVE (a) Apply vacuum directly to the EGR valve with the engine idling. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to the proper locations. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, SYS- TEM IS NORMAL;...
Page 184 EC–11 EMISSION CONTROL SYSTEMS – Three–Way Catalyst (TWC) System THREE–WAY CATALYST (TWC) SYSTEM To reduce CO, HC, and NOx emissions, they are oxidized, reduced and converted into nitrogen (N carbon dioxide (CO ) and water (H 0) by the catalyst. Sub–TWC Exhaust Port Main TWC...
Page 185 EC–12 EMISSION CONTROL SYSTEMS – Three–Way Catalyst (TWC) System INSPECTION OF HEAT INSULATOR CHECK HEAT INSULATOR FOR DAMAGE CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR REPLACEMENT OF CATALYTIC CONVERTER REMOVE CONVERTER (a) Jack up the vehicle. (b) Check that the converter is cool. (c) Remove the four bolts and nuts holding the pipes to the converter.
Page 186 CO–1 COOLING SYSTEM...
Page 187 CO–2 COOLING SYSTEM – Description, Operation DESCRIPTION This engine utilizes a pressurized, forced circulation cooling system which includes a thermostat equipped with a by–pass valve mounted on the inlet side. OPERATION...
Page 188 CO–2 COOLING SYSTEM – Description, Operation DESCRIPTION This engine utilizes a pressurized, forced circulation cooling system which includes a thermostat equipped with a by–pass valve mounted on the inlet side. OPERATION...
Page 189 CO–3 COOLING SYSTEM – Operation The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electric fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which an electric fan blows air to cool the coolant as it passes through.
Page 190 CO–4 COOLING SYSTEM – Preparation PREPARATION RECOMMENDED TOOLS Illustration Part No. Part Name Note TOYOTA Electrical 09082–00015 Tester EQUIPMENT Part Name Note Ammeter Ohmmeter Radiator cap tester Torque wrench LUBRICANT Capacity Item Item Classification Classification Liters US qts lmp. Qts Engine Coolant 10.0...
Page 191 CO–5 COOLING SYSTEM – Check and Replacement of Engine Coolant CHECK AND REPLACEMENT OF ENGINE COOLANT CHECK ENGINE COOLANT LEVEL AT RESERVE TANK The coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add coolant up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant...
Page 192 CO–6 COOLING SYSTEM – Water Pump WATER PUMP COMPONENTS REMOVAL OF WATER PUMP DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 193 CO–7 COOLING SYSTEM – Water Pump REMOVE WATER PUMP (a) Remove the seven bolts. (b) Remove the water pump by prying a screwdriver between the water pump and cylinder block. INSPECTION OF WATER PUMP INSPECT WATER PUMP Turn the pulley and check that the water pump bearing moves smoothly and quietly.
Page 194 CO–8 COOLING SYSTEM – Water Pump INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe. (b) Apply soapy water to the O–ring. (c) Connect the water inlet pipe to the water inlet. (d) Install the bolt holding the water inlet pipe to the alternator belt adjusting bar.
Page 195 CO–9 COOLING SYSTEM – Thermostat THERMOSTAT REMOVAL OF THERMOSTAT DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 196 CO–10 COOLING SYSTEM – Thermostat INSTALLATION OF THERMOSTAT PLACE THERMOSTAT IN WATER PUMP (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with stud bolt (A), and insert the thermostat in the water pump. INSTALL WATER INLET Install the water inlet with the three nuts.
Page 197 CO–11 COOLING SYSTEM – Radiator RADIATOR CLEANING OF RADIATOR Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 30–35 kg/cm (427–498 psi, 2,942–3,432 kPa), keep a distance at least 40–50 cm (15.75–19.69 in.)
Page 198 CO–12 COOLING SYSTEM – Radiator REMOVAL OF RADIATOR DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 199 CO–13 COOLING SYSTEM – Radiator 10. REMOVE RADIATOR AND ELECTRIC COOLING FANS Remove the two bolts, supports and radiator. 11. REMOVE ELECTRIC COOLING FANS FROM RADIATOR INSTALLATION OF RADIATOR (See page CO–12) INSTALL ELECTRIC COOLING FANS TO RADIATOR INSTALL RADIATOR Place the radiator in position, and install the two supports with the two bolts.
Page 200 CO–14 COOLING SYSTEM – Electric Cooling Fans ELECTRIC COOLING FANS SYSTEM CIRCUIT LOCATION OF ELECTRIC COOLING FAN COMPONENTS...
Page 201 CO–15 COOLING SYSTEM – Electric Cooling Fans ON–VEHICLE INSPECTION Low Temperature (Below 85°C (185°F)) TURN IGNITION SWITCH ”ON” Check that the fan stops. If not, check the cooling fan relays and water temperature sensor, and check for a separated connector or severed wire between the cooling fan relay and water temperature sensor.
Page 202 CO–16 COOLING SYSTEM – Electric Cooling Fans Check for Tester connection Condition Specified valve Continuity 2–Ground Continuity – Voltage 3–Ground Ignition switch ON Battery voltage Voltage 4–Ground Ignition switch ON Battery voltage 80°C (176°F) Approx. 1.53 k 90°C (194°F) Approx. 1.18 k 5–7 Coolant temp.
Page 203 CO–17 COOLING SYSTEM – Electric Cooling Fans INSPECT NO.2 COOLING FAN RELAY (”A.C FAN NO.2”) A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 2 and 6. (b) Check that there is continuity between terminals 1 and (c) Check that there is no continuity between terminals 1 and 4.
Page 204 CO–18 COOLING SYSTEM – Service Specifications SERVICE SPECIFICATIONS SPECIFICATIONS Engine coolant capacity 9.5 liters 10.0 US pts 8.4 lmp. qts 9.4 liters 9.9 US qts 8.3 lmp. qts Radiator Relief valve opening pressure 0.75–1.05 kg/cm (10.7–14.9 psi, 74–103 kPa) Limit 0.6 kg/cm 8.5 psi 59 kPa...
Page 205 LU–1 LUBRICATION SYSTEM – Description, Operation LUBRICATION SYSTEM...
Page 206 LU–2 LUBRICATION SYSTEM – Description, Operation DESCRIPTION A fully pressurized, fully filtered lubrication system has been adopted for this engine. OPERATION CAMSHAFT GEAR CAMSHAFT GEAR VALVE LIFTERS & STEMS VALVE LIFTERS & STEMS CAMS CAMS PISTONS CAMSHAFT JOURNALS CAMSHAFT JOURNALS CONNECTING ROD CYLINDER HEAD CYLINDER HEAD...
Page 207 LU–2 LUBRICATION SYSTEM – Description, Operation DESCRIPTION A fully pressurized, fully filtered lubrication system has been adopted for this engine. OPERATION CAMSHAFT GEAR CAMSHAFT GEAR VALVE LIFTERS & STEMS VALVE LIFTERS & STEMS CAMS CAMS PISTONS CAMSHAFT JOURNALS CAMSHAFT JOURNALS CONNECTING ROD CYLINDER HEAD CYLINDER HEAD...
Page 208 LU–3 LUBRICATION SYSTEM – Operation A Pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block.
Page 209 LU–4 LUBRICATION SYSTEM – Preparation PREPARATION SST (SPECIAL SERVICE TOOLS) 09032–00100 Oil Pan Seal Cutter Oil Filter Wrench 09228–07500 RECOMMENDED TOOLS For suspending engine Engine Sling Device 09090–04000 09200–00010 Engine Adjust Kit 09905–00013 Snap Ring Pliers EQUIPMENT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 210 LU–5 LUBRICATION SYSTEM – Oil Pressure Check OIL PRESSURE CHECK CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is poor, replace the oil. Oil grade: API grade SG, multigrade, fuel–efficient and rec- ommended viscosity oil CHECK ENGINE OIL LEVEL The oil level should be between the “L”...
Page 211 LU–6 LUBRICATION SYSTEM – Replacement of Engine Oil and Oil Filter REPLACEMENT OF ENGINE OIL AND OIL FILTER CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Page 212 LU–7 LUBRICATION SYSTEM – Replacement of Engine Oil and Oil Filter FILL WITH ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 250 kg–cm (18 ft–lb, 25 N m) (b) Fill with new engine oil. Oil grade: See page LU–5 Capacity:...
Page 213 LU–8 LUBRICATION SYSTEM – Oil Pump OIL PUMP REMOVAL OF OIL PUMP HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20 se- conds or longer from the time the ignition switch is turned to the “LOCK”...
Page 214 LU–9 LUBRICATION SYSTEM – Oil Pump REMOVE STIFFENER PLATE Remove the two bolts and stiffener plate. 10. REMOVE OIL PAN (a) Remove the dipstick. (b) Remove the fifteen bolts and four nuts. (c) Insert the blade of SST between the cylinder block and oil pan, cut off applied sealer and remove the oil pan.
Page 215 LU–10 LUBRICATION SYSTEM – Oil Pump 13. SUSPEND ENGINE WITH ENGINE HOIST CHAIN 14. REMOVE TIMING BELT, NO.1 IDLER AND CRANKSHAFT TIMING PULLEYS (See pages EM–15 to EM–20) 15. REMOVE ALTERNATOR (See page CH–8) 16. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES (See step 29 on page EM–66) 17.
Page 216 LU–11 LUBRICATION SYSTEM – Oil Pump COMPONENTS DISASSEMBLY OF OIL PUMP REMOVE RELIEF VALVE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retainer, spring and relief valve. REMOVE DRIVE AND DRIVEN ROTORS Remove the eight screws, pump body cover, the drive and driven rotors.
Page 217 LU–12 LUBRICATION SYSTEM – Oil Pump INSPECTION OF OIL PUMP INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesnt, replace the relief valve. If necessary, replace the oil pump assembly.
Page 218 LU–13 LUBRICATION SYSTEM – Oil Pump ASSEMBLY OF OIL PUMP (See page LU–11) INSTALL DRIVE AND DRIVEN ROTORS (a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install the pump body cover with the eight screws. INSTALL RELIEF VALVE (a) Insert the relief valve, spring and retainer into the pump body hole.
Page 219 LU–14 LUBRICATION SYSTEM – Oil Pump INSTALLATION OF OIL PUMP (See page LU–8) INSTALL OIL PUMP (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Page 220 LU–15 LUBRICATION SYSTEM – Oil Pump (e) Install the oil pump with the nine bolts. Torque: 12 mm head bolt (C and D) 200 kg–cm (14 ft–lb, 20 N m) 14 mm head bolt (A and B) 420 kg–cm (30 ft–lb, 41 N m) INSTALL PS BELT ADJUSTING BAR INSTALL A/C COMPRESSOR BRACKET INSTALL ALTERNATOR (See page CH–8)
Page 221 LU–16 LUBRICATION SYSTEM – Oil Pump (b) Apply seal packing to the baffle plate as shown in the figure. Seal packing: Part No. 08826–00080 or equivalent Install a nozzle that has been cut to a 3–4 mm (0.12–0.16 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Page 222 LU–17 LUBRICATION SYSTEM – Oil Pump (c) Install the oil pan with the fifteen bolts and four nuts. Torque: 60 kg–cm (52 in.–lb, 5.9 N m) (d) Install the dipstick. 11. INSTALL STIFFENER PLATE Install the stiffener plate with the two bolts. Torque: 380 kg–cm (27 ft–lb, 37 N m) 12.
Page 223 LU–18 LUBRICATION SYSTEM – Service Specifications SERVICE SPECIFICATIONS SPECIFICATIONS TORQUE SPECIFICATIONS...
Page 224 IG–1 IGNITION SYSTEM...
Page 225 IG–2 IGNITION SYSTEM – General Description GENERAL DESCRIPTION PRECAUTIONS Do not leave the ignition switch on for more than 10 minutes if the engine will not start. When a tachometer is connected to the system, connect the test probe of the tachometer to terminal IG of the check connector.
Page 226 IG–3 IGNITION SYSTEM – Description DESCRIPTION The ECU is programmed with data for optimum ignition timing under any and all operating conditions. Using data provided by sensors which monitor various engine functions (rpm, intake air volume, eng, temperature, etc.), the microcomputer (ECU) triggers the spark at precisely the right instant. The ECU monitors the engine condition by sig- IGNITION COIL nals from each sensor, calculates the ignition timing...
Page 227 IG–4 IGNITION SYSTEM – Operation OPERATION To maintain the most appropriate ignition timing, the ECU sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark.
Page 228 IG–5 IGNITION SYSTEM – Preparation PREPARATION SST (SPECIAL SERVICE TOOLS) 09843-18020 Diagnosis Check Wiring RECOMMENDED TOOLS TOYOTA Electrical 09082-00015 Tester 09200-00010 Engine Adjust Kit EQUIPMENT Part Name Note Timing light Ignition timing Tachometer Megger Insulation resistance meter Ohmmeter Spark plug cleaner...
Page 229 IG–6 IGNITION SYSTEM – On-Vehicle Inspection ON–VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS (a) Disconnect the high–tension cord from the distributor. (b) Hold the end approx. 12.5 mm (0.50 in.) from body of vehicle. (c) See if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors dur- ing this test, crank the engine for no more than 1–2 seconds at time.
Page 230 IG–7 IGNITION SYSTEM – On-Vehicle Inspection INSPECTION OF HIGH–TENSION CORDS CAREFULLY REMOVE HIGH–TENSION CORDS FROM SPARK PLUGS BY THEIR RUBBER BOOTS NOTICE: Pulling on or bending the cords may damage the conductor inside. INSPECT HIGH–TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 k per cord If the resistance is greater than maximum, replace the high–...
Page 231 IG–8 IGNITION SYSTEM – On-Vehicle Inspection Visually inspect the spark plugs. If the electrode is dry ..Okay If the electrode is wet ..Proceed to step 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the spark plug. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread or insulation damage.
Page 232 IG–9 IGNITION SYSTEM – On-Vehicle Inspection INSPECTION OF IGNITION COIL INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between posi- tive (+) and negative (–) terminals. Primary coil resistance (Cold): 0.40 – 0.50 If the resistance is not as specified, replace the ignition coil. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and high–tension terminals.
Page 233 IG–10 IGNITION SYSTEM – Distributor DISTRIBUTOR COMPONENTS REMOVAL OF DISTRIBUTOR REMOVE UPPER BRACE REMOVE AIR CLEANER CAP, AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the air flow meter connector. (b) Disconnect the air hoses. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the air cleaner cap clips.
Page 234 IG–11 IGNITION SYSTEM – Distributor INSTALLATION OF DISTRIBUTOR SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft clockwise, and position the slit of the in- take camshaft (RH cylinder head) as shown. Look at the dis- tributor attachment hole to set. INSTALL DISTRIBUTOR (a) Install a new O–ring to the housing.
Page 235 IG–12 IGNITION SYSTEM – Distributor (b) (Ex. Center Cord) Align the spline of the distributor cap with the spline groove of the holder, and slide the holder. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustra- tion.
Page 236 IG–13 IGNITION SYSTEM – Distributor WARM UP ENGINE Allow the engine to reach normal operating temperature. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the tachometer test probe to terminal IG of the check connector. NOTICE: NEVER allow the tachometer test probe to touch ground as it could result in damage to the igniter and/or ignition coil.
Page 237 IG–14 IGNITION SYSTEM – Service Specifications SERVICE SPECIFICATIONS...
Page 238 TR–1 ENGINE TROUBLESHOOTING...
Page 239 TR–2 ENGINE TROUBLESHOOTING – How to Proceed with Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING The Engine Control System broadly consists of the sensors, ECU and actuators. The ECU receives signals from various sensors, judges the operating conditions and determines the optimum injection duration, timing, ignition timing and idle speed.
Page 240 TR–3 ENGINE TROUBLESHOOTING – How to Proceed with Troubleshooting [10] CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in [6] and [8]. Determine whether the cause of the problem is in the sensors, actuators, wire harness and connectors, or the ECU.
Page 241 TR–4 ENGINE TROUBLESHOOTING – How to Proceed with Troubleshooting Vehicle Brought to Workshop Customer Problem Analysis TR–7 Diagnostic Code Check, Diagnostic Code Clearance P. TR–9, TR–13 Problem Symptom Symptom Simulation Does Not Exist Problem Symptom Confirmation TR–14 Problem Symptom Exist Diagnostic Code Check TR–9 Malfunction Code...
Page 242 TR–5 ENGINE TROUBLESHOOTING – How to Proceed with Troubleshooting How to Proceed with Troubleshooting Using Volt/Ohm Meter and TCCS Checker For the explanation of steps [1] ~ [6] , [9] ~ [14] , see the explanation of steps with the same title on page TR–2. [7] [8] CIRCUIT INSPECTION BY CHECKER If the Normal code is displayed in the diagnostic code check, connect the checker to the vehicle and check...
Page 243 TR–6 ENGINE TROUBLESHOOTING – How to Proceed with Troubleshooting TR–7 TR–9 TR–13 TR–14 TR–9 TR–18 TR–19 TR–23 TR–26...
Page 244 TR–7 ENGINE TROUBLESHOOTING – Customer Problem Analysis Check Sheet CUSTOMER PROBLEM ANALYSIS CHECK SHEET Inspector’s ENGINE CONTROL System Check Sheet Name: Registration No. Customer’s Name Registration Year Frame No. Miles Date Vehicle Brought In Odometer Reading Date of Problem Occurrence Constant Sometimes ( times/...
Page 245 TR–8 ENGINE TROUBLESHOOTING – Diagnosis System DIAGNOSIS SYSTEM DESCRIPTION The ECU contains a built–in self–diagnosis system by which troubles with the engine signal network are detected and a ”CHECK” engine warning light on the instrument panel lights By analyzing various signals as shown in the table later on (See page TR–11) the Electronic Control Unit (ECU) detects system malfunctions relating to the sensors or actuators.
Page 246 TR–9 ENGINE TROUBLESHOOTING – Diagnosis System Diagnosis Inspection ”CHECK” ENGINE WARNING LIGHT CHECK The ”CHECK” engine warning light will come on when the ignition switch is turned ON and the engine is not running. When the engine is started, the ”CHECK” engine warning light should go off.
Page 247 TR–10 ENGINE TROUBLESHOOTING – Diagnosis System (b) Malfunction Code Indication In the event of a malfunction, the light will blink every 0.5 seconds. The first number of blinks will equal the first digit of a 2–digit diagnostic code and, after a 1.5 second pause, the 2nd number of blinks will equal the 2nd.
Page 248 TR–11 ENGINE TROUBLESHOOTING – Diagnosis System DIAGNOSTIC CODES “CHECK” Code Number to blinks System Engine Diagnosis Trouble Areas “CHECK” engine Memory Warning Light Output when no other code is re- — — — Normal – corded Open or short in NE, G Circuit No G or NE signal is input to the Distributor ECU for 2 sec.
Page 249 TR–12 ENGINE TROUBLESHOOTING – Diagnosis System DIAGNOSTIC CODES (Cont’d) “CHECK” Code Number to blinks System Diagnosis Trouble Areas Engine “CHECK” engine Memory Warning Light When sub–oxygen sensor is warmed up apply acceleration with Short or open in Sub– the throttle fully open for 2 sec- sub–oxygen sensor circuit oxygen onds, output of main oxygen sen-...
Page 250 TR–13 ENGINE TROUBLESHOOTING – Diagnosis System This indicates items for which ”2 trip detection logic” is used. With this logic, when a logic malfunction is first detected, the malfunction is temporarily stored in the ECU memory. If the same case is detected again during the second drive test, this second detection causes the ”CHECK”...
Page 251 TR–14 ENGINE TROUBLESHOOTING – Symtom Simulation SYMPTOM SIMULATION ”Intermittent troubles or problems” are the malfunctions about which the customer has a complaint, but which do not occur and can not be confirmed in the workshop. The intermittent problems also include complaints about the ”CHECK”...
Page 252 TR–15 ENGINE TROUBLESHOOTING – Symtom Simulation When vibration seems to be the major VIBRATION METHOD: cause. (cont’d) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thor- oughly.
Page 253 TR–16 ENGINE TROUBLESHOOTING – Symtom Simulation When a malfunction seems to occur when electrical OTHER: load is excessive. Turn on all electrical loads including the heater blower, head lamps, rear window defogger, etc. and check to see if the malfunction will occur.
Page 254 TR–17 ENGINE TROUBLESHOOTING – Terminals of ECU TERMINALS OF ECU When measuring the voltage or resistance of the connector part of the ECU, remove the locks as required in the following procedure and always insert the test probe into the connector from the wire harness side.
Page 255: Table Of Contents
TR–18 ENGINE TROUBLESHOOTING – Diagnostic Code Chart DIAGNOSTIC CODE CHART After confirming the symptoms, check the diagnosis codes. If a trouble code is output, check the circuit corre- sponding to that circuit as found in the diagnostic code chart below. Code No.
Page 256 TR–19 ENGINE TROUBLESHOOTING – Basic Inspection BASIC INSPECTION When the normal code is displayed in the diagnostic code check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently.
Page 257 TR–20 ENGINE TROUBLESHOOTING – Basic Inspection Is air leaking into intake air system? Is air leaking into air intake system? Loose or missing engine oil dipstick, oil filler cap, PCV hose, etc., can allow air to leak into air intake system, causing mixture to become too lean.
Page 258 TR–21 ENGINE TROUBLESHOOTING – Basic Inspection Check ignition timing (Cont’d). Check ignition timing using a timing light. Ignition timing: 10° BTDC at idle. Transmission into “N” range. FURTHER CHECK Disconnect SST. Check if the ignition timing advances using a timing light.
Page 259 TR–22 ENGINE TROUBLESHOOTING – Basic Inspection Check fuel pressure. (1) Be sure that fuel is enough in tank. (2) Turn ignition switch ON. (3) Using SST, connect terminals +B and FP of check connector. SST 09843–18020 Check if there is a pressure in hose from fuel filter by pinching hose by fingers.
Page 260 TR–23 ENGINE TROUBLESHOOTING – Matrix Chart of Problem Symptoms MATRIX CHART OF PROBLEM SYMPTOMS When the malfunction code is not confirmed in the diagnostic code check and the problem still can not be con- firmed in the basic inspection, then proceed to this step and perform troubleshooting according to the number in order given in the table below.
Page 261 TR–24 ENGINE TROUBLESHOOTING – Matrix Chart of Problem Symptoms See page Parts Name Trouble Engine does not crank Starter runs–engine does not crank No initial combusion No complete combusion Engine cranks slowly Difficult to start ordinaly Difficult to start in cold Difficult to start in hot Incorrect first idle High engine idle speed...
Page 262 Accelerator – Pedal Link Brakes drag even – when released Cooling Fan CO–19 System Dash Pot EC–8 Clutch CL–1 Compression EM–14 Valve Clearance EM–8 Valve Timing EM–27 Timing Belt EM–15 Water Pump CO–6 Valve Stem EM–39 Guide Bushing Oil Pump LU–8 Connecting Rod EM–86...
Page 263 TR–26 ENGINE TROUBLESHOOTING – Circuit Inspection CIRCUIT INSPECTION Diag. Code RPM Signal CIRCUIT DESCRIPTION The distributor in the Engine Control System contains three pick–up coils (G1, G2 and Ne). The G1, G2 signals inform the ECU of the standard crankshaft angle. The Ne signals inform the ECU of the crankshaft angle and the engine speed.
Page 264 TR–27 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Does engine crank? Go to Matrix Chart of Problem Symptom (See page TR–21). Check air gap. Remove distributor cap. Using a thickness gauge, measure the gap between signal rotor projection and pickup coil. Air gap: 0.2 mm (0.008 in) or more Replace distributor.
Page 265 TR–28 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code RPM Signal CIRCUIT DESCRIPTION The distributor in the Engine Control System contains three pick–up coils (G1, G2 and Ne). The G1, G2 signals inform the ECU of the standard crankshaft angle. The Ne signals inform the ECU of the crankshaft angle and the engine speed. Code No.
Page 266: Ignition Signal
TR–29 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Ignition Signal CIRCUIT DESCRIPTION The ECU determines the ignition timing, turns on TR1 at a predetermined angle before the desired ignition timing, and outputs an ignition signal (IGT) “1” to the ignitor. Since the length of the IGT signal is constant, the dwell angle control circuit in the ignitor determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing in one revolution ago, that is, the time the TR2 turns on.
Page 267 TR–30 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Check for spark. Check voltage between terminal IGF Replace ECU> * of ECU connector and body ground. Check voltage between terminal IGF Replace Igniter of ignitor connector and body ground. Repair or replace harness or Check harness and connector between connector.
Page 268 TR–31 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 269 TR–32 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check for spark. Go to step [ 5 ]. Check voltage between terminal IGF of ECU connector and body ground. Measure voltage between terminal IGF of ECU con- nector and body ground, both with ignition switch ON but engine not cranking, and with engine crank- ing.
Page 270 TR–33 ENGINE TROUBLESHOOTING – Circuit Inspection Check power source line voltage of ignitor. (1) Disconnect ignitor connector. (2) Turn ignition switch ON. Measure voltage between terminal +B of ignitor connector and body ground. Voltage: Battery voltage Repair or replace harness or connector between ignitor and ignition switch.
Page 271 TR–34 ENGINE TROUBLESHOOTING – Circuiit Inspection Check ignition coil. (cont’d) CHECK SECONDARY COIL RESISTANCE Measure resistance between terminal +B and high tension terminal of ignition coil. Secondary coil resistance (cold): 10.2 – 13.8 Replace ignition coil. Check voltage between terminal IGT of ignitor connector and body ground.
Page 272: Ect Control Signal
TR–35 ENGINE TROUBLESHOOTING – Circuiit Inspection Diag. Code ECT Control Signal CIRCUIT DESCRIPTION Code No. Diagnosis Trouble Area Normal signal is not output from ECU of ECT. When the ECU stores diagnostic code 16 in memory, torque control which performs smooth gear shift- ing is prohibited.
Page 273: Main Oxygen Sensor Heater Signal
TR–36 ENGINE TROUBLESHOOTING – Circuiit Inspection Diag. Code Main Oxygen Sensor and Heater Signal CIRCUIT DESCRIPTION The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the concentration of oxygen present in the exhaust gas. The main oxygen sensor is provided with a heater.
Page 274 TR–37 ENGINE TROUBLESHOOTING – Circuiit Inspection CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS CODE DETECTION DRIVING PATTERN Purpose of the driving patten. (a) After the diag. code is erased, the malfunction is reproduced and the diag. code is recorded again. (b) To check that the malfunction is cleared once the repair is completed (confirm that diag. code is no longer detected).
Page 275 TR–38 ENGINE TROUBLESHOOTING – Circuiit Inspection DIAGNOSTIC CHART Check main oxygen sensor. Replace main oxygen sensor. Disconnect ECU connector and check Check and repair harness and voltage between terminal HT ECU connector between ECU and EFI connector and body ground. main relay.
Page 276 TR–39 ENGINE TROUBLESHOOTING – Circuiit Inspection INSPECTION PROCEDURE Check main oxygen sensor heater. Disconnect main oxygen sensor connector. Measure resistance between terminals +B and HT of main oxygen sensor connector. Resistance: 5.1 – 6.3 at 20°C (68°F) Replace main oxygen sensor. Disconnect ECU connector and check voltage between terminal HT of ECU connector and body ground.
Page 277: Water Temp. Sensor Signal
TR–40 ENGINE TROUBLESHOOTING – Circuiit Inspection Diag. Code Water Temp. Sensor Signal CIRCUIT DESCRIPTION The water temperature sensor senses the coolant temperature. The resistance value of a thermistor built in the sensor changes according to the coolant temperature. The lower the coolant temperature, the larger the resistance value becomes.
Page 278 TR–41 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check water temp sensor. Disconnect water temp. sensor connector. Using an ohmmeter, measure resistance between both terminals. Replace water temp. sensor. Check voltage between terminals THW and E2 of ECU connector. (1) Connect water temp. sensor connector. (2) Turn ignition switch ON.
Page 279: Intake Air Temp. Sensor Signal
TR–42 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Intake Air Temp. Sensor Signal CIRCUIT DESCRIPTION The intake air temperature sensor is built in the air flow meter and senses the intake air temperature. The resistance value of a thermistor built in sensor changes according to the intake air temperature. The lower the intake air temperature, the larger the resistance value becomes.
Page 280 TR–43 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check intake air temp. sensor. Disconnect air flow meter connector. Using an ohmmeter, measure resistance between terminals THA and E2. Replace air flow meter. Check voltage between terminals THA and E2 of ECU connector. (1) Connect air flow meter connector.
Page 281: Air-Fuel Ratio Lean Malfunction
TR–44 ENGINE TROUBLESHOOTING – Circuit Inspection Air–fuel Ratio Lean Malfunction Diag Code Diag. Code Air–fuel Ratio Rich Malfunction CIRCUIT DESCRIPTION The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the concentration of oxygen present in the exhaust gas. Code No.
Page 282 TR–45 ENGINE TROUBLESHOOTING – Circuit Inspection CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS CODE DETECTION DRIVING PATTERN Purpose of the driving patten. (a) After the diag. code is erased, the malfunction is reproduced and the diag. code is recorded again. (b) To check that the malfunction is cleared once the repair is completed (confirm that diag. code is no longer detected).
Page 283 TR–46 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART (For vehicles other than for California) Check voltage between terminals VF1 and E1 of check connector. Check harness or connector between ECU Repair or replace harness or and main oxygen sensor, ECU and check connector.
Page 284 TR–47 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART (California specification vehicles) Check voltage between terminals VF1 and When code 25 is displayed, go to E1 of check connector. step [ 3 ]. When code 26 is displayed, go to (Voltage stays step [ 5 ].
Page 285 TR–48 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 286 TR–49 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE (Vehicles other than for California) Check voltage between terminals THW and E1 of ECU connector. Warm up engine at normal operating temperature. (1) Using SST, connect terminals TE1 and E1 of check connector. Measure voltage between terminals THW and E2 of SST 09843–18020 ECU connector.
Page 287 TR–50 ENGINE TROUBLESHOOTING – Circuit Inspection (California specification vehicles) Check voltage between terminals VF1 and E1 of ECU connector. Warm up engine at normal operating temperature. (1) Using SST, connect terminals TE1 and E1 of check connector. SST 09843–18020 (2) Using an analog voltmeter, connect positive prove to VF1 terminal and negative prove to E1 terminal of check connector, and set it to 5–20 V range.
Page 288 TR–51 ENGINE TROUBLESHOOTING – Circuit Inspection Does malfunction disappear when a known good main oxygen sensor is installed? Repair or replace. Replace ECU Check each item found to be a possible cause of problem. Check each item found to be a possible cause of problem. Check item See page Check fuel system.
Page 289: Sub-Oxygen Sensor Signal (California Only
TR–52 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Sub–oxygen Sensor Signal (California Only) CIRCUIT DESCRIPTION The sub–oxygen sensor is located in the exhaust pipe behind the TWC. It rechecks the exhaust emission level after it is purified by the TWC and feeds the results back to the ECU. Code No.
Page 290 TR–53 ENGINE TROUBLESHOOTING – Circuit Inspection CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS CODE DETECTION DRIVING PATTERN For M/T Vehicle (1) Start engine and warm engine up. (2) After engine is warmed up, let it idle for 3 min. (3) With the A/C ON and the transmission in 4th gear, drive at 45–70 mph for 6 min. (4) After the driving in , stop the vehicle.
Page 291 TR–54 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Check connector of sub–oxygen sensor Repair. connector. Check continuity between terminals CHK Replace sub–oxygen sensor. and GND of sub–oxygen sensor connector. Check voltage between terminals CHK and GND of sub–oxygen sensor connector. Check voltage between terminal CHK of Check and repair harness and sub–oxygen sensor connector and body...
Page 292 TR–55 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 293 TR–56 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE HINT: If other codes are output at the same time code No. 27 is output, check the other codes first. Check connection of sub–oxygen sensor connector. Repair. Check continuity between terminals CHK and GND of sub–oxygen sensor connector.
Page 294 TR–57 ENGINE TROUBLESHOOTING – Circuit Inspection Check voltage between terminals CHK of ECU connector and body ground. (1) Disconnect sub–oxygen sensor connector. (2) Turn ignition switch ON. Measure voltage between terminals CHK of ECU connector and body ground. Voltage: 12V Check and repair harness and connector between ECU and sub–oxygen sensor.
Page 295 TR–58 ENGINE TROUBLESHOOTING – Circuit Inspection Check harness or connector between ECU, sub–oxygen sensor, and body ground. Repair or replace harness or connector. Check fuel system (See page FI–15). Repair fuel system Replace sub–oxygen sensor.
Page 296: Air Flow Meter Signal
TR–59 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code 31 or 32 Air Flow Meter Signal CIRCUIT DESCRIPTION The air flow meter is located directly behind the air cleaner, and detects the intake air volume. It con- verts the intake air readings into a voltage signal by means of a potentiometer. Intake air volume signal is used to calculate the basic injection duration and basic ignition advance angle.
Page 297 TR–60 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Check VS circuit for short circuit between Replace ECU. ECU and air flow meter. Repair or replace harness or connector. WIRING DIAGRAM AND ECU CONNECTORS...
Page 298 TR–61 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check voltage between terminals VC and E2 of air flow meter connector. (1) Carefully remove water–proofing rubber cover of air flow meter connector. (2) Turn ignition switch ON. Measure voltage between terminals Vc and E of air flow meter connector.
Page 299 TR–62 ENGINE TROUBLESHOOTING – Circuit Inspection Check voltage between terminals VC and E2 of air flow meter connector. (1) Turn ignition switch LOCK. (2) Disconnect air flow meter connector. (3) Turn ignition switch ON. Measure voltage between terminals Vc and E of air flow meter connector.
Page 300: Throttle Position Sensor Signal
TR–63 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Throttle Position Sensor Signal CIRCUIT DESCRIPTION The throttle position sensor is provided to the throttle body and detects the opening angle of the throttle valve. The ECU judges the vehicle driving conditions from the signals input from the terminal VTA of the throttle position sensor.
Page 301 TR–64 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 302 TR–65 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check voltage between terminals VC and E2 of throttle position sensor connector. (1) Disconnect throttle position sensor connector. (2) Turn ignition switch ON. Measure voltage between terminals Vc and E throttle position sensor connector. Voltage: 5V Go to step [ 4 ].
Page 303 TR–66 ENGINE TROUBLESHOOTING – Circuit Inspection Check voltage between terminal VC of throttle position sensor connector and body ground. Measure voltage between terminal Vc of throttle position sensor connector and body ground. Voltage: 5V Check harness and connector between ECU and throttle position sensor.
Page 304: Vehicle Speed Sensor Signal
TR–67 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Vehicle Speed Sensor Signal CIRCUIT DESCRIPTION The speed sensor is located inside the speedometer, and outputs four–pulse signals for each revolu- tion of the speedometer cable. Code No. Diagnosis Trouble Area SPD signal is not input to the ECU for at ·...
Page 305 TR–68 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check continuity between terminal SP1 of ECU connector and body ground. (1) Disconnect ECU connector. (2) Jack up a front wheel on one side. Check continuity between terminal SP1 of ECU connector and body ground while turning wheel slowly by hand.
Page 306: Starter Signal
TR–69 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Starter Signal CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich–mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the bat- tery voltage is applied to terminal STA of the ECU.
Page 307 TR–70 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check starter operation. Replace air flow meter. Check starter circuit. Check voltage between terminals STA and E1 of ECU circuit. Turn ignition switch STA. Measure voltage between terminals STA and E1 of ECU connector.
Page 308: Knock Sensor Signal
TR–71 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Knock Sensor Signal CIRCUIT DESCRIPTION The knock sensor is located on the cylinder block. If knocking develops in the engine, the knock sensor, by resonating with the knocking vibration, generates a voltage which corresponds to the knocking strength and sends a signal to the ECU. Code No.
Page 309 TR–72 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Check continuity between terminal KNK of ECU connector and body ground. Replace knock sensor. Check knock sensor. Check for short circuit between ECU and knock sensor. Check for open circuit between ECU and Repair or replace harness and knock sensor.
Page 310 TR–73 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check continuity between terminal KNK of ECU connector and body ground. Disconnect ECU connector. Check continuity between terminal KNK of ECU connector and boy ground. Open Go to step [ 3 ]. Check knock sensor.
Page 311: Knock Control Signal
TR–74 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Knock Control Signal CIRCUIT DESCRIPTION The knock sensor generates a voltage when the cylinder block vibrates due to knocking and sends a signal to the ECU. If engine knocking occurs, ignition timing is retarded to reduce it. Code No.
Page 312: Egr System Malfunction (California Only
TR–75 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code EGR System Malfunction (California Only) CIRCUIT DESCRIPTION To reduce NOx emission, part of the exhaust gases are recirculated through the EGR valve to the in- take manifold to lower the maximum combustion temperature. Code No.
Page 313 TR–76 ENGINE TROUBLESHOOTING – Circuit Inspection CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS CODE DETECTION DRIVING PATTERN For M/T Vehicle Á Start engine. Â Soon after starting the engine (no warming up), drive for 5 min. at 45–70 mph in 4th gear with air conditioner ON. (Keep the accelerator pedal position constant). Turn the IG switch to OFF (not Acc) when you finish driving, then 30 min.
Page 314 TR–77 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Repair EGR system. Check EGR system (See page EC–10). Check voltage between terminals THG and E2 of EGR gas temp. sensor connector. Replace EGR gas temp. sensor. Check EGR gas temp. sensor. Repair or replace EGR gas temp.
Page 315 TR–78 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 316 TR–79 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Check EGR system (See page EC–10). Repair EGR system. Check voltage between terminals THG and E2 of EGR gas temp. sensor connector. (1) Disconnect EGR gas temp. sensor connector. (2) Turn ignition switch ON. Measure voltage between terminals THG and E2 of EGR gas temp.
Page 317 TR–80 ENGINE TROUBLESHOOTING – Circuit Inspection Check voltage between terminal THG of EGR gas temp. sensor connector and body ground. Measure voltage between terminal THG of EGR gas temp. sensor connector and body ground. Voltage: 5V Check harness and connector between terminal E2 of ECU connector and EGR gas temp.
Page 318: Switch Condition Signal
TR–81 ENGINE TROUBLESHOOTING – Circuit Inspection Diag. Code Switch Condition Signal CIRCUIT DESCRIPTION Neutral Start Switch Signal The ECU uses the signals from the neutral start switch to determine whether the transmission is in park or neutral, or in some other gear. Air Conditioner Switch Signal The ECU uses the signal from the air conditioner switch to determine whether or not the air conditioner is operating, and increases the idling speed of the engine.
Page 319 TR–82 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART Air Conditioner Switch Signal Repair A/C system. Check operation of A/C system. Check voltage between terminal A/C of Check harness or connector ECU connector and body ground. between ECU and A/C amplifier. Replace ECU.
Page 320 TR–83 ENGINE TROUBLESHOOTING – Circuit Inspection DIAGNOSTIC CHART WIRING DIAGRAM AND ECU CONNECTORS...
Page 321 TR–84 ENGINE TROUBLESHOOTING – Circuit Inspection INSPECTION PROCEDURE Is code 51 being output? (1) Shift automatic transmission into “P” or “N” range. (2) Turn air conditioner switch OFF. (3) Set throttle valve to fully closed (throttle position sensor IDL contacts closed). Is code 51 being output? System is normal.
Page 322 TR–85 ENGINE TROUBLESHOOTING – Circuit Inspection Air Conditioner Switch Signal Check operation of A/C system. Repair A/C system. Check voltage between terminal A/C of ECU connector and body ground. Turn ignition switch ON. Measure voltage between terminal A/C of ECU connector and body ground.
Page 323 TR–86 ENGINE TROUBLESHOOTING – Circuit Inspection Throttle Position Sensor IDL Signal Check voltage between terminals IDL and E2 of throttle position sensor connector. (1) Disconnect throttle position sensor connector. (2) Turn ignition switch ON. Measure voltage between terminals IDL and E2 of throttle position sensor connector.
Page 324 TR–87 ENGINE TROUBLESHOOTING – Circuit Inspection Check voltage between terminals IDL and E2 of ECU connector. Connect throttle position sensor connector. Measure voltage between terminals IDL and E2 of ECU connector. Check for open circuit between ECU and throttle position sensor. Check for short circuit between ECU and throttle position sensor.

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