Toyota 7M-GTE Manuals

Manuals and User Guides for Toyota 7M-GTE. We have 1 Toyota 7M-GTE manual available for free PDF download: Repair Manual

Toyota 7M-GTE Repair Manual

Toyota 7M-GTE Repair Manual (364 pages)

Brand: Toyota | Category: Engine | Size: 12.71 MB

Table of Contents

Repair Procedures
4
Warnings, Cautions, Notes
5
Replace Drive Shaft Bearing
5
Specifications
5
References
5
Identification Information
6
General Repair Instructions
6
Engine Serial Number
6
Table of Contents
8
Engine Mechanical
8
Engine Mechanical Description
9
Engine Mechanical
10
Description
10
- Engine Mechanical Troubleshooting
  11
- Inspection of Air Filter
  14
Engine Tune-Up
14
- Inspection and Adjustment of Valve Clearance
  15
- Remove Air Intake Connector
  15
- Measure Valve Clearance
  16
- Adjust Valve Clearance
  16
- Install Air Intake Connector
  17
- Remove ISC Pipe
  19
- Remove PCV Pipe with Hoses
  19
- Remove Intake Air Connector
  19
- Remove Ignition Cover
  19
- Remove Cylinder Head Covers
  20
- Install Ignition Coil with Bracket
  20
- Install Ignition Coil Cover
  20
- Install Intake Air Connector
  21
- Install PCV Pipe with Hoses
  21
- Install ISC Pipe
  21
- Adjusting Shim Selection Using Chart
  22
- Intake
  22
- Exhaust
  23
- Inspection and Adjustment of Ignition Timing
  24
- Connect Tachometer and Timing Light to Engine
  24
- Check Ignition Timing
  24
- Further Check Ignition Timing
  25
- Inspection and Adjustment of Idle Mixture
  26
- Initial Conditions
  26
- Inspect and Adjust Idle CO Concentration
  26
- Method with CO Meter
  26
- Alternative Method
  28
- Inspection of Idle HC/CO Concentration
  29
- Check Idle Speed
  29
- Check Oxygen Sensor Operation
  29
- Measure HC/CO Concentration at Idle
  30
- Inspection and Adjustment of Dash POT (DP) System
  31
- Inspect and Adjust DP Setting Speed
  31
- Check Operatoin of VTV
  32
- Check Cylinder Compression Pressure
  33
- Remove Throttle Body
  33
Compression Check
33
- Removal of Timing Belt
  35
- Timing Belt Components
  35
- Remove No.3 Timing Belt Cover
  36
- Remove Timing Belt from Camshaft Timing Pulleys
  36
- Set No.1 Cylinder to Tdc/Compression
  36
- Remove Camshaft Timing Pulleys
  37
- Remove Crankshaft Pulley
  37
- Remove PS Air Pipe
  37
- Inspection of Components
  38
- Remove Crankshaft Timing Pulley
  38
- Remove Oil Pump Drive Pulley
  38
- Inspect Idler Pulley
  39
- Inspect Tension Spring
  39
- Install Crankshaft Timing Pulley
  40
- Install Oil Pump Pulley
  40
- Installation of Timing Belt
  40
- Temporarily Install Timing Belt
  40
- Install Camshaft Timing Pulleys
  41
- Install Crankshaft Pulley
  41
- Check Timing Belt Tension
  42
- Install No.3 Timing Belt
  42
- Install Timing Belt
  42
- Adjust Drive Belts
  43
- Install Alternator Drive Belt and Fan
  43
- Install Water Outlet
  43
- Cylinder Head Components
  44
- Removal of Cylinder Head
  46
- Remove Air Intake Chamber with Connector
  46
- Remove Alternator
  46
- Remove Engine Wire
  48
- Remove No.2 Fuel Pipe
  48
- Remove Exhaust Manifold
  49
- Remove Water Outlet Housing
  49
- Remove Cylinder Head
  50
- Disassembly of Cylinder Head
  51
- Remove Bearing Caps and Camshafts
  51
- Remove Delivery Pipe with Injectors
  51
- Remove Intake Manifold
  51
- Inspection, Cleaning and Repair of Cylinder Head Components
  52
- Remove Gasket Material
  52
- Remove Valve Lifters with Shims
  52
- Remove Valves
  52
- Clean Combustion Chamber
  53
- Clean Cylinder Head
  53
- Clean Valve Guide Bushings
  53
- Inspect Cylinder Head for Flatiness
  53
- Clean Valves
  54
- Inspect Cylinder Head for Cracks
  54
- Inspect Valve Stems and Guide Bushings
  54
- Replace Valve Guide Bushings
  55
- Inspect and Grind Valves
  56
- Inspect and Clean Valve Seats
  57
- Inspect Camshaft and Bearing Caps
  58
- Inspect Valve Springs
  58
- Inspect Camshaft Oil Clearance
  59
- Inspect Camshaft Thrust Clearance
  60
- Inspect Valve Lifter Oil Clearance
  60
- Maximum Oil Clearance
  60
- Standard Oil Clearance
  60
- Check Air Control Valve Operation
  61
- Check Vacuum Tank by Blowing Air into each Pipe
  61
- Inspection of Intake Air Control System
  61
- Assembly of Cylinder Head
  62
- Install Camshafts and Oil Seals
  62
- Install Valve Lifters with Shims
  62
- Install Valves
  62
- Install Heater Union
  64
- Install Intake Manifold
  64
- Install Delivery Pipe with Injectors
  65
- Install Cylinder Head Covers
  66
- Installation of Cylinder Head
  66
- Install Exhaust Manifold
  67
- Install Water Outlet Housing
  67
- Install Air Intake Chamber with Connector
  69
- Install Engine Wire
  69
- Install No.1 Fuel Pipe and Pulsation Damper
  69
- Install No.2 Fuel Pipe
  69
- Install Alternator and Adjusting Bar
  71
- Install PS Reservoir Tank
  71
- Cylinder Block Components
  72
- Disassembly of Cylinder Block
  73
- Check Connecting Rod Thrust Clearance
  74
- Remove Oil Pump
  74
- Remove Oil Pump Drive Shaft
  74
- Remove Rear Oil Seal Retainer
  74
- Check Crankshaft Thrust Clearance
  77
- Remove Main Bearing Caps and Check Oil Clearance
  77
- Remove Piston and Connecting Rod Assemblies
  77
- Remove Crankshaft
  79
- Clean Cylinder Block
  80
- Inspect Cylinder Bore
  80
- Inspect Top of Cylinder Block for Flatness
  80
- Inspection of Cylinder Block
  80
- Check Fit between Piston and Pin
  81
- Disassembly of Piston and Connecting Rod Assemblies
  81
- Remove Cylinder Ridges
  81
- Remove Piston Rings
  81
- Clean Pistons
  82
- Inspection of Piston and Connecting Rod Assemblies
  82
- Inspect Clearance between Wall of Ring Groove and New Piston Ring
  83
- Inspect Piston Diameter and Oil Clearance
  83
- Inspect Piston Ring End Gap
  83
- Check Piston Pin Fit
  84
- Inspect Connecting Rods
  84
- Maximum End Gap
  84
- Standard End Gap
  84
- Bushing Inside Diameter
  85
- Maximum Twist
  85
- Replace Connecting Rod Bushings
  85
- Bore and Hone Cylinders to Calculated Dimensions
  87
- Boring of Cylinders
  87
- Calculate Amount to Bore Cylinder
  87
- Select Oversized Piston
  87
- Grind and Hone Main Journals And/Or Crank Pins
  88
- Inspect Crankshaft for Runout
  88
- Inspect Main Journals and Crank Pins
  88
- Inspection of Crankshaft
  88
- Inspect Oil Pump Drive Shaft
  89
- Replace Oil Pump Drive Shaft Bearing
  89
- Inspect Oil Pump Drive Shaft Thrust Clearance
  90
- Replace Thrust Plate and Collar
  90
- Replace Crankshaft Front Oil Seal
  91
- Replacement of Oil Seals
  91
- Replace Crankshaft Rear Oil Seal
  92
- Replace Pump Drive Shaft Oil Seal
  93
- Assembly of Piston and Connecting Rod
  94
- Install Piston Rings
  94
- Assembly of Cylinder Block
  95
- Install Bearings
  95
- Install Main Bearings
  95
- Install Main Bearing Caps and Lower Thrust
  96
- Install Upper Thrust Washers
  96
- Place Crankshaft on Cylinder Block
  96
- Install Connecting Rod Caps
  97
- Install Oil Pump Assembly
  97
- Install Piston and Connecting Rod Assemblies
  97
- Install Oil Pump Drive Shaft
  98
- Install Rear Oil Seal Retainer
  98
- Install Timing Belt Case with Water Pump
  98
- Install Flywheel or Drive Plate on Crankshaft
  99
- Install Oil Hole Cover Plate
  99
- Install Oil Regulator
  99
- Install Water By-Pass Pipe
  99
- Turbocharger System
  100
- Turbocharger System Description
  101
- Intercooler
  102
- Operation of Turbocharger
  102
- Waste Gate Valve
  102
- Precautions
  103
- Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
  104
- Turbocharger System Troubleshooting
  104
- Abnormal Noise
  105
- Excessive Oil Consumption or White Exhaust
  105
- Inspect Exhaust System
  106
- Inspect Intake Air System
  106
- Inspect Operation of Actuator and Waste Gate Valve
  106
- On-Vehicle Inspection of Turbocharger
  106
- Check Turbocharging Pressure
  107
- Inspect Impeller Wheel Rotation
  107
- Turbocharger System Components
  108
- Removal of Turbocharger
  109
- Remove Turbo Heat Insulator
  109
- Disconnect Front Exhaust Pipe
  110
- Remove Oil Dipstick Guide
  110
- Inspect Axial Play of Shaft Bearing
  113
- Inspection of Turbocharger
  113
- Install Turbine Outlet Elbow
  113
- Installation of Turbocharger
  113
- Install No.1 Turbo Water Pipe
  114
- Install Turbocharger
  114
- Connect Front Exhaust Pipe
  115
- Connect Union Pipe
  115
- Install Turbocharger Stay
  115
- Install Oil Dipstick Guide
  116
- Install Turbo Heat Insulator
  116
- EFI System
  118
- EFI System System Description
  119
- System Description
  121
  - Air Induction System
    123
  - Electronic Control System
    123
  - Fuel System
    123
  - Idle Speed Control
    123
- Inspection Precautions
  124
  - Maintenance Precautions
    124
  - If Vehicle Is Equipped with Mobile Radio System
    125
  - EFI System Troubleshooting
    129
  - Difficult to Start or no Start
    130
  - Engine Often Stalls
    133
  - Engine Sometimes Stalls
    134
  - Rough Idling And/Or Missing
    135
  - High Engine Idle Speed (no Drop)
    137
  - Engine Backfires
    138
  - Lean Fuel Mixture
    138
  - Muffler Explosion
    139
  - Rich Fuel Mixture Misfire
    139
  - Engine Hesitates And/Or Poor Acceleration
    140
- Diagnosis System
  142
  - Check Engine Warning Light Check
    143
  - Output of Diagnosis Codes
    143
  - Malfunction Code Indication
    144
  - Test Mode
    145
  - Cancelling out Diagnostic Code
    146
  - Diagnosis Indication
    146
  - Inspection of Diagnosis Circuit
    150
  - Location of Fuses and Fusible Links
    151
  - Troubleshooting with Volt/Ohmmeter (MA)
    151
  - EFI System Check Procedure
    152
  - Terminals of ECU
    152
  - Voltage at ECU Wiring Connectors
    154
- Troubleshooting with Volt/Ohmmeter (Ma
  157
- Troubleshooting with Volt/Ohmmeter (MS)
  174
- Fuel Pump
  190
- Fuel System
  190
  - Inspect Fuel Pressure
    191
  - Inspect Fuel Pump Operation
    191
- Cold Start Injector
  192
  - Check Connector Location
    193
  - Removal of Fuel Pump
    195
  - Remove Fuel Pump Bracket from Fuel Tank
    195
  - Remove Fuel Pump from Fuel Pump Bracket
    195
  - Install Fuel Pump Filter to Fuel Pump
    196
  - Install Fuel Tank
    196
  - Installation of Fuel Pump
    196
  - Remove Fuel Pump Filter from Fuel Pump
    196
  - Cold Start Injector
    197
  - Inspect Resistance of Cold Start Injector
    197
  - Removal of Cold Start Injector
    197
  - Remove Cold Start Injector Tube
    197
  - Inspect Injection of Cold Start Injector
    198
  - Inspection of Cold Start Injector
    198
  - Remove Cold Start Injector
    198
  - Inspect Leakage
    199
  - Install Cold Start Injector Tube
    200
  - Installation of Cold Start Injector
    200
  - Disconnect No.2 Fuel Pipe
    201
- Pressure Regulator
  201
  - Removal of Pressure Regulator
    201
  - Remove Pressure Regulator
    201
  - Installation of Pressure Regulator
    202
  - Check Injector Operation
    203
- Injectors
  203
  - Inspect Resistance of Injector
    203
  - On-Vehicle Inspection
    203
  - Disconnect Following Connections
    204
  - Disconnect Following Hoses
    204
  - Removal of Injector
    204
  - Remove ISC Valve
    204
  - Remove No.1 Fuel Pipe
    205
  - Remove Delivery Pipe
    206
  - Remove Injectors
    206
  - Inspection of Injector
    207
  - Install Injectors into Delivery Pipe
    209
  - Install Pressure Regulator
    210
  - Install ISC Valve
    211
  - Connect Following Connectors
    212
  - Connect Following Hoses
    212
- Air Flow Meter (7M-GE
  213
- Inspect Resistance of Air Flow Meter
  213
- Air Flow Meter (7M-GTE
  214
  - Inspection of Air Flow Meter
    214
  - Installation of Air Flow Meter
    214
  - Removal of Air Flow Meter
    214
- Throttle Body
  219
  - Inspect Throttle Position Sensor
    220
  - Removal of Throttle Body
    220
  - Clean Throttle Body
    221
  - Inspect Throttle Valve
    221
  - Inspection of Throttle Body
    221
  - Installation of Throttle Body
    223
  - Check for Operating Sound from Isc Valve
    225
- Idle Speed Control (ISC) Valve
  225
  - Removal of ISC Valve
    225
  - Inspection of Check Valve
    226
  - Inspection of ISC Valve
    226
  - Installation of Isc Valve
    226
- Electronic Control System
  227
- Location of Electronic Control Parts
  227
- Location of Electronic Control Parts
  228
- EFI Main Relay
  229
  - Inspect Relay Continuity
    229
  - Inspect Relay Operation
    229
  - Inspection of Efi Main Relay
    229
- Circuit Opening Relay
  230
  - Inspection of Circuit Opening Relay
    230
  - Inspection of Solenoid Resistor
    231
- Solenoid Resistor
  231
- Cold Start Injector Time Switch
  232
- Inspect Resistance of Water Temperature Sensor
  233
- Water Temperature Sensor
  233
- Fuel Pump Relay and Resistor
  234
  - Inspect Fuel Pump Relay
    234
  - Inspection of Pump Relay and Resistor
    234
  - Inspect Fuel Pump Resistor
    235
  - High Temperature Line Pressure up System
    236
  - Inspect VSV for Open Circuit
    236
  - Inspect VSV for Short Circuit
    236
  - Inspection of High Temperature Line Pressure up System
    236
  - High Altitude Compensation System
    238
  - Inspect Resistance of HAC Sensor
    238
  - Inspect Feedback Voltage
    239
  - Inspection of Oxygen Sensor
    239
  - Oxygen Sensor
    239
- Oxygen Sensor
  240
- System (7M-GTE
  240
- Electronic Controlled Unit (ECU
  242
  - Inspect Voltage of ECU
    242
  - Inspection of ECU
    242
  - Inspect Resistance of ECU
    244
- Fuel Cut RPM
  245
  - Inspection of Fuel Cut Rpm
    245
  - Radiator
    247
  - Radiator Cap
    247
  - Reservoir Tank
    247
  - Water Pump
    247
  - Cooling System Troubleshooting
    248
  - Check and Replacement of Engine Coolant
    249
  - Check Engine Coolant Level at Reserve Tank
    249
  - Check Engine Coolant Quality
    249
  - Replace Engine Coolant
    249
  - Removal of Water Pump
    250
  - Water Pump Components
    250
  - Inspect Water Pump Bearing
    251
  - Inspect Water Pump Body and Timing Belt Case
    251
  - Inspection of Water Pump
    251
  - Installation of Water Pump
    251
  - Inspection of Thermostat
    252
  - Install Thermostat and Water Outlet
    252
  - Removal of Thermostat
    252
  - Remove Water Outlet and Thermostat
    252
  - Check Cooling System for Leaks
    253
  - Check Radiator Cap
    253
  - Cleaning of Radiator
    253
  - Inspection of Radiator
    253
  - Disassembly of Radiator
    254
  - Remove Tank Plate
    254
  - Assembly of Radiator
    255
  - Remove Tank and O-Ring
    255
  - Install New O-Ring and Tank
    256
  - Install Oil Cooler to Lower Tank
    256
  - Install Tank Plate
    257
  - Stake Claw of Tank Plate
    257
  - Inspect for Water Leaks
    258
  - Paint Tank Plates
    258
  - Lubrication System
    259
  - Lubrication System Description
    260
  - Oil Filter
    261
  - Oil Pressure Regulator
    261
  - Oil Pump
    261
  - High Oil Pressure
    262
  - Low Oil Pressure
    262
  - Lubrication System Troubleshooting
    262
  - Oil Leakage
    262
  - Check Engine Oil Level
    263
  - Check Engine Oil Quality
    263
  - Measure Oil Pressure
    263
  - Oil Pressure Check
    263
  - Fill with Engine Oil
    264
  - Recheck Engine Oil Level
    264
  - Drain Engine Oil
    265
  - Replace Oil Filter
    265
  - Replacement of Engine Oil and Oil Filter
    265
  - Oil Pump Components
    267
  - Removal of Oil Pump
    268
  - Remove Oil Pan
    268
  - Disassembly of Oil Pump
    269
  - Remove Oil Pump Outlet Pipe
    269
  - Remove Oil Pump Strainer
    269
  - Remove Relief Valve
    269
  - Inspect Body Clearance
    270
  - Inspect Gear Backlash
    270
  - Inspect Relief Valve
    270
  - Inspection of Oil Pump
    270
  - Assembly and Operation Check of Oil Pump
    271
  - Check Pump Operation
    271
  - Install Oil Pump Driven Gear
    271
  - Install Oil Pump Outlet Pipe
    272
  - Install Oil Pump Strainer
    272
  - Installation of Oil Pump
    272
  - Install Oil Pan
    273
  - Oil Cooler and Oil Pressure Regulator
    274
  - Assembly and Installation of Oil Pressure Regulator
    276
  - Inspection of Oil Pressure Regulator
    276
  - Removal and Disassembly of Oil Pressure Regulator
    276
  - Remove Oil Pressure Regulator
    276
  - Removal and Disassembly of Oil Filter Bracket
    277
  - Remove Oil Filter Bracket
    277
  - Assembly and Installation of Oil Filter Bracket
    278
  - Inspection of Relief Valve
    278
  - Install Oil Filter Bracket
    278
  - Ignition System
    279
  - Ignition System Precautions
    280
  - Ignition System Troubleshooting
    281
  - Electronic Spark Advance
    282
- Ignition System Circuit
  282
  - Spark Test
    283
  - Inspect High-Tension Cord Resistance
    284
  - Inspection of High-Tension Cords
    284
  - Install High-Tension Cords
    284
  - Remove High-Tension Cords
    284
  - Adjust Electrode Gap
    285
  - Clean Spark Plugs
    285
  - Inspection of Spark Plugs
    285
  - Remove Spark Plugs
    285
  - Inspect Electrode
    286
  - Inspect Electrode Gap
    287
  - Install Spark Plugs
    287
- ON-VEHICLE Inspktlon (7M-GE
  287
  - Visually Inspect Spark Plugs
    287
  - Inspect Primary Coil Resistance
    288
  - Inspect Secondary Coil Resistance
    288
  - Inspection of Ignition Coil
    288
  - Inspect Air Gaps
    289
  - Inspect Pickup Coils
    289
  - Inspection of Distributor
    289
  - Disconnect Following Cables and Rod
    290
  - Remove Ignition Coil Cover
    291
  - Remove Ignition Coil with Bracket
    291
  - Inspect Ignition Coil Ground
    292
  - Inspect Power Source Line
    292
  - Replace Ignition Coil
    292
  - Check Power Source Line Voltage
    295
  - Check Power Transistor in Igniter
    295
  - Inspection of Igniter
    295
  - Inspect Air Gap
    296
  - Inspection of Cam Position Sensor
    296
- On-Vehicle Inspection (7M-Gte
  296
- Removal of Ditributor
  297
- Distributor Components
  297
- Remove Distributor
  298
- Remove O-Ring
  298
- Replacement of Distributor Driven Gear
  299
- Grind Driven Gear and Pin
  299
- Install New Driven Gear and Pin
  299
- Installation of Distributor
  300
- Removal of Cam Position Sensor
  301
- Cam Position Sensor Components
  301
- Replacement of Cam Position Sensor Driven Gear
  303
- Remove Cam Position Sensor
  303
- Installation of Cam Position Sensor
  304
- Install Cam Position Sensor
  304
- Starting System
  306
- Starting System Troubleshooting
  307
- Starting System Circuit
  307
- Starter Components
  308
- Disassembly of Starter
  309
- Remove Field Frame with Armature from Magnetic Switch Assembly
  309
- Brushes
  310
- Inspect Undercut Depth of Segment
  310
- Field Frame
  310
- Brush Springs
  311
- Inspect Brush Spring Load
  311
- Brush Holder
  311
- Clutch and Gears
  311
- Magnetic Switch
  312
- Inspect Bearings
  312
- Replace Bearings
  312
- Assembly of Starter
  313
- Install Brush Holder
  313
- Install Gears and Clutch Assembly
  313
- Install Starter Housing
  314
- Install Field Frame with Armature to Magnetic Switch Assembly
  314
- Inspect Clutch Pinion Gear Return
  315
- Perform Pull-In Test
  315
- Perform Hold-In Test
  315
- Performance Test of Starter
  315
- Starter Relay
  316
- Inspection of Starter Relay
  316
- Charging System
  317
- Charging System Precautions
  318
- Charging System Troubleshooting
  318
- Charging System Circuit
  319
- Check Battery Specific Gravity
  319
- Check Battery Terminals, Fusible Links and Fuses
  319
- Inspect Drive Belt
  320
- Inspect Fuses for Continuity
  320
- Check Alternator Wiring and Listen for Abnormal Noises
  321
- Check Discharge Warning Light Circuit
  321
- Check Charging Circuit Without Load
  321
- Check Charging Circuit with Load
  322
- Remove Brush Holder
  323
- Remove Reara End Cover
  323
- Disassembly of Alternator
  323
- Alternator Components
  323
- Remove IC Regulator
  324
- Remove Rectifier Holder
  324
- Remove Pulley
  324
- Remove Rectifier End Frame
  324
- Inspect Slip Rings
  325
- Inspect Rotor for Ground
  325
- Inspect Rotor for Open Circuit
  325
- Inspection and Repair of Alternator
  325
- Inspect Exposed Brush Length
  326
- Replace Brushes
  326
- Inspect Positive Side Rectifier
  326
- Inspect Negative Side Rectifier
  327
- Replace Front Bearing
  327
- Inspect Rear Bearing
  328
- Install Rectifier Holder
  329
- Assembly of Alternator
  329
- Install Pulley
  329
- Install Rectifier End Frame
  329
- Install Brush Holder and IC Regulator
  330
- Install Rear End Cover
  330
- Service Specifications
  331
- New Car Features
  347
- Differential
  348
- LSD Construction
  348
- Differential Operation
  349
- Suspension
  350
- Tems
  350
- Location of System Components
  350
- Function of Components
  351
- Wiring Diagram
  352
- Slepless Reclining Adjustment
  353
- Stepless Reclining Adjuster System
  353
- Front Seat
  353
- Normal Position
  355
- Forward Reclining Position
  355
- Power Side Support and Power Lumbar Support
  356
- Backward Reclining Lock Position
  356
- Power Lumbar Support Adjustment
  357
- Power Side Support Adjustment
  357
- Construction and Operation
  357
- System Circuit
  358
- Lumbar and Side Support Switch
  358
- Connecter for Lumbar and Side Support Switch
  358
- Cruise Control System (CCS)
  359
- Major Connectors
  360
- Main Switch
  361
- Vacuum Pump
  362
- Vacuum Switch
  363

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