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22R-E
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Toyota 22R-E - SSM (Special Service Materials)
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08833–00080
Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent
SSM
(SPECIAL SERVICE MA
TERIALS)
Oil pump, Oil pan baf
fle plate,
Oil pan
08826–00080 Seal packing or equivalent
Oil pressure sender gauge
–
ENGINE
LUBRICA
TION SYSTEM
EG2–275
551
553
Table of Contents
Main Page
How to Use this Manual
2
Index
2
General Description
2
Repair Procedures
2
The Procedures Are Presented in a Step–By–Step Format
3
Check Piston Stroke of Overdrive Brake
3
Specifications
3
Cautions, Notices, Hints
4
SI Unit
4
Identification Information Vehicle Identification Number
4
Engine Serial Number
4
General Repair Instructions
5
Medium Current Fuse and High Current Fuse Equal Amperage Rating
6
Observe the Following Precautions to Avoid Damage to the Parts
7
Precaution
8
For Vehicles Equipped with a Catalytic Converter
8
For Vehicles with an Audio System with Built–In Anti–Theft System
8
Vehicle Lift and Support Locations
9
Abbreviations Used in this Manual
10
Glossary of SAE and Toyota Terms
12
Standard Bolt Torque Specifications
15
How to Determine Bolt Strength
15
Specified Torque for Standard Bolts
16
Maintenance Operations Engine
17
Cold Engine Operations
17
3VZ–E Engine
17
Inspect Drive Belts
17
Replace Spark Plugs
18
Inspect Air Filter
18
Replace Air Filter
18
Replace Engine Oil and Oil Filter
18
Replace Engine Coolant
19
Inspect Charcoal Canister
20
Replace Gasket in Fuel Tank Cap
20
Inspect Fuel Lines and Connections
20
Inspect Exhaust Pipes and Mountings
21
Adjust Valve Clearance
21
Replace Oxygen Sensor (Federal and Canada)
21
Hot Engine Operations
22
Adjust Valve Clearance (22R-E Engine)
22
Adjust Idle Speed
22
Inspect Brake Line Pipes and Hoses
23
Idle Speed
23
Inspect Brake Line Pipes and Hoses Hint
23
Inspect Front Brake Pads and Discs
24
Check the Thickness of the Disc Brake Pad and Check for Irregular Wear
24
Check the Disc for Wear
24
Minimum Disc Thickness
24
Inspect Rear Brake Linings and Drums
25
Inspect Steering Linkage
25
Inspect Steering Gear Housing
26
Inspect Drive Shaft Boots (4WD)
26
Inspect Ball Joints and Dust Covers
26
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 Oil
29
Replace Automatic Transmission Fluid
31
Repack Front Wheel Bearings and Thrust Bush
32
Lubricate Propeller Shaft (4WD)
32
Tighten Bolts and Nuts on Chassis and Body
33
Final Inspection
34
22R–E Engine
35
Engine Mechanical
36
Description
36
Preparation
38
SST (Special Service Tools)
38
Recommended Tools
39
Equipment
39
SSM (Service Special Materials)
40
Troubleshooting
41
Eg1-8
42
Tune-Up
44
Air Filter Inspection
44
Idle and or 2500 RPM CO HC Check
46
Compression Check
48
Measure Cylinder Compression Pressure
48
Install Spark Plugs
48
Cylinder Head
49
Components
49
Preparation for Removal
50
Disconnect Accelerator Cable
50
Disconnect Throttle Cable (A/T)
50
Disconnect Following Parts
50
Disconnect Following Wires
51
Remove Chamber with Throttle Body
51
Disconnect Fuel Hose from Delivery Pipe
51
Remove PS Belt (W/Ps)
51
Disconnect PS Bracket from Cylinder Head
52
Cylinder Head Removal
52
Remove Cam Sprocket Bolt
52
Remove Distributor Drive Gear and Camshaft Thrust Plate
52
Remove Cam Sprocket
53
Remove Chary Cover Bolt
53
Remove Cylinder Head Bolts
53
Cylinder Head Disassembly
53
Remove Intake Manifold with Delivery Pipe and Injectors
54
Remove EGR Valve
54
Remove Exhaust Manifold with No. 2 Secondary Air Injection Manifold
54
Remove Two Engine Hangers and Ground Strap
54
Measure Camshaft Thrust Clearance
55
Remove Valves
55
Inspection, Cleaning and Repair of Cylinder Head Components
55
Clean Top of Pistons and Top of Cylinder Block
55
Clean Combustion Chambers
56
Clean Valve Guide Bushings
56
Clean Cylinder Head
56
Inspect Cylinder Head for Flatness
56
Inspect Cylinder Head for Cracks
57
Clean Valves
57
Inspect Valve Stems and Guide Bushings
57
If Necessary, Replace Valve Guide Bushings
58
Bore Intake and Exhaust
58
Inspect and Grind Valves
59
Inspect and Clean Valve Seats
60
Inspect Valve Springs
61
Inspect Camshaft and Bearing Caps
62
Inspect Camshaft Oil Clearance
62
Inspect Rocker Arms
63
Inspect Intake, Exhaust Manifolds and Air Intake Chamber
64
Cylinder Head Assembly
64
Install Valves
65
Install Camshaft
65
Install Cylinder Head Rear Cover
65
Install RH Engine Hanger
65
Install Plug Pate
66
Install Exhaust Manifold
66
Install EGR Valve
66
Install Intake Manifold
67
Install No. 1 Secondary Air Injection Manifold
67
Cylinder Head Installation
67
Apply Seal Packing to Cylinder Block
67
Install Rocker Arm Assembly
68
Install Chain Cover Bolt
68
Install Distributor Drive Gear and Camshaft Thrust Plate
68
Install Half–Circular Plugs
69
Install Head Cover
70
Post Installation
70
Connect PS Bracket to Cylinder Head (W/Ps)
70
Connect By–Pass Hose to Intake Manifold
70
Connect Fuel Return Hose
71
Install Chamber with Throttle Body
71
Connect Following Wires
71
Connect Following Parts
71
Connect Throttle Cable (A/T)
72
Connect Exhaust Pipe to Exhaust Manifold
72
Start Engine
72
Road Test
72
Timing Chain Components
73
Preparation of Removal
73
Remove Oil Pan
73
Timing Chain Removal
74
Remove Fluid Coupling with Fan and Water Pump Pulley
74
Remove Crankshaft Pulley
74
Remove No. 1 Water By–Pass Pipe
75
Remove Fan Belt Adjusting Bar
75
Disconnect Heater Water Outlet Pipe
75
Remove Chain Cover Assembly
75
Remove Pump Drive Spline and Crankshaft Sprocket
76
Components Inspection
76
Measure Chain and Sprocket Wear
76
Measure Chain Tensioner & Dampers
76
Timing Chain Installation
77
Install Crankshaft Sprocket and Chain
77
Place Chain on Camshaft Sprocket
77
Install Timing Chain Cover Assembly
77
Install Heater Water Outlet Pipe
78
Install No.1 Water By–Pass Pipe
78
Install Crankshaft Pulley
78
Install Water Pump Pulley and Fluid Coupling with Fan
78
Engine Removal
81
Disconnect Following Wires and Connectors
81
Disconnect Following Hoses
81
Disconnect Following Cable
81
Remove PS Pump from Bracket
82
Remove Compressor from Bracket
82
Disconnect Transfer Shift Linkage
82
Remove Front Exhaust Pipe
83
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 Vehicle
84
Remove Transmission from Engine (A/T)
84
Cylinder Block Disassembly
84
Remove Oil Strainer
85
Remove Rear Oil Seal Retainer
85
Measure Connecting Rod Thrust Clearance
85
Measure Connecting Rod Oil Clearance
85
Push out Piston and Connecting Rod Assembly
87
Measure Crankshaft Thrust Clearance
87
Measure Crankshaft Oil Clearance
88
Remove Crankshaft
89
Cylinder Block Inspection
89
Remove Gasket Material
89
Clean Cylinder Block
89
Inspect Cylinder Block Warpage
90
Measure Cylinder Bore
90
Remove Cylinder Ridge
91
Disassembly of Piston and Connecting Rod Assembly
91
Check Fit between Piston and Pin
91
Remove Piston Rings
91
Disconnect Connecting Rod from Piston
92
Inspection of Piston and Connecting Rod
92
Clean Piston
92
Inspect Piston Diameter and Oil Clearance
93
Measure Clearance between Piston Groove and Piston Ring
94
Piston Diameter
94
Measure Ring End Gap
95
Inspect Piston Pin Fit
95
Inspect Connecting Rods
95
Rod Bushing Replacement
96
Remove Rod Bushing
96
Install New Rod Bushing
96
Hone New Bushing and Check Pin Fit in Connecting Rod
97
Crankshaft Inspection and Repair
97
Measure Crankshaft for Runout
97
Inspect Main Journals and Crank Pins
97
Oil Seals Replacement
98
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 Boring
100
Select Oversized Piston
100
Calculate Dimension to Bore Cylinders
100
Piston and Connecting Rod Assembly
100
Place Rings on Piston
101
Install Bearings
101
Installation of Crankshaft, Piston and Connecting Rod Assembly
102
Install Main Bearings
102
Install Upper Thrust Washers
102
Install Main Bearing Caps with Lower Thrust Washers
102
Install Piston and Connecting Rod Assembly
103
Install Connecting Rod Caps
103
Cylinder Block Assembly
104
Install Rear Oil Seal Retainer
104
Install Oil Strainer
104
Install Flywheel or Drive Plate
104
Engine Installation
105
Place Engine with Transmission in Vehicle
105
Install Engine Mounting to Frame Bracket
105
Install Engine Rear Mounting and Bracket (2WD)
105
Install No.2 Frame Crossmember
106
Install Brake Tube Heat Insulator and No.1 Front Floor Heat Insulator
106
Install Clutch Release Cylinder with Bracket to Transmission
106
Install Exhaust Pipe
106
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 Hoses
108
Connect Following Wires and Connectors
108
Install PS Pump and Belt
108
Exhaust System Components
110
Service Specifications
111
Service Data
111
Torque Specifications
114
Emission Control Systems
115
System Purpose
115
Layout and Schematic Drawing (Federal and Canada)
116
Layout and Schematic Drawing (Calif.)
117
Positive Crankcase Ventilation (PCV) System
118
PCV Valve Inspection
119
Blow Air from Cylinder Head Side
119
Blow Air from Intake Manifold Side
119
PCV Hoses and Connections Inspection
119
Evaporative Emission (EVAP) Control System
120
Inspection of Fuel Vapor Lines, Fuel Tank and Tank Cap
120
Visually Inspect Lines and Connections
120
Visually Inspect Fuel Tank
120
Visually Inspect Fuel Tank Cap
121
Charcoal Canister Inspection
121
Check for Clogged Filter and Stuck Check Valve
121
Clean Filter in Canister
121
Exhaust Gas Recirculation (EGR) System (Federal and Canada)
122
EGR System Inspection
123
Check and Clean Filter in EGR Vacuum Modulator
123
Check TVV with Cold Engine
123
Check TVV and EGR Vacuum Modulator with Hot Engine
123
Check EGR Valve
124
TVV Inspection
124
Check TVV by Blowing Air into Pipe
124
Check EGR Vacuum Modulator Operation
124
EGR Valve Inspection
125
Exhaust Gas Recirculation (EGR) System (Calif.)
126
Check Seating of EGR Valve
127
Check VSV with a Cold Engine
127
Check VSV and EGR Vacuum Modulator with Hot Engine
127
EGR Vacuum Modulator Inspection
128
VSV Inspection
128
Check Vacuum Circuit Continuity in the VSV by Blowing Air into Pipe
128
Check for Short Circuit
129
Check for Open Circuit
129
Pulsed Secondary Air Injection (Pair) System
130
Pair System Inspection
131
Pair Valve Inspection
131
Check Pair System with Cold Engine
131
Check Pair System with Warm Engine
131
Check Valve Inspection
132
Check Vacuum Circuit Continuity in VSV by Blowing Air into Pipe
132
Check for Short & Open Circuit
132
Three–Way Catalytic Converter (TWC) System
133
Exhaust Pipe Assembly Inspection
133
Catalytic Converter Inspection
133
Heat Insulator Inspection
134
Catalytic Converter Replacement
134
Remove Converter
134
Install Converter
134
MFI System Description
135
Electronic Control System
136
Maintenance Precautions
139
Precaution When Connecting Gauge
139
In Event of Engine Misfire, the Following Precautions Should be Taken
139
Precautions When Handling Oxygen Sensor
139
If Vehicle Equipped with a Mobile Radio System (HAM, CB, Etc.)
140
Air Induction System
140
Fuel System
142
Union Bolt Type
142
Flare Nut Type
142
Diagnosis System Description
144
Malfunction Indicator Lamp
144
Diagnostic Trouble Codes Output
144
Normal System Operation
145
Malfunction Code Indication
145
Diagnostic Trouble Codes Cancellation
146
2 Trip Detection Logic
146
Diagnosis Indication
147
Diagnostic Trouble Codes
148
Diagnostic Trouble Code Detection Driving Pattern
150
Main Oxygen Sensor Circuit
150
Air–Fuel Ratio Lean Malfunction
151
Air–Fuel Ratio Lean Malfunction (California)
152
Air–Fuel Ratio Rich Malfunction (California)
152
Sub–Oxygen Sensor Circuit
153
EGR System Malfunction
154
Inspection of Diagnosis Circuit
155
Troubleshooting with Volt Ohmmeter
156
Fuses, H–Fuses and Fusible Link Location
156
System Check Procedure (2WD)
157
Terminals of ECM (2WD)
157
Voltage at ECM Wiring Connectors (2WD)
158
Batt–E1
159
There Is no Voltage between ECM Terminals BATT and E1
159
+B (+B1 )–E1
160
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 E1
171
California Vehicles Only
172
There Is no Voltage between ECM Terminals VF and E1
172
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/T
175
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+)–E1
196
There Is no Voltage between ECM Terminals +B (+B1) and E1 (IG SW ON)
196
Throttle Position Sensor
197
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 Pump
211
On–Vehicle Inspection
212
Check Fuel Pump Operation
212
Fuel Pump Removal
214
Drain Fuel from Fuel Tank
214
Remove Fuel Pump Bracket
214
Fuel Pump Installation
215
Remove Fuel Pump Filter
215
Install Fuel Pump Filter
215
Measure Resistance of Cold Start Injector
217
Cold Start Injector Removal
217
Remove Cold Start Injector
217
Cold Start Injector Inspection
218
Cold Start Injector Installation
219
Fuel Pressure Regulator
220
Pressure Regulator Removal & Installation
220
Check Injector Operation
221
Injectors Removal & Inspection
222
Remove Delivery Pipe with Injectors
222
Test Injection of Injector
222
Check Leakage
223
Install Injectors into Delivery Pipe
224
Install Delivery Pipe with Injectors
224
Connect Fuel Hose to Delivery Pipe
225
Connect Wires
225
Fuel Tank and Line Components
226
Fuel Lines and Connections Inspection
227
Measure Resistance of Volume Air Flow Meter
228
VAF Meter Removal, Inspection and Installation
229
Remove Air Cleaner Cap with Volume Air Flow Meter
229
Remove Volume Air Flow Meter
229
Measure Resistance of VAF Meter
229
Inspect Throttle Body
231
Inspect Throttle Position Sensor
231
Inspect Dash Pot (DP) (M/T)
232
Inspect Throttle Opener (A/T)
233
Throttle Body Removal
234
Disconnect Throttle Sensor Connector
234
Remove Throttle Body
234
Clean Throttle Body before Inspection
235
Check Throttle Valve
235
If Necessary, Adjust Throttle Position Sensor
235
Throttle Body Disassembly, Assembly and Installation
236
Remove Throttle Position Sensor
236
Remove Auxiliary Air Valve
236
Install Throttle Position Sensor
236
Check Operation of Auxiliary Air Valve
238
Electronic Parts Location
239
EFI Main Relay Inspection
240
Inspect Relay Continuity
240
Inspect Relay Operation
240
Circuit Opening Relay Inspection
241
Cold Start Injector Time Switch
242
Start Injector Time Switch Inspection
242
Measure Resistance of Start Injector Time Switch
242
Engine Coolant Temperature (ECT) Sensor Inspection
243
Fuel Pressure Control System
244
Oxygen Sensor Inspection
246
Inspect Heater Resistance of Oxygen Sensor
246
Inspection of Feedback Voltage (VF1)
246
EGR Gas Temp. Sensor Inspection
248
Engine Control Module (ECM)
249
Inspect Voltage of ECM
249
Voltage at ECM Wiring Connectors
250
Inspect Resistance of ECM
251
Resistance of ECM Wiring Connectors
252
Fuel Cut Rpm Inspection
253
Warm up Engine
253
Connect Tachometer
253
Inspect Fuel Cut Operation
253
Cooling System Description
257
Radiator Cap
257
Water Pump
258
Thermostat
258
Coolant Check and Replacement
259
Check Engine Coolant Level in Reservoir Tank
259
Check Engine Coolant Quality
259
Water Pump Components
260
Water Pump Removal
260
Water Pump Inspection and Installation
261
Remove Water Pump
261
Inspect Water Pump Bearing
261
Inspect Fluid Coupling
261
Thermostat Removal, Inspection and Installation
262
Remove Thermostat
262
Place Thermostat in Intake Manifold
262
Radiator Cleaning
263
Radiator Inspection
263
Check Radiator Cap
263
Radiator Removal
264
Check Cooling System for Leaks
264
Lubrication System Description
266
Oil Pump
267
Oil Pressure Regulator (Relief Valve)
267
Oil Filter
267
Lubricant
268
Oil Pressure Check
269
Check Oil Quality and Level
269
Measure Oil Pressure
269
Oil and Filter Replacement
270
Drain Engine Oil
270
Replace Oil Filter
270
Fill with Engine Oil
270
Recheck Engine Oil Level
271
Oil Capacity
271
Oil Pump Components
272
Oil Pump Removal
272
Oil Pump Disassembly
273
Oil Pump Inspection
273
Remove Oil Pump Assembly
273
Remove Oil Pump Drive Spline
273
Pressure Regulator Inspection
274
Front Oil Seal Replacement
274
Measure Tip Clearance
274
Measure Side Clearance
274
Oil Pump Assembly and Installation
275
Install Oil Seal
275
Install Oil Pump Drive Spline and O–Ring
275
Install Oil Pump
275
Engine Mechanical Description
279
Tune–Up
289
Check Engine Coolant Level at Reservoir Tank
289
Engine Oil Inspection
290
Check Oil Quality
290
Check Engine Oil Level
290
Battery Inspection
291
Check Battery Specific Gravity and Electrolyte Level
291
Check Hydrometer
291
Check Battery Terminals, Fusible Link and Fuses
291
High–Tension Cords Inspection
292
Disconnect High–Tension Cords from Spark Plugs
292
Inspect High–Tension Cord Terminals
292
Inspect High–Tension Cord Resistance
292
Spark Plugs Inspection
293
Clean Spark Plugs
293
Adjust Electrode Gap
293
Reconnect High–Tension Cords to Sparkplugs
294
Generator Drive Belt Inspection
294
Valve Clearance Inspection and Adjustment
295
Remove Spark Plugs
295
Remove Engine Wire
295
Set No.1 Cylinder to Tdc/Compression
296
Inspect Valve Clearance
296
Remove the Adjusting Shim
297
Determine the Replacement Adjusting Shim Size Byfollowing–The Formula or Chart
298
Adjusting Shim Selection Chart (Intake)
299
New Shim Thickness
299
Intake Valve Clearance (Cold)
299
Adjusting Shim Selection Chart (Exhaust)
300
Instill Cylinder Head Covers
301
Install Engine Wire
301
Install Air Intake Chamber
301
Ignition Timing Inspection and Adjustment
302
Connect Tachometer and Timing Light to Engine
302
Adjust Ignition Timing
302
Further Check Ignition Timing
303
Idle Speed Inspection and Adjustment
304
Initial Conditions
304
Insert CO/HC Meter Testing Probe into Tailpipe at Least 40 CM (1.3 Ft) During Idling
305
Immediately Check CO/HC Concentration at Idle And/Or 2,500 RPM
305
Check Cylinder Compression Pressure
307
Reinstall Spark Plugs
308
Timing Belt Components
309
Timing Belt Removal
309
Remove Engine under Cover
309
Remove Radiator
309
Disconnect No.2 and No.3 Air Hoses from Air Pipe
310
Remove Cooling Fan
310
Remove Water Outlet
311
Remove No.2 Timing Belt Cover
311
If Re–Using Timing Belt, Check Installation Marks on Timing Belt
311
Set No.1 Cylinder at Tdc/Compression
312
Remove Timing Belt Tensioner
312
Remove Fan Bracket
312
Disconnect Timing Belt from Camshaft Timing Pulleys
312
Remove Camshaft Timing Pulleys
313
Remove No.1 Timing Belt Cover Hint
314
Remove Timing Belt Guide
314
Remove No.1 Idler Pulley
315
Remove Crankshaft Timing Pulley
315
Timing Belt Components Inspection
315
Inspect Timing Belt
315
Inspect Idler Pulleys
316
Inspect Timing Belt Tensioner
317
Install Crankshaft Timing Pulley
318
Install No.1 Idler Pulley
318
Temporarily Install Timing Belt
318
Install Timing Belt Guide
318
Timing Belt Installation
318
Install No.1 Timing Belt Cover
319
Install LH Camshaft Timing Pulley
319
Crankshaft Position
320
RH Camshaft Pulley Position
320
LH Camshaft Pulley Position
320
Connect Timing Belt to LH Camshaft Timing Pulley
320
Install RH Camshaft Timing Pulley and Timing Belt
321
Install Fan Bracket
322
Set Timing Belt Tensioner
322
Install Timing Belt Tensioner
322
Check Valve Timing
323
Install No.2 Timing Belt Cover
323
Install Water Outlet
324
Install Generator Drive Belt
324
Install Cooling Fan
324
Install A/C Drive Belt
324
Install Ps Pump Pulley and Drive Belt
325
Install Radiator
325
Recheck Engine Coolant Level
325
Cylinder Head Components
326
Cylinder Heads Removal
328
Disconnect Clutch Release Cylinder Hose (M/T Only)
328
Remove A/C Drive Belt
328
Remove Generator Drive Belt
329
Disconnect Strap, Wires, Connectors
329
Disconnect Heater Hoses
329
Remove Timing Belt
330
Remove Air Intake Chamber
330
Remove No.2 and No.3 Fuel Pipes
333
Remove No.4 Timing Belt Cover
333
Remove No.2 Idler Pulley
333
Remove No.3 Timing Belt Cover
334
Remove Delivery Pipes and Injectors
334
Remove Water By–Pass Outlet
334
Remove Intake Manifold
334
Remove Exhaust Crossover Pipe
335
Disconnect Water By–Pass Pipe from RH Cylinder Head
335
Remove No.2 Engine Hanger from LH Cylinder Head
335
Remove Cylinder Head Covers
335
Remove Camshafts
336
Remove Cylinder Heads
336
Remove Generator Bracket
337
Remove Exhaust Manifold from RH Cylinder Head
337
Remove Exhaust Manifold from LH Cylinder Head
338
Cylinder Heads Disassembly
338
Remove Camshaft Housing Plugs
338
Remove Valve Lifters and Shims
338
Cylinder Head Components Inspection and Repair
340
Clean Top Surfaces of Pistons and Cylinder Block
340
Inspect Cylinder Head
341
Inspect Camshafts and Bearings
347
Inspect Valve Lifters and Lifter Bores
348
Inspect Air Intake Chamber
349
Inspect Intake Manifold
349
Cylinder Head Side
349
Air Intake Chamber Side
349
Inspect Exhaust Manifold
350
Cylinder Heads Assembly
351
Install Valve Lifters and Shims
352
Install Camshaft Housing Plugs
352
Cylinder Heads Installation
353
Install RH Exhaust Manifold to RH & LH Cylinder Head
353
Install Generator Bracket
353
Install Cylinder Heads
353
Install Cylinder Head (12 Pointed Head) Bolts
354
Install Cylinder Head (6 Pointed Head) Bolts
355
Install Camshafts
355
Check and Adjust Valve Clearance
356
Install Cylinder Head Covers
357
Install Water By–Pass Pipe to RH Cylinder Head
357
Install No.2 Engine Hanger
358
Install Oil Dipstick Guide and Dipstick
358
Install Exhaust Crossover Pipe
358
Install Water By–Pass Outlet
358
Install Injectors and Delivery Pipe
359
Install Pair Reed Valve and No.1 Injection Manifold
360
Install VSV Bracket and VSV to Pair Reed Valve
360
Install No.3 Timing Belt Cover
360
Install No.2 Idler Pulley
360
Install No.4 Timing Belt Cover
361
Install No.2 and No.3 Fuel Pipes
361
Connect High–Tension Cords to Spark Plugs
364
Install Front Exhaust Pipe
364
Connect Fuel Inlet and Outlet Hoses
364
Connect Heater Hoses
364
Connect Cables, Hoses, Connectors, Strap and Wires
365
Connect Clutch Release Cylinder Hose (M/T Only)
366
Install Air Cleaner and Hose
366
Perform Road Test
366
Cylinder Block Components
367
Disconnect Clutch Release Cylinder Hose
368
Remove PS Drive Belt and Pump Pulley
368
Disconnect Strap, Wires
369
Remove Engine Rear Mounting Bracket
370
Remove No.2 Frame Crossmember
371
Remove Engine and Transmission Assembly from Vehicle
371
Preparation for Disassembly
372
Remove Flywheel or Drive Plate
372
Remove Rear End Plate
372
Remove RH and LH Engine Mounting Brackets
372
Remove No.1 Water By–Pass Pipe
373
Remove Oil Pressure Sender Gauge
373
Remove Knock Sensor
373
Remove Oil Cooler and Bracket Assembly (2WD)
373
Remove Oil Cooler (4WD)
374
Remove Oil Filter Union
374
Remove Oil Pan Baffle Plate
375
Remove Oil Pump
375
Check Connecting Rod Thrust Clearance
376
Remove Connecting Rod Caps and Check Oil Clearance
376
Remove Piston and Connecting Rod Assemblies
378
Check Crankshaft Thrust Clearance
379
Remove Main Bearing Cap and Check Oil Clearance
379
Inspect Top Surface of Cylinder Block for Flatness
383
Inspect Cylinder for Vertical Scratches
383
Inspect Cylinder Bore Diameter
383
Piston and Connecting Rod Disassembly
384
Check Fit between Piston and Piston Pin
384
Piston and Connecting Rod Inspection
385
Inspect Piston Oil Clearance
386
Inspect Piston Ring Groove Clearance
387
Inspect Piston Ring End Gap
387
Inspect Connecting Rod Alignment
388
Inspect Connecting Rod Bolts
388
Cylinder Boring
389
Keep Oversized Pistons
389
Calculate Amount to Bore Cylinders
389
Bore and Hone Cylinder to Calculated Dimensions
389
Inspect Crankshaft for Runout
390
If Necessary, Grind and Hone Main Journals And/Or Crank Pins
390
Crankshaft Oil Seals Replacement
391
Replace Crankshaft Front Oil Seal
391
If Oil Pump Is Removed from Cylinder Block
391
If Oil Pump Is Installed to the Cylinder Block
391
Replace Crankshaft Rear Oil Seal
392
If Rear Oil Seal Retainer Is Removed from Cylinder Block
392
If Rear Oil Seal Retainer Is Installed to Cylinder Block
392
Pistons and Connecting Rods Assembly
393
Assemble Piston and Connecting Rod
393
Install Piston Rings
393
Install Main Bearing Cap and Lower Thrust Washers
395
Place Main Bearing Cap and Lower Thrust Washers on Cylinder Block
395
Install Main Bearing Cap Bolts
395
Install Piston and Connecting Rod Assemblies
396
Place Connecting Rod Cap on Connecting Rod
397
Post Assembly
399
Install Oil Pan Baffle Plate
400
Install Oil Pan
401
Install Oil Filter Union
401
Install Knock Sensor
402
Install Oil Cooler and Bracket Assembly (2WD)
402
Install Oil Cooler
403
Install Engine Coolant Drain Plugs
403
Install LH and RH Engine Mounting Brackets
403
Install Oil Filter
403
Install Oil Pressure Sender Gauge
404
Install Generator Adjusting Bar
404
Install Water Pump
404
Install Thermostat and Water Inlet
405
Install No.1 Water By-Pass Pipe
405
Install Rear End Plate
406
Insert Engine and Transmission Assembly in Vehicle
407
Install Engine Rear Mounting Bracket (2WD)
407
Install No.2 Frame Crossmember (4WD)
407
Tighten RH and LH Engine Mounting Insulator Bolts
408
Connect Clutch Release Cylinder Hose
408
Install A/C Compressor
408
Connect Strap, Wires, Connectors, Hoses and Cables
409
Exhaust System
411
Layout and Schematic Drawing
419
Evaporative (EVAP) Emission Control System
422
Fuel Vapor Lines, Fuel Tank and Tank Cap Inspection
423
Exhaust Gas Recirculation (EGR) System
425
Check VSV with Cold Engine
426
Check VSV and EGR Vacuum Modulator with Warm Engine
426
Check Pair System with Cold & Warm Engine
430
Pair Reed Valve Inspection
430
Check Reed Valve by Blowing Air into Pipe
430
Check Valve by Blowing Air into each Pipe
431
Check for Dents or Damage
432
MFI System
435
Description System Circuit
435
Operation Fuel System
437
Precautions When Connecting Gauge
442
Precautions When Handling Heated Oxygen Sensor
442
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 Procedure
445
When Connecting the Flare Nut or Union Bolt on the High Pressure Pipe Union, Observe the Following Procedure
445
Observe the Following Precautions When Removing and Installing the Injectors
446
Install the Injector to the Delivery Pipe and Intake Manifold as Shown in the Illustration
446
Confirm that There Are no Fuel Leaks after Performing any Maintenance on the Fuel System
446
Malfunction Indicator Lamp Check
448
Diagnostic Trouble Codes Output (Normal Mode)
448
Normal System Operation (no Malfunction)
449
Test Mode
450
Diagnostic Trouble Code Cancellation
452
DTC 12 Heated Oxygen Sensor Circuit
455
Air–Fuel Ratio Lean Malfunction (California, C & C)
457
Air–Fuel Ratio Rich Malfunction (California, C & C)
457
Diagnosis Circuit Inspection
459
Fuses and Fusible Link Location
460
MFI System Check Procedure
461
Engine Control Module (ECM) Terminals
461
Engine Control Module (ECM) Wiring Connectors Voltage
462
+B (+B1)-E1
464
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 E1
477
System Circuit
479
On-Vehicle Inspection
479
Check Fuel Pressure
480
Components for Removal and Installation
482
Remove Fuel Pump from Fuel Pump Bracket
483
Remove Fuel Pump Filter from Fuel Pump
483
Install Fuel Pump Filter to Fuel Pump
483
Install Fuel Pump to Fuel Pump Bracket
483
Install Fuel Pump Bracket
484
Install Fuel Tank
484
Cold Start Injector On-Vehicle Inspection
485
Inspect Resistance of Cold Start Injector
485
Check Injection of Cold Start Injector
486
Inspect Leakage
487
Install Cold Start Injector
487
Install Cold Start Injector Tube
488
Check for Fuel Leakage
488
Fuel Pressure Regulator On-Vehicle Inspection
489
Fuel Pressure Regulator Removal
489
Disconnect Following Cables
490
Disconnect Vacuum Sensing Hose
490
Disconnect Fuel Return Hose
490
Remove Fuel Pressure Regulator
492
Fuel Pressure Regulator Installation
493
Install Fuel Pressure Regulator
493
Connect Vacuum Sensing Hose
496
Connect Air Cleaner Hose
496
Connect Following Cables
496
Injector Components for Removal and Installation
497
Injectors Removal
498
Injectors Inspection
501
Measure Resistance of Injector
501
Injectors Installation
503
Install Injectors and Delivery Pipes
503
Volume Air Flow (VAF) Meter On-Vehicle Inspection
510
Volume Air Flow Meter Removal
511
Disconnect Resonator Bracket
511
Remove Volume Air Flow Meter from Air Cleaner Cap
511
Volume Air Flow Meter Inspection
511
Volume Air Flow Meter Installation
512
Install Volume Air Flow Meter to Air Cleaner Cap
512
Install Resonator Bracket
512
Throttle Body On-Vehicle Inspection
513
Inspect Dashpot (DP)
514
Inspect Throttle Opener
515
Inspect Air Valve Operation
516
Disconnect Air Cleaner Hose
517
Throttle Body Inspection
518
Throttle Body Installation
520
Connect Throttle Position Sensor Connector
520
Install Accelerator Cable Bracket
520
EFI Main Relay
522
Circuit Opening Relay
523
Cold Start Injector Time Switch Inspection
524
Measure Resistance of Cold Start Injector Time Switch
524
Engine Coolant Temp. Sensor Inspection
525
Measure Resistance of Engine Coolant Temp. Sensor
525
Fuel Pressure VSV Inspection
526
Check VSV Operation
526
Measure Resistance of EGR Gas Temp. Sensor
528
Heated Oxygen Sensor Inspection
529
Inspect Heater Resistance of Heated Oxygen Sensor
529
Engine Control Module (ECM) Inspection
531
Inspect Voltage of Engine Control Module (ECM)
531
Inspect Resistance of Engine Control Module (ECM)
533
Engine Control Module (ECM) Wiring Connectors Resistance
533
Fuel Cut RPM
534
Cooling System
538
Operation
538
Reservoir Tank
539
Engine Coolant
540
Inspect Fan Pulley Bracket
543
Water Pump Installation
543
Thermostat Removal
545
Thermostat Inspection
545
Thermostat Installation
545
Radiator Installation
547
Lubrication System
549
SSM (Special Service Materials)
552
Check Oil Level
553
Remove Oil Pressure Sender
553
Recheck Engine Level
556
Remove Driven and Drive Rotors
558
Remove Relief Valve
558
Inspect Body Clearance
559
Inspect Tip Clearance
559
Inspect Side Clearance
559
Inspect Relief Valve
559
Crankshaft Front Oil Seal Replacement
560
Oil Pump Assembly and Installation
561
Install Drive and Driven Rotors
561
Install Pump Body Cover
561
Install Relief Valve
561
Clean Oil Pan Baffle Plate and Oil Pan
562
Oil Cooler Components
565
Oil Cooler Removal
565
Disconnect Oil Cooler Hoses
565
Remove Oil Cooler (2WD)
566
Oil Cooler Inspection
566
Oil Cooler Installation
566
Connect Oil Cooler Hoses
567
Ignition System
569
Electronic Spark Advance (ESA)
571
Spark Test
573
High–Tension Cord Inspection
574
Inspect High–Tension Cord Resistance & Terminals
574
Clean and Inspect Spark Plugs
574
Ignition Coil Inspection
575
Measure Primary Coil Resistance
575
Measure Secondary Coil Resistance
575
Distributor Inspection
575
Check Signal Generator (Pickup Coil)
576
Distributor Components
577
Distributor Removal
577
Distributor Installation
577
Install Distributor and Set
577
Connect High–Tension Cords and Wiring Connector
578
Disconnect Tachometer and Timing Light from Engine
579
3Vz–E
581
Ignition Coil
582
Pickup Coils
582
Check that Spark Occurs
586
Disconnect High-Tension Cords from Spark Plugs
587
Disconnect High–Tension Cords from Distributor Cap and Ignition Coil
587
Reconnect High–Tension Cords to Distributor Cap and Ignition Coil
587
Reconnect High-Tension Cords to Spark Plugs
588
Visually Inspect Spark Plugs
589
Clean Coil and Check Following
590
Inspect Primary Coil Resistance
590
Inspect Secondary Coil Resistance
590
Inspect Air Gaps
591
Inspect Signal Generator (Pickup Coil)
591
Disconnect High–Tension Cords from Distributor Cap
592
Remove Distributor
593
Remove O–Ring
593
Check No.1 Cylinder to Tdc/Compression
593
Install Dust Proof Packing and Distributor Cap
594
Connect High–Tension Cords to Distributor Cap
594
Connect Distributor Connector
594
Starting System
596
Starter Components
597
Removal of Starter
598
Disconnect Two Wires from Starter
598
Remove Starter Motor
598
Disassembly of Starter
598
Remove Clutch Assembly and Gears from Starter Housing
599
Remove Steel Ball and Spring
599
Remove Brushes and Brush Holder
599
Remove Armature from Field Frame
599
Inspection of Starter
600
Armature Coil
600
Inspect Commutator Circle Runout
600
Inspect Commutator Diameter
600
Inspect Undercut Depth of Segment
601
Inspect Field Coil for Open Circuit
601
Inspect that Field Coil Is Not Grounded
601
Inspect Brush Length
601
Inspect Brush Spring Load
602
Inspect Insulation of Brush Holder
602
Clutch and Gears
602
Inspect Bearings
602
If Necessary, Replace Bearings
603
Magnetic Switch
603
Perform Pull–In Coil Open Circuit Test
603
Perform Hold–In Coil Circuit Test
603
Assembly of Starter
604
Install Brush Holder
604
Insert Steel Ball into Clutch Shaft Hole
604
Install Gears and Clutch Assembly
604
Install Starter Housing
605
Install Field Frame with Armature to Magnetic Switch Assembly
605
Performance Test of Starter
606
Perform Pull–In and Hold–In Test
606
Inspect Clutch Pinion Gear Return
606
Perform No–Load Performance Test
606
Installation of Starter
607
Install Starter Motor on Transaxle
607
Connect Two Wires to Starter
607
Connect Cable to Negative Terminal of Battery
607
Inspection of Starter Relay
608
Charging System
609
Inspect Battery Specific Gravity and Electrolyte Level
610
Check Battery Terminals and Fusible Links
610
Inspect Drive Belt
610
Inspect Fuses for Continuity
611
Visually Check Generator Wiring and Listen for Abnormal Noises
611
Inspect Discharge Warning Light Circuit
611
Check Charging Circuit Without Load
612
Inspect Charging Circuit with Load
612
Generator Components
613
Removal of Generator
614
Disconnect Wiring from Generator
614
Remove Water Inlet Hose (W/Ps)
614
Remove Generator
614
Disassembly of Generator
616
Remove IC Regulator
616
Remove Rectifier Holder
616
Remove Pulley
616
Remove Rear End Frame
617
Inspection and Repair of Generator
618
Rotor
618
Stator
618
Inspect Exposed Brush Length
619
If Necessary, Replace Brushes
619
Inspect Positive Side Rectifier
619
Inspect Negative Side Rectifier
620
Inspect Front Bearing
620
If Necessary, Replace Front Bearing
620
Inspect Rear Bearing
621
If Necessary, Replace Rear Bearing
621
Assembly of Generator
622
Install Rear End Frame
622
Install Pulley
622
Install Rectifier Holder
622
Install Brush Holder and IC Regulator
623
Install Rear End Cover
623
Make Sure Rotor Rotates Smoothly
623
Install Generator
624
Install Water Inlet Hose
624
Connect Wiring to Generator
624
Fill with Coolant
624
Installation of Generator
625
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