Toyota 22R-E - Exhaust Gas Recirculation (EGR) System (Calif.)

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EXHAUST GAS RECIRCULATION

(EGR) SYSTEM

(Calif.)

–ENGINE EMISSION CONTROL SYSTEMS

EG1–92

Main Page

How to Use this Manual2
Index2
General Description2
Repair Procedures2
The Procedures Are Presented in a Step–By–Step Format3
Check Piston Stroke of Overdrive Brake3
Specifications3
Cautions, Notices, Hints4
SI Unit4
Identification Information Vehicle Identification Number4
Engine Serial Number4
General Repair Instructions5
Medium Current Fuse and High Current Fuse Equal Amperage Rating6
Observe the Following Precautions to Avoid Damage to the Parts7
Precaution8
For Vehicles Equipped with a Catalytic Converter8
For Vehicles with an Audio System with Built–In Anti–Theft System8
Vehicle Lift and Support Locations9
Abbreviations Used in this Manual10
Glossary of SAE and Toyota Terms12
Standard Bolt Torque Specifications15
How to Determine Bolt Strength15
Specified Torque for Standard Bolts16
Maintenance Operations Engine17
Cold Engine Operations17
3VZ–E Engine17
Inspect Drive Belts17
Replace Spark Plugs18
Inspect Air Filter18
Replace Air Filter18
Replace Engine Oil and Oil Filter18
Replace Engine Coolant19
Inspect Charcoal Canister20
Replace Gasket in Fuel Tank Cap20
Inspect Fuel Lines and Connections20
Inspect Exhaust Pipes and Mountings21
Adjust Valve Clearance21
Replace Oxygen Sensor (Federal and Canada)21
Hot Engine Operations22
Adjust Valve Clearance (22R-E Engine)22
Adjust Idle Speed22
Inspect Brake Line Pipes and Hoses23
Idle Speed23
Inspect Brake Line Pipes and Hoses Hint23
Inspect Front Brake Pads and Discs24
Check the Thickness of the Disc Brake Pad and Check for Irregular Wear24
Check the Disc for Wear24
Minimum Disc Thickness24
Inspect Rear Brake Linings and Drums25
Inspect Steering Linkage25
Inspect Steering Gear Housing26
Inspect Drive Shaft Boots (4WD)26
Inspect Ball Joints and Dust Covers26
Check Oil Level in Manual Transmission, Automatic Transmission and Differential (2WD)27
Check Oil Level in Manual Transmission, Automatic Transmission, Transfer and Differential (4WD)28
Replace Manual Transmission. Transfer (4WD) and Differential Oil29
Replace Automatic Transmission Fluid31
Repack Front Wheel Bearings and Thrust Bush32
Lubricate Propeller Shaft (4WD)32
Tighten Bolts and Nuts on Chassis and Body33
Final Inspection34
22R–E Engine35
Engine Mechanical36
Description36
Preparation38
SST (Special Service Tools)38
Recommended Tools39
Equipment39
SSM (Service Special Materials)40
Troubleshooting41
Eg1-842
Tune-Up44
Air Filter Inspection44
Idle and or 2500 RPM CO HC Check46
Compression Check48
Measure Cylinder Compression Pressure48
Install Spark Plugs48
Cylinder Head49
Components49
Preparation for Removal50
Disconnect Accelerator Cable50
Disconnect Throttle Cable (A/T)50
Disconnect Following Parts50
Disconnect Following Wires51
Remove Chamber with Throttle Body51
Disconnect Fuel Hose from Delivery Pipe51
Remove PS Belt (W/Ps)51
Disconnect PS Bracket from Cylinder Head52
Cylinder Head Removal52
Remove Cam Sprocket Bolt52
Remove Distributor Drive Gear and Camshaft Thrust Plate52
Remove Cam Sprocket53
Remove Chary Cover Bolt53
Remove Cylinder Head Bolts53
Cylinder Head Disassembly53
Remove Intake Manifold with Delivery Pipe and Injectors54
Remove EGR Valve54
Remove Exhaust Manifold with No. 2 Secondary Air Injection Manifold54
Remove Two Engine Hangers and Ground Strap54
Measure Camshaft Thrust Clearance55
Remove Valves55
Inspection, Cleaning and Repair of Cylinder Head Components55
Clean Top of Pistons and Top of Cylinder Block55
Clean Combustion Chambers56
Clean Valve Guide Bushings56
Clean Cylinder Head56
Inspect Cylinder Head for Flatness56
Inspect Cylinder Head for Cracks57
Clean Valves57
Inspect Valve Stems and Guide Bushings57
If Necessary, Replace Valve Guide Bushings58
Bore Intake and Exhaust58
Inspect and Grind Valves59
Inspect and Clean Valve Seats60
Inspect Valve Springs61
Inspect Camshaft and Bearing Caps62
Inspect Camshaft Oil Clearance62
Inspect Rocker Arms63
Inspect Intake, Exhaust Manifolds and Air Intake Chamber64
Cylinder Head Assembly64
Install Valves65
Install Camshaft65
Install Cylinder Head Rear Cover65
Install RH Engine Hanger65
Install Plug Pate66
Install Exhaust Manifold66
Install EGR Valve66
Install Intake Manifold67
Install No. 1 Secondary Air Injection Manifold67
Cylinder Head Installation67
Apply Seal Packing to Cylinder Block67
Install Rocker Arm Assembly68
Install Chain Cover Bolt68
Install Distributor Drive Gear and Camshaft Thrust Plate68
Install Half–Circular Plugs69
Install Head Cover70
Post Installation70
Connect PS Bracket to Cylinder Head (W/Ps)70
Connect By–Pass Hose to Intake Manifold70
Connect Fuel Return Hose71
Install Chamber with Throttle Body71
Connect Following Wires71
Connect Following Parts71
Connect Throttle Cable (A/T)72
Connect Exhaust Pipe to Exhaust Manifold72
Start Engine72
Road Test72
Timing Chain Components73
Preparation of Removal73
Remove Oil Pan73
Timing Chain Removal74
Remove Fluid Coupling with Fan and Water Pump Pulley74
Remove Crankshaft Pulley74
Remove No. 1 Water By–Pass Pipe75
Remove Fan Belt Adjusting Bar75
Disconnect Heater Water Outlet Pipe75
Remove Chain Cover Assembly75
Remove Pump Drive Spline and Crankshaft Sprocket76
Components Inspection76
Measure Chain and Sprocket Wear76
Measure Chain Tensioner & Dampers76
Timing Chain Installation77
Install Crankshaft Sprocket and Chain77
Place Chain on Camshaft Sprocket77
Install Timing Chain Cover Assembly77
Install Heater Water Outlet Pipe78
Install No.1 Water By–Pass Pipe78
Install Crankshaft Pulley78
Install Water Pump Pulley and Fluid Coupling with Fan78
Engine Removal81
Disconnect Following Wires and Connectors81
Disconnect Following Hoses81
Disconnect Following Cable81
Remove PS Pump from Bracket82
Remove Compressor from Bracket82
Disconnect Transfer Shift Linkage82
Remove Front Exhaust Pipe83
Remove Clutch Release Cylinder with Bracket from Transmission (M/T)83
Remove No.1 Front Floor Heat Insulator and Brake Tube Heat Insulator (4WD)83
Remove Engine Rear Mounting and Bracket (2WD)83
Remove No.2 Frame Crossmember from Side Frame (4WD)84
Remove Engine with Transmission for Vehicle84
Remove Transmission from Engine (A/T)84
Cylinder Block Disassembly84
Remove Oil Strainer85
Remove Rear Oil Seal Retainer85
Measure Connecting Rod Thrust Clearance85
Measure Connecting Rod Oil Clearance85
Push out Piston and Connecting Rod Assembly87
Measure Crankshaft Thrust Clearance87
Measure Crankshaft Oil Clearance88
Remove Crankshaft89
Cylinder Block Inspection89
Remove Gasket Material89
Clean Cylinder Block89
Inspect Cylinder Block Warpage90
Measure Cylinder Bore90
Remove Cylinder Ridge91
Disassembly of Piston and Connecting Rod Assembly91
Check Fit between Piston and Pin91
Remove Piston Rings91
Disconnect Connecting Rod from Piston92
Inspection of Piston and Connecting Rod92
Clean Piston92
Inspect Piston Diameter and Oil Clearance93
Measure Clearance between Piston Groove and Piston Ring94
Piston Diameter94
Measure Ring End Gap95
Inspect Piston Pin Fit95
Inspect Connecting Rods95
Rod Bushing Replacement96
Remove Rod Bushing96
Install New Rod Bushing96
Hone New Bushing and Check Pin Fit in Connecting Rod97
Crankshaft Inspection and Repair97
Measure Crankshaft for Runout97
Inspect Main Journals and Crank Pins97
Oil Seals Replacement98
If Timing Chain Cover Is Removed from Cylinder Block (Replacement of Front Oil Seal)98
If Timing Chain Cover Is Installed on Cylinder Block (Replacement of Front Oil Seal)98
If Rear Oil Seal Retainer Is Removed from Cylinder Block (Replacement of Rear Oil Seal)99
If Rear Oil Seal Retainer Is Installed on Cylinder Block (Replacement of Rear Oil Seal)99
Cylinders Boring100
Select Oversized Piston100
Calculate Dimension to Bore Cylinders100
Piston and Connecting Rod Assembly100
Place Rings on Piston101
Install Bearings101
Installation of Crankshaft, Piston and Connecting Rod Assembly102
Install Main Bearings102
Install Upper Thrust Washers102
Install Main Bearing Caps with Lower Thrust Washers102
Install Piston and Connecting Rod Assembly103
Install Connecting Rod Caps103
Cylinder Block Assembly104
Install Rear Oil Seal Retainer104
Install Oil Strainer104
Install Flywheel or Drive Plate104
Engine Installation105
Place Engine with Transmission in Vehicle105
Install Engine Mounting to Frame Bracket105
Install Engine Rear Mounting and Bracket (2WD)105
Install No.2 Frame Crossmember106
Install Brake Tube Heat Insulator and No.1 Front Floor Heat Insulator106
Install Clutch Release Cylinder with Bracket to Transmission106
Install Exhaust Pipe106
Connect Transfer Shift Linkage (4WD A/T)107
Install Shift Lever (M/T)107
Install Compressor to Bracket (with A/C)107
Install Ps Pump with Ps Pump Bracket (W/Ps)107
Connect Following Hoses108
Connect Following Wires and Connectors108
Install PS Pump and Belt108
Exhaust System Components110
Service Specifications111
Service Data111
Torque Specifications114
Emission Control Systems115
System Purpose115
Layout and Schematic Drawing (Federal and Canada)116
Layout and Schematic Drawing (Calif.)117
Positive Crankcase Ventilation (PCV) System118
PCV Valve Inspection119
Blow Air from Cylinder Head Side119
Blow Air from Intake Manifold Side119
PCV Hoses and Connections Inspection119
Evaporative Emission (EVAP) Control System120
Inspection of Fuel Vapor Lines, Fuel Tank and Tank Cap120
Visually Inspect Lines and Connections120
Visually Inspect Fuel Tank120
Visually Inspect Fuel Tank Cap121
Charcoal Canister Inspection121
Check for Clogged Filter and Stuck Check Valve121
Clean Filter in Canister121
Exhaust Gas Recirculation (EGR) System (Federal and Canada)122
EGR System Inspection123
Check and Clean Filter in EGR Vacuum Modulator123
Check TVV with Cold Engine123
Check TVV and EGR Vacuum Modulator with Hot Engine123
Check EGR Valve124
TVV Inspection124
Check TVV by Blowing Air into Pipe124
Check EGR Vacuum Modulator Operation124
EGR Valve Inspection125
Exhaust Gas Recirculation (EGR) System (Calif.)126
Check Seating of EGR Valve127
Check VSV with a Cold Engine127
Check VSV and EGR Vacuum Modulator with Hot Engine127
EGR Vacuum Modulator Inspection128
VSV Inspection128
Check Vacuum Circuit Continuity in the VSV by Blowing Air into Pipe128
Check for Short Circuit129
Check for Open Circuit129
Pulsed Secondary Air Injection (Pair) System130
Pair System Inspection131
Pair Valve Inspection131
Check Pair System with Cold Engine131
Check Pair System with Warm Engine131
Check Valve Inspection132
Check Vacuum Circuit Continuity in VSV by Blowing Air into Pipe132
Check for Short & Open Circuit132
Three–Way Catalytic Converter (TWC) System133
Exhaust Pipe Assembly Inspection133
Catalytic Converter Inspection133
Heat Insulator Inspection134
Catalytic Converter Replacement134
Remove Converter134
Install Converter134
MFI System Description135
Electronic Control System136
Maintenance Precautions139
Precaution When Connecting Gauge139
In Event of Engine Misfire, the Following Precautions Should be Taken139
Precautions When Handling Oxygen Sensor139
If Vehicle Equipped with a Mobile Radio System (HAM, CB, Etc.)140
Air Induction System140
Fuel System142
Union Bolt Type142
Flare Nut Type142
Diagnosis System Description144
Malfunction Indicator Lamp144
Diagnostic Trouble Codes Output144
Normal System Operation145
Malfunction Code Indication145
Diagnostic Trouble Codes Cancellation146
2 Trip Detection Logic146
Diagnosis Indication147
Diagnostic Trouble Codes148
Diagnostic Trouble Code Detection Driving Pattern150
Main Oxygen Sensor Circuit150
Air–Fuel Ratio Lean Malfunction151
Air–Fuel Ratio Lean Malfunction (California)152
Air–Fuel Ratio Rich Malfunction (California)152
Sub–Oxygen Sensor Circuit153
EGR System Malfunction154
Inspection of Diagnosis Circuit155
Troubleshooting with Volt Ohmmeter156
Fuses, H–Fuses and Fusible Link Location156
System Check Procedure (2WD)157
Terminals of ECM (2WD)157
Voltage at ECM Wiring Connectors (2WD)158
Batt–E1159
There Is no Voltage between ECM Terminals BATT and E1159
+B (+B1 )–E1160
There Is no Voltage between ECM Terminals + B (+B1) and E1 (IG SW ON)160
Idl–E2 (E21)161
There Is no Voltage between ECM Terminals IDL and E2 (E21) (IG SW ON) (Throttle Valve Open)161
VCC–E2 (E21)162
Vta–E2 (E21)162
Here Is no Voltage between ECM Terminals VCC and E2 (E21) (IG SW ON)162
There Is no Voltage between ECM Terminals VTA and E2 (E21 ) (IG SW ON)162
VC–E2 (E21)163
There Is no Voltage between ECM Terminals VC and E2 (E21) (IG SW ON)163
Vs–E2 (E21)164
Tha–E2 (E21)164
There Is no Voltage between ECM Terminals Vs and E2 (E21) (IG SW ON)164
There Is no Voltage between ECM Terminals THA and E2 (E21) (IG SW ON)164
There Is no Voltage between ECM Terminals THW and E2 (E21) (IG SW ON)165
There Is no Voltage between ECM Terminals STA and E1 (IG SW START)166
There Is no Voltage between ECM Terminals No. 10 And/Or No. 20 and E01, And/Or E02 (IG SW ON)167
There Is no Voltage between ECM Terminals Igt and E1 (Idling)168
There Is no Voltage between ECM Terminals W and E1 (Idling)169
There Is no Voltage between ECM Terminals STJ and E1 (IG SW Start)170
There Is no Voltage between ECM Terminals STP and E1171
California Vehicles Only172
There Is no Voltage between ECM Terminals VF and E1172
There Is no Voltage between ECM Terminals THG and E2 (E21) (Engine Running at 2,000 Rpm)174
MFI System Check Procedure (4WD M/T)175
Terminals of ECM KWD M/T175
Voltage at ECM Wiring Connectors (4WD M/T)176
There Is no Voltage between ECM Terminals + B (+ B1) and E1 (IG SW ON)178
There Is no Voltage between ECM Terminals IDL and E2 (E21) (IG SW ON)179
There Is no Voltage between ECM Terminals VCC and E2 (E21) (IG SW ON)180
There Is no Specified Voltage between ECM Terminals VTA and E2 (E21) (IG SW ON)180
Vs-E2 (E21)182
There Is no Voltage between ECM Terminals No. 10 And/Or No. 20 and E01, And/Or E02–(IG SW ON)185
There Is no Voltage between ECM Terminals STJ and E1 (IG SW ON)188
MFI System Check Procedure (4WD A/T)193
Terminals of ECM (4WD A/T)193
Voltage at ECM Connectors (4WD A/T)194
+B (B+)–E1196
There Is no Voltage between ECM Terminals +B (+B1) and E1 (IG SW ON)196
Throttle Position Sensor197
There Is no Voltage between ECM Terminals VCC and E2 (IG SW ON)198
There Is no Voltage between ECM Terminals VTA and E2 (E21) (IG SW ON)198
There Is no Voltage between ECM Terminals W and E1 (Ldling)205
Fuel Pump211
On–Vehicle Inspection212
Check Fuel Pump Operation212
Fuel Pump Removal214
Drain Fuel from Fuel Tank214
Remove Fuel Pump Bracket214
Fuel Pump Installation215
Remove Fuel Pump Filter215
Install Fuel Pump Filter215
Measure Resistance of Cold Start Injector217
Cold Start Injector Removal217
Remove Cold Start Injector217
Cold Start Injector Inspection218
Cold Start Injector Installation219
Fuel Pressure Regulator220
Pressure Regulator Removal & Installation220
Check Injector Operation221
Injectors Removal & Inspection222
Remove Delivery Pipe with Injectors222
Test Injection of Injector222
Check Leakage223
Install Injectors into Delivery Pipe224
Install Delivery Pipe with Injectors224
Connect Fuel Hose to Delivery Pipe225
Connect Wires225
Fuel Tank and Line Components226
Fuel Lines and Connections Inspection227
Measure Resistance of Volume Air Flow Meter228
VAF Meter Removal, Inspection and Installation229
Remove Air Cleaner Cap with Volume Air Flow Meter229
Remove Volume Air Flow Meter229
Measure Resistance of VAF Meter229
Inspect Throttle Body231
Inspect Throttle Position Sensor231
Inspect Dash Pot (DP) (M/T)232
Inspect Throttle Opener (A/T)233
Throttle Body Removal234
Disconnect Throttle Sensor Connector234
Remove Throttle Body234
Clean Throttle Body before Inspection235
Check Throttle Valve235
If Necessary, Adjust Throttle Position Sensor235
Throttle Body Disassembly, Assembly and Installation236
Remove Throttle Position Sensor236
Remove Auxiliary Air Valve236
Install Throttle Position Sensor236
Check Operation of Auxiliary Air Valve238
Electronic Parts Location239
EFI Main Relay Inspection240
Inspect Relay Continuity240
Inspect Relay Operation240
Circuit Opening Relay Inspection241
Cold Start Injector Time Switch242
Start Injector Time Switch Inspection242
Measure Resistance of Start Injector Time Switch242
Engine Coolant Temperature (ECT) Sensor Inspection243
Fuel Pressure Control System244
Oxygen Sensor Inspection246
Inspect Heater Resistance of Oxygen Sensor246
Inspection of Feedback Voltage (VF1)246
EGR Gas Temp. Sensor Inspection248
Engine Control Module (ECM)249
Inspect Voltage of ECM249
Voltage at ECM Wiring Connectors250
Inspect Resistance of ECM251
Resistance of ECM Wiring Connectors252
Fuel Cut Rpm Inspection253
Warm up Engine253
Connect Tachometer253
Inspect Fuel Cut Operation253
Cooling System Description257
Radiator Cap257
Water Pump258
Thermostat258
Coolant Check and Replacement259
Check Engine Coolant Level in Reservoir Tank259
Check Engine Coolant Quality259
Water Pump Components260
Water Pump Removal260
Water Pump Inspection and Installation261
Remove Water Pump261
Inspect Water Pump Bearing261
Inspect Fluid Coupling261
Thermostat Removal, Inspection and Installation262
Remove Thermostat262
Place Thermostat in Intake Manifold262
Radiator Cleaning263
Radiator Inspection263
Check Radiator Cap263
Radiator Removal264
Check Cooling System for Leaks264
Lubrication System Description266
Oil Pump267
Oil Pressure Regulator (Relief Valve)267
Oil Filter267
Lubricant268
Oil Pressure Check269
Check Oil Quality and Level269
Measure Oil Pressure269
Oil and Filter Replacement270
Drain Engine Oil270
Replace Oil Filter270
Fill with Engine Oil270
Recheck Engine Oil Level271
Oil Capacity271
Oil Pump Components272
Oil Pump Removal272
Oil Pump Disassembly273
Oil Pump Inspection273
Remove Oil Pump Assembly273
Remove Oil Pump Drive Spline273
Pressure Regulator Inspection274
Front Oil Seal Replacement274
Measure Tip Clearance274
Measure Side Clearance274
Oil Pump Assembly and Installation275
Install Oil Seal275
Install Oil Pump Drive Spline and O–Ring275
Install Oil Pump275
Engine Mechanical Description279
Tune–Up289
Check Engine Coolant Level at Reservoir Tank289
Engine Oil Inspection290
Check Oil Quality290
Check Engine Oil Level290
Battery Inspection291
Check Battery Specific Gravity and Electrolyte Level291
Check Hydrometer291
Check Battery Terminals, Fusible Link and Fuses291
High–Tension Cords Inspection292
Disconnect High–Tension Cords from Spark Plugs292
Inspect High–Tension Cord Terminals292
Inspect High–Tension Cord Resistance292
Spark Plugs Inspection293
Clean Spark Plugs293
Adjust Electrode Gap293
Reconnect High–Tension Cords to Sparkplugs294
Generator Drive Belt Inspection294
Valve Clearance Inspection and Adjustment295
Remove Spark Plugs295
Remove Engine Wire295
Set No.1 Cylinder to Tdc/Compression296
Inspect Valve Clearance296
Remove the Adjusting Shim297
Determine the Replacement Adjusting Shim Size Byfollowing–The Formula or Chart298
Adjusting Shim Selection Chart (Intake)299
New Shim Thickness299
Intake Valve Clearance (Cold)299
Adjusting Shim Selection Chart (Exhaust)300
Instill Cylinder Head Covers301
Install Engine Wire301
Install Air Intake Chamber301
Ignition Timing Inspection and Adjustment302
Connect Tachometer and Timing Light to Engine302
Adjust Ignition Timing302
Further Check Ignition Timing303
Idle Speed Inspection and Adjustment304
Initial Conditions304
Insert CO/HC Meter Testing Probe into Tailpipe at Least 40 CM (1.3 Ft) During Idling305
Immediately Check CO/HC Concentration at Idle And/Or 2,500 RPM305
Check Cylinder Compression Pressure307
Reinstall Spark Plugs308
Timing Belt Components309
Timing Belt Removal309
Remove Engine under Cover309
Remove Radiator309
Disconnect No.2 and No.3 Air Hoses from Air Pipe310
Remove Cooling Fan310
Remove Water Outlet311
Remove No.2 Timing Belt Cover311
If Re–Using Timing Belt, Check Installation Marks on Timing Belt311
Set No.1 Cylinder at Tdc/Compression312
Remove Timing Belt Tensioner312
Remove Fan Bracket312
Disconnect Timing Belt from Camshaft Timing Pulleys312
Remove Camshaft Timing Pulleys313
Remove No.1 Timing Belt Cover Hint314
Remove Timing Belt Guide314
Remove No.1 Idler Pulley315
Remove Crankshaft Timing Pulley315
Timing Belt Components Inspection315
Inspect Timing Belt315
Inspect Idler Pulleys316
Inspect Timing Belt Tensioner317
Install Crankshaft Timing Pulley318
Install No.1 Idler Pulley318
Temporarily Install Timing Belt318
Install Timing Belt Guide318
Timing Belt Installation318
Install No.1 Timing Belt Cover319
Install LH Camshaft Timing Pulley319
Crankshaft Position320
RH Camshaft Pulley Position320
LH Camshaft Pulley Position320
Connect Timing Belt to LH Camshaft Timing Pulley320
Install RH Camshaft Timing Pulley and Timing Belt321
Install Fan Bracket322
Set Timing Belt Tensioner322
Install Timing Belt Tensioner322
Check Valve Timing323
Install No.2 Timing Belt Cover323
Install Water Outlet324
Install Generator Drive Belt324
Install Cooling Fan324
Install A/C Drive Belt324
Install Ps Pump Pulley and Drive Belt325
Install Radiator325
Recheck Engine Coolant Level325
Cylinder Head Components326
Cylinder Heads Removal328
Disconnect Clutch Release Cylinder Hose (M/T Only)328
Remove A/C Drive Belt328
Remove Generator Drive Belt329
Disconnect Strap, Wires, Connectors329
Disconnect Heater Hoses329
Remove Timing Belt330
Remove Air Intake Chamber330
Remove No.2 and No.3 Fuel Pipes333
Remove No.4 Timing Belt Cover333
Remove No.2 Idler Pulley333
Remove No.3 Timing Belt Cover334
Remove Delivery Pipes and Injectors334
Remove Water By–Pass Outlet334
Remove Intake Manifold334
Remove Exhaust Crossover Pipe335
Disconnect Water By–Pass Pipe from RH Cylinder Head335
Remove No.2 Engine Hanger from LH Cylinder Head335
Remove Cylinder Head Covers335
Remove Camshafts336
Remove Cylinder Heads336
Remove Generator Bracket337
Remove Exhaust Manifold from RH Cylinder Head337
Remove Exhaust Manifold from LH Cylinder Head338
Cylinder Heads Disassembly338
Remove Camshaft Housing Plugs338
Remove Valve Lifters and Shims338
Cylinder Head Components Inspection and Repair340
Clean Top Surfaces of Pistons and Cylinder Block340
Inspect Cylinder Head341
Inspect Camshafts and Bearings347
Inspect Valve Lifters and Lifter Bores348
Inspect Air Intake Chamber349
Inspect Intake Manifold349
Cylinder Head Side349
Air Intake Chamber Side349
Inspect Exhaust Manifold350
Cylinder Heads Assembly351
Install Valve Lifters and Shims352
Install Camshaft Housing Plugs352
Cylinder Heads Installation353
Install RH Exhaust Manifold to RH & LH Cylinder Head353
Install Generator Bracket353
Install Cylinder Heads353
Install Cylinder Head (12 Pointed Head) Bolts354
Install Cylinder Head (6 Pointed Head) Bolts355
Install Camshafts355
Check and Adjust Valve Clearance356
Install Cylinder Head Covers357
Install Water By–Pass Pipe to RH Cylinder Head357
Install No.2 Engine Hanger358
Install Oil Dipstick Guide and Dipstick358
Install Exhaust Crossover Pipe358
Install Water By–Pass Outlet358
Install Injectors and Delivery Pipe359
Install Pair Reed Valve and No.1 Injection Manifold360
Install VSV Bracket and VSV to Pair Reed Valve360
Install No.3 Timing Belt Cover360
Install No.2 Idler Pulley360
Install No.4 Timing Belt Cover361
Install No.2 and No.3 Fuel Pipes361
Connect High–Tension Cords to Spark Plugs364
Install Front Exhaust Pipe364
Connect Fuel Inlet and Outlet Hoses364
Connect Heater Hoses364
Connect Cables, Hoses, Connectors, Strap and Wires365
Connect Clutch Release Cylinder Hose (M/T Only)366
Install Air Cleaner and Hose366
Perform Road Test366
Cylinder Block Components367
Disconnect Clutch Release Cylinder Hose368
Remove PS Drive Belt and Pump Pulley368
Disconnect Strap, Wires369
Remove Engine Rear Mounting Bracket370
Remove No.2 Frame Crossmember371
Remove Engine and Transmission Assembly from Vehicle371
Preparation for Disassembly372
Remove Flywheel or Drive Plate372
Remove Rear End Plate372
Remove RH and LH Engine Mounting Brackets372
Remove No.1 Water By–Pass Pipe373
Remove Oil Pressure Sender Gauge373
Remove Knock Sensor373
Remove Oil Cooler and Bracket Assembly (2WD)373
Remove Oil Cooler (4WD)374
Remove Oil Filter Union374
Remove Oil Pan Baffle Plate375
Remove Oil Pump375
Check Connecting Rod Thrust Clearance376
Remove Connecting Rod Caps and Check Oil Clearance376
Remove Piston and Connecting Rod Assemblies378
Check Crankshaft Thrust Clearance379
Remove Main Bearing Cap and Check Oil Clearance379
Inspect Top Surface of Cylinder Block for Flatness383
Inspect Cylinder for Vertical Scratches383
Inspect Cylinder Bore Diameter383
Piston and Connecting Rod Disassembly384
Check Fit between Piston and Piston Pin384
Piston and Connecting Rod Inspection385
Inspect Piston Oil Clearance386
Inspect Piston Ring Groove Clearance387
Inspect Piston Ring End Gap387
Inspect Connecting Rod Alignment388
Inspect Connecting Rod Bolts388
Cylinder Boring389
Keep Oversized Pistons389
Calculate Amount to Bore Cylinders389
Bore and Hone Cylinder to Calculated Dimensions389
Inspect Crankshaft for Runout390
If Necessary, Grind and Hone Main Journals And/Or Crank Pins390
Crankshaft Oil Seals Replacement391
Replace Crankshaft Front Oil Seal391
If Oil Pump Is Removed from Cylinder Block391
If Oil Pump Is Installed to the Cylinder Block391
Replace Crankshaft Rear Oil Seal392
If Rear Oil Seal Retainer Is Removed from Cylinder Block392
If Rear Oil Seal Retainer Is Installed to Cylinder Block392
Pistons and Connecting Rods Assembly393
Assemble Piston and Connecting Rod393
Install Piston Rings393
Install Main Bearing Cap and Lower Thrust Washers395
Place Main Bearing Cap and Lower Thrust Washers on Cylinder Block395
Install Main Bearing Cap Bolts395
Install Piston and Connecting Rod Assemblies396
Place Connecting Rod Cap on Connecting Rod397
Post Assembly399
Install Oil Pan Baffle Plate400
Install Oil Pan401
Install Oil Filter Union401
Install Knock Sensor402
Install Oil Cooler and Bracket Assembly (2WD)402
Install Oil Cooler403
Install Engine Coolant Drain Plugs403
Install LH and RH Engine Mounting Brackets403
Install Oil Filter403
Install Oil Pressure Sender Gauge404
Install Generator Adjusting Bar404
Install Water Pump404
Install Thermostat and Water Inlet405
Install No.1 Water By-Pass Pipe405
Install Rear End Plate406
Insert Engine and Transmission Assembly in Vehicle407
Install Engine Rear Mounting Bracket (2WD)407
Install No.2 Frame Crossmember (4WD)407
Tighten RH and LH Engine Mounting Insulator Bolts408
Connect Clutch Release Cylinder Hose408
Install A/C Compressor408
Connect Strap, Wires, Connectors, Hoses and Cables409
Exhaust System411
Layout and Schematic Drawing419
Evaporative (EVAP) Emission Control System422
Fuel Vapor Lines, Fuel Tank and Tank Cap Inspection423
Exhaust Gas Recirculation (EGR) System425
Check VSV with Cold Engine426
Check VSV and EGR Vacuum Modulator with Warm Engine426
Check Pair System with Cold & Warm Engine430
Pair Reed Valve Inspection430
Check Reed Valve by Blowing Air into Pipe430
Check Valve by Blowing Air into each Pipe431
Check for Dents or Damage432
MFI System435
Description System Circuit435
Operation Fuel System437
Precautions When Connecting Gauge442
Precautions When Handling Heated Oxygen Sensor442
If Vehicle Is Equipped with Mobile Radio System (HAM, CB, ETC)443
When Disconnecting the Connection of the High Fuel Pressure Line, a Large Amount of Gasoline May Come out so Observe the Following Procedure445
When Connecting the Flare Nut or Union Bolt on the High Pressure Pipe Union, Observe the Following Procedure445
Observe the Following Precautions When Removing and Installing the Injectors446
Install the Injector to the Delivery Pipe and Intake Manifold as Shown in the Illustration446
Confirm that There Are no Fuel Leaks after Performing any Maintenance on the Fuel System446
Malfunction Indicator Lamp Check448
Diagnostic Trouble Codes Output (Normal Mode)448
Normal System Operation (no Malfunction)449
Test Mode450
Diagnostic Trouble Code Cancellation452
DTC 12 Heated Oxygen Sensor Circuit455
Air–Fuel Ratio Lean Malfunction (California, C & C)457
Air–Fuel Ratio Rich Malfunction (California, C & C)457
Diagnosis Circuit Inspection459
Fuses and Fusible Link Location460
MFI System Check Procedure461
Engine Control Module (ECM) Terminals461
Engine Control Module (ECM) Wiring Connectors Voltage462
+B (+B1)-E1464
Idl-E2 (E21)465
VC-E2 (E21)466
Vta-E2 (E21)466
Tha-E2 (E21)468
There Is no Voltage between ECM Terminals #10 And/Or #20 and E01 And/Or E02 (IG SW ON)471
There Is no Voltage between ECM Terminals IGT and EI (Idling)472
There Is no Voltage between ECM Terminals W and EI (Idling)473
There Is no Voltage between ECM Terminals 11F and E1477
System Circuit479
On-Vehicle Inspection479
Check Fuel Pressure480
Components for Removal and Installation482
Remove Fuel Pump from Fuel Pump Bracket483
Remove Fuel Pump Filter from Fuel Pump483
Install Fuel Pump Filter to Fuel Pump483
Install Fuel Pump to Fuel Pump Bracket483
Install Fuel Pump Bracket484
Install Fuel Tank484
Cold Start Injector On-Vehicle Inspection485
Inspect Resistance of Cold Start Injector485
Check Injection of Cold Start Injector486
Inspect Leakage487
Install Cold Start Injector487
Install Cold Start Injector Tube488
Check for Fuel Leakage488
Fuel Pressure Regulator On-Vehicle Inspection489
Fuel Pressure Regulator Removal489
Disconnect Following Cables490
Disconnect Vacuum Sensing Hose490
Disconnect Fuel Return Hose490
Remove Fuel Pressure Regulator492
Fuel Pressure Regulator Installation493
Install Fuel Pressure Regulator493
Connect Vacuum Sensing Hose496
Connect Air Cleaner Hose496
Connect Following Cables496
Injector Components for Removal and Installation497
Injectors Removal498
Injectors Inspection501
Measure Resistance of Injector501
Injectors Installation503
Install Injectors and Delivery Pipes503
Volume Air Flow (VAF) Meter On-Vehicle Inspection510
Volume Air Flow Meter Removal511
Disconnect Resonator Bracket511
Remove Volume Air Flow Meter from Air Cleaner Cap511
Volume Air Flow Meter Inspection511
Volume Air Flow Meter Installation512
Install Volume Air Flow Meter to Air Cleaner Cap512
Install Resonator Bracket512
Throttle Body On-Vehicle Inspection513
Inspect Dashpot (DP)514
Inspect Throttle Opener515
Inspect Air Valve Operation516
Disconnect Air Cleaner Hose517
Throttle Body Inspection518
Throttle Body Installation520
Connect Throttle Position Sensor Connector520
Install Accelerator Cable Bracket520
EFI Main Relay522
Circuit Opening Relay523
Cold Start Injector Time Switch Inspection524
Measure Resistance of Cold Start Injector Time Switch524
Engine Coolant Temp. Sensor Inspection525
Measure Resistance of Engine Coolant Temp. Sensor525
Fuel Pressure VSV Inspection526
Check VSV Operation526
Measure Resistance of EGR Gas Temp. Sensor528
Heated Oxygen Sensor Inspection529
Inspect Heater Resistance of Heated Oxygen Sensor529
Engine Control Module (ECM) Inspection531
Inspect Voltage of Engine Control Module (ECM)531
Inspect Resistance of Engine Control Module (ECM)533
Engine Control Module (ECM) Wiring Connectors Resistance533
Fuel Cut RPM534
Cooling System538
Operation538
Reservoir Tank539
Engine Coolant540
Inspect Fan Pulley Bracket543
Water Pump Installation543
Thermostat Removal545
Thermostat Inspection545
Thermostat Installation545
Radiator Installation547
Lubrication System549
SSM (Special Service Materials)552
Check Oil Level553
Remove Oil Pressure Sender553
Recheck Engine Level556
Remove Driven and Drive Rotors558
Remove Relief Valve558
Inspect Body Clearance559
Inspect Tip Clearance559
Inspect Side Clearance559
Inspect Relief Valve559
Crankshaft Front Oil Seal Replacement560
Oil Pump Assembly and Installation561
Install Drive and Driven Rotors561
Install Pump Body Cover561
Install Relief Valve561
Clean Oil Pan Baffle Plate and Oil Pan562
Oil Cooler Components565
Oil Cooler Removal565
Disconnect Oil Cooler Hoses565
Remove Oil Cooler (2WD)566
Oil Cooler Inspection566
Oil Cooler Installation566
Connect Oil Cooler Hoses567
Ignition System569
Electronic Spark Advance (ESA)571
Spark Test573
High–Tension Cord Inspection574
Inspect High–Tension Cord Resistance & Terminals574
Clean and Inspect Spark Plugs574
Ignition Coil Inspection575
Measure Primary Coil Resistance575
Measure Secondary Coil Resistance575
Distributor Inspection575
Check Signal Generator (Pickup Coil)576
Distributor Components577
Distributor Removal577
Distributor Installation577
Install Distributor and Set577
Connect High–Tension Cords and Wiring Connector578
Disconnect Tachometer and Timing Light from Engine579
3Vz–E581
Ignition Coil582
Pickup Coils582
Check that Spark Occurs586
Disconnect High-Tension Cords from Spark Plugs587
Disconnect High–Tension Cords from Distributor Cap and Ignition Coil587
Reconnect High–Tension Cords to Distributor Cap and Ignition Coil587
Reconnect High-Tension Cords to Spark Plugs588
Visually Inspect Spark Plugs589
Clean Coil and Check Following590
Inspect Primary Coil Resistance590
Inspect Secondary Coil Resistance590
Inspect Air Gaps591
Inspect Signal Generator (Pickup Coil)591
Disconnect High–Tension Cords from Distributor Cap592
Remove Distributor593
Remove O–Ring593
Check No.1 Cylinder to Tdc/Compression593
Install Dust Proof Packing and Distributor Cap594
Connect High–Tension Cords to Distributor Cap594
Connect Distributor Connector594
Starting System596
Starter Components597
Removal of Starter598
Disconnect Two Wires from Starter598
Remove Starter Motor598
Disassembly of Starter598
Remove Clutch Assembly and Gears from Starter Housing599
Remove Steel Ball and Spring599
Remove Brushes and Brush Holder599
Remove Armature from Field Frame599
Inspection of Starter600
Armature Coil600
Inspect Commutator Circle Runout600
Inspect Commutator Diameter600
Inspect Undercut Depth of Segment601
Inspect Field Coil for Open Circuit601
Inspect that Field Coil Is Not Grounded601
Inspect Brush Length601
Inspect Brush Spring Load602
Inspect Insulation of Brush Holder602
Clutch and Gears602
Inspect Bearings602
If Necessary, Replace Bearings603
Magnetic Switch603
Perform Pull–In Coil Open Circuit Test603
Perform Hold–In Coil Circuit Test603
Assembly of Starter604
Install Brush Holder604
Insert Steel Ball into Clutch Shaft Hole604
Install Gears and Clutch Assembly604
Install Starter Housing605
Install Field Frame with Armature to Magnetic Switch Assembly605
Performance Test of Starter606
Perform Pull–In and Hold–In Test606
Inspect Clutch Pinion Gear Return606
Perform No–Load Performance Test606
Installation of Starter607
Install Starter Motor on Transaxle607
Connect Two Wires to Starter607
Connect Cable to Negative Terminal of Battery607
Inspection of Starter Relay608
Charging System609
Inspect Battery Specific Gravity and Electrolyte Level610
Check Battery Terminals and Fusible Links610
Inspect Drive Belt610
Inspect Fuses for Continuity611
Visually Check Generator Wiring and Listen for Abnormal Noises611
Inspect Discharge Warning Light Circuit611
Check Charging Circuit Without Load612
Inspect Charging Circuit with Load612
Generator Components613
Removal of Generator614
Disconnect Wiring from Generator614
Remove Water Inlet Hose (W/Ps)614
Remove Generator614
Disassembly of Generator616
Remove IC Regulator616
Remove Rectifier Holder616
Remove Pulley616
Remove Rear End Frame617
Inspection and Repair of Generator618
Rotor618
Stator618
Inspect Exposed Brush Length619
If Necessary, Replace Brushes619
Inspect Positive Side Rectifier619
Inspect Negative Side Rectifier620
Inspect Front Bearing620
If Necessary, Replace Front Bearing620
Inspect Rear Bearing621
If Necessary, Replace Rear Bearing621
Assembly of Generator622
Install Rear End Frame622
Install Pulley622
Install Rectifier Holder622
Install Brush Holder and IC Regulator623
Install Rear End Cover623
Make Sure Rotor Rotates Smoothly623
Install Generator624
Install Water Inlet Hose624
Connect Wiring to Generator624
Fill with Coolant624
Installation of Generator625

Toyota 22R-E - Exhaust Gas Recirculation (EGR) System (Calif.)

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