Toyota 4A-GE Manuals

Manuals and User Guides for Toyota 4A-GE. We have 3 Toyota 4A-GE manuals available for free PDF download: Repair Manual

Toyota 4A-GE Repair Manual

Toyota 4A-GE Repair Manual (455 pages)

Brand: Toyota | Category: Engine | Size: 29.55 MB

Table of Contents

Applicable Models
4
Caution
5
Contents
6
Introduction/Contents
8
How to Use this Manual
9
General Repair Instructions
11
Engine Serial Number
11
Precautions for Vehicles Equipped with a Catalytic Converter
14
Abbreviations Used in this Manual
15
Engine Mechanical/Contents
16
4A-FE Engine Description
17
4A-GE Engine Description
19
Troubleshooting (4A-FE)
21
Engine Overheating
21
Rough Idling
22
Engine Hesitates/Poor Acceleration
23
Engine Dieseling
23
After Fire, Backfire
24
Excessive Oil Consumption
24
Poor Gasoline Mileage
25
Unpleasant Odor
25
Troubleshooting (4A-GE)
26
Hard Starting
26
Excessive Fuel Consumption
29
Engine Tune-Up (4A-FE)
30
Inspection of Engine Coolant/Oil
30
Inspection of Battery/Air Filter
30
Inspection of Spark Plugs/High Tension Cords/Alternator Drive Belt
30
Inspection and Adjustment of Valve Clearance
31
Adjusting Shim Selection Chart/Intake
33
Adjusting Shim Selection Chart/Exhaust
34
Inspection and Adjustment of Ignition Timing
35
Inspection and Adjustment of Idle Speed (W/Twc)
37
Inspection and Adjustment of Idle Speed and Idle Mixture (W/O TWC)
38
Troubleshooting
39
Engine Tune-Up (4A-GE)
40
Idle HC/CO Concentration Check Method (W/Twc)
48
Inspection and Adjustment of Dash Pot (DP) System (4A-FE)
50
Inspection and Adjustment of Dash Pot (DP) System (4A-GE W/Air Flow Meter)
52
Compression Check
53
Timing Belt Component (4A-FE)
54
Removal of Timing Belt
54
Inspection of Timing Components
57
Installation of Timing Belt
59
Timing Belt (4A-GE)
62
Inspection of Timing Belt Components
65
Cylinder Head Components(4A-FE)
71
Removal of Cylinder Head
73
Disassembly of Cylinder Head
82
Inspection, Cleaning and Repair of Cylinder Head Components
83
Assembly of Cylinder Head
93
Installation of Cylinder Head
95
Cylinder Head Components (4A-GE)
107
Cylinder Block Components
132
Preparation for Disassembly
133
Disassembly of Cylinder Block
134
Inspection of Cylinder Block
140
Disassembly of Piston and Connecting Rod Assemblies
141
Inspection of Piston and Connecting Rod Assemblies
143
Boring of Cylinders
148
Inspection and Repair of Crankshaft
149
Inspection of Check Valves and Oil Nozzles
149
Replacement of Crankshaft Oil Seals
150
Replacement of Union (4A-GE)
151
Assembly of Piston and Connecting Rod
152
Assembly of Cylinder Block
153
Assembly of Engine
158
EFI System/Contents
160
EFI System Description
161
Maintenance Precautions
167
When Car Is Equipped with a Mobile Radio System (HAM, CB, Etc.)
168
Air Induction System
168
Electronic Control System
169
Fuel System
170
Troubleshooting Hints
173
Engine will Not Crank or Cranks Slowly
174
Difficult to Start or no Start (Cranks OK)
174
Engine Often Stalls
176
Rough Idling And/Or Missing
178
High Engine Idle Speed
179
Engine Backfires (Lean Fuel Mixture)
180
Muffler Explosion (after Fire) - Rich Fuel Mixture
181
Engine Hesitates And/Or Poor Acceleration
182
Diagnosis System Description
184
Check Engine Warning Light Check
184
Output of Diagnostic Codes
184
Cancelling Diagnostic Code
186
Diagnosis Indication
186
Diagnostic Codes (4A-FE)
187
Diagnostic Codes (4A-GE)
188
Inspection of Diagnosis Circuit
191
Troubleshooting with Volt/Ohmmeter
193
Location of Fuses and Fusible Links
193
EFI System Check Procedure
195
Terminals of ECU (4A-FE 2WD)
196
Voltage at ECU Wiring Connectors (4A-FE 2WD)
197
Terminals of ECU (4A-FE 4WD)
210
Voltage at ECU Wiring Connectors (4A-FE 4WD)
211
Terminals of ECU (4A-GE W/O Air Flow Meter)
224
Terminals of ECU Wiring Connectors (4A-GE W/O Air Flow Meter)
225
Terminals of ECU (4A-GE W/ Air Flow Meter)
238
Terminals of ECU Wiring Connectors (4A-GE W/ Air Flow Meter)
239
Fuel System/Pump
253
On-Vehicle Inspection
254
Removal of Fuel Pump (AE 92, 95, AT171)
258
Installation of Fuel Pump (AE 92, 95, AT171)
259
Removal of Fuel Pump (AT180)
260
Components (AT180)
261
Disassembly/Assembly of Fuel Pump (AT180)
262
Installation of Fuel Pump (AT180)
263
Cold Start Injector
264
Inspect Resistance of Cold Start Injector
264
Removal of Cold Start Injector
264
Inspection of Cold Start Injector
265
Installation of Cold Start Injector
267
Fuel Pressure Regulator
268
Removal of Fuel Pressure Regulator
268
Inspect Fuel Pressure
268
Installation of Fuel Pressure Regulator
269
Injector
270
Removal of Injectors
272
Inspection of Injectors
273
Installation of Injectors
275
Air Flow Meter (4A-GE W/Air Flow Meter)
279
Inspect Resistance of Air Flow Meter
279
Removal/Inspection/Installation of Air Flow Meter
280
Throttle Body (4A-FE)
281
Removal of Throttle Body
282
Inspection of Throttle Body
283
Installation of Throttle Body
285
Throttle Body (4A-GE)
286
Removal/Inspection of Throttle Body
287
Auxiliary Air Valve
290
Inspect Air Valve Operation (W/O Air Flow Meter)
290
Removal of Auxiliary Air Valve
291
Installation of Air Valve
291
Location of Electronic Control Parts
292
EFI Main Relay
293
Inspection of EFI Main Relay (AE/AT)
293
Circuit Opening Relay
294
Inspection of Circuit Opening Relay (W/O Air Flow Meter)
294
Inspection of Circuit Opening Relay (W/ Air Flow Meter)
295
Start Injector Time Switch
296
Inspection of Start Injector Time Switch
296
Water Temperature Sensor
297
Inspection of Water Temperature Sensor
297
Intake Air Temperature Sensor (W/O Air Flow Meter)
298
Inspection of Intake Air Temperature Sensor
298
Vacuum Sensor (W/O Air Flow Meter)
299
Inspection of Vacuum Sensor
299
Variable Resistor (W/O TWC)
301
Inspection of Variable Resistor
301
Inspection of Oxygen Sensor
304
Inspection of ECU
306
Voltage at ECU Wiring Connectors (4A-FE)
307
Voltage at ECU Wiring Connectors (4A-GE W/O Air Flow Meter)
308
Voltage at ECU Wiring Connectors (4A-GE W/ Air Flow Meter)
309
Resistance of ECU Wiring Connectors (4A-FE)
310
Resistance of ECU Wiring Connectors (4A-GE With/Without Air Flow Meter)
311
Inspection of Fuel Cut RPM
312
Fuel Pressure Control System (4A-GE Europe)
313
Inspection of Fuel Pressure Control System
313
Idle-Up System (W/ Air Flow Meter)
315
Inspection of Idle-Up System
315
Idle Speed Contro (ISC) Valve (4A-FE)
317
Inspection of ISC Valve
317
Air Control Valve (ACV) (4A-GE W/O Air Flow Meter)
319
Inspection of ACV
319
Cooling System/Contents
322
Cooling System Description
323
Cooling System Troubleshooting
325
Check and Replacement of Engine Coolant
326
Water Pump Components
327
Removal of Water Pump
327
Inspection of Water Pump
328
Disassembly of Water Pump
329
Assembly of Water Pump
330
Installation of Water Pump
332
Removal/Inspection/Installation of Thermostat
334
Cleaning/Inspection of Radiator
336
Radiator Components
337
Disassembly of Radiator (AE, AT171)
337
Assembly of Radiator (AE, AT171)
339
Installation of Radiator
341
Radiator Cooling Fan System Circuit/Components
342
Low/High Coolant Temperature
343
Inspection of Electric Cooling Fan
344
Lubrication System/Contents
346
Lubrication System Description
347
Lubrication System Troubleshooting
350
Oil Pressure Check
351
Replacement of Engine Oil and Oil Filter
352
Oil Pump Components
354
Removal of Oil Pump
355
Disassembly of Oil Pump
356
Inspection of Oil Pump
357
Replacement of Crankshaft Front Oil Seal
357
Assembly of Oil Pump
358
Installation of Oil Pump
359
Oil Cooler and Pressure Regulator Components
362
Ignition System/Contents
364
Ignition System Precautions
365
Ignition System Troubleshooting
366
Ignition System Circuit
367
Electronic Spark Advance (ESA)
367
Check that Spark Occurs (4A-FE)
369
Inspection of High-Tension Cords
370
Inspection of Spark Plugs
370
Inspection of Ignition Coil
371
Distributor
371
Inspection of Igniter
372
Check that Spark Occurs (4A-GE)
373
Inspection of Spark Plugs (Conventional Tipped Type)
374
Inspection of Spark Plugs (Platinum Tipped Type)
375
Inspection of Distributor
377
Integrated Ignition Assembly (IIA) (4A-FE) Components
378
Disassembly of IIA
378
Inspection of IIA
379
Inspect Governor Shaft
379
Installation of IIA
381
Distributor (4A-GE) Components
382
Installation of Distributor
382
Starting System/Contents
384
Starting System Troubleshooting/Circuit
385
Planetary Type Starter Components
386
Disassembly of Planetary Type Starter
387
Inspection of Planetary Type Starter
390
Armature Coil
390
Commutator
390
Field Coil (Field Frame)
391
Inspect Brush Length
391
Inspect Brush Spring Load
392
Inspect Brush Holder Insulation
392
Starter Clutch and Gears
392
Magnetic Switch
392
Planet Carrier Shaft and Center Bearing
393
Assembly of Planetary Type Starter
394
Performance Test of Planetary Type Starter
398
Reduction Type Starter Components
400
Disassembly of Reduction Type Starter
401
Inspection of Starter
402
Field Coil
403
Measure Brush Length
404
Mesure Brush Spring Load with Pull Scale
404
Inspect Insulation of Brush Holder
404
Clutch and Gears
404
Bearings
405
Assembly of Reduction Type Starter
406
Performance Test of Starter
408
Charging System/Contents
410
Charging System Precautions/Troubleshooting
411
Charging Circuit
411
Alternator Components
416
Disassembly of Alternator
417
Inspection and Repair of Alternator
418
Rotor
418
Stator
418
Brushes
419
Rectifier
419
Assembly of Alternator
422
Service Specifications/Contents
424
Engine Mechanical (4A-FE) Specifications
425
Torque Specifications
428
Engine Mechanical (4A-GE) Specifications
429
EFI System (4A-FE) Specifications
433
Cooling System Service Specifications
438
Lubrication/Ignition System Service Specifications
439
Starting/Charging System Service Specifications
440
Standard Bolt Torque Specifications
442
How to Determine Bolt Strength
443
Specified Torque for Standard Bolts
444
SST and Ssm/Contents
446
SST (Special Service Tools)
447
SSM (Special Service Materials)
451

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Toyota 4A-GE Repair Manual

Toyota 4A-GE Repair Manual (319 pages)

Brand: Toyota | Category: Engine | Size: 22.82 MB

Table of Contents

Toyota 4A-GE Repair Manual

Toyota 4A-GE Repair Manual (228 pages)

Brand: Toyota | Category: Engine | Size: 7.76 MB

Table of Contents

Introduction

2
Efi System

76
- System Description
  77
- Inspection Precautions
  80
- Precautions
  80
- Troubleshooting
  85
- Diagnosis System
  96
- Troubleshooting with Volt/Ohmmeter
  103
- Fuel System
  120
  - Fuel Pump
    120
  - Cold Start Injector
    125
  - Fuel Pressure Regulator
    129
  - Injectors
    131
- Air Induction System
  140
  - Throttle Body (4A-FE
    140
  - Auxiliary Air Valve
    145
- Electronic Control System
  147
  - Location of Electronic Control Parts
    147
  - Circuit Opening Relay
    149
  - Start Injector Time Switch
    151
  - Water Temperature Sensor
    152
  - Intake Air Temperature Sensor (W/O Air Flow Meter
    153
  - Vacuum Sensor (W/O Air Flow Meter) (Manifold Absolute Pressure Sensor
    154
  - Variable Resistor (W/O TWC
    156
  - Oxygen Sensor (W/ TWC
    159
  - Engine ECU
    161
  - Fuel Cut RPM
    165
  - Idle-Up System (W/ Air Flow Meter
    166
  - Idle Speed Control (ISC) Valve (4A-FE
    168
Cooling System

170
- Description
  171
- Troubleshooting
  173
- Check and Replacement of Engine Coolant
  174
- Water Pump
  175
- Thermostat
  182
- Radiator
  184
- Electric Cooling Fan
  185
  - Lubrication System
    189

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