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Toyota 4A-F Repair Manual

Toyota 4A-F
319 pages
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4A-F,4A-GE
ENGINE
REPAIR MANUAL
,
May, 1987
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Toyota 4A-F Specifications

General IconGeneral
Engine TypeInline-4
Displacement1.6 L (1, 587 cc)
Fuel TypeGasoline
Bore x Stroke81.0 mm x 77.0 mm
Torque136 Nm (100 lb-ft) at 4, 800 rpm
Fuel SystemFuel injection
ValvetrainDOHC

Summary

Standard Bolt Torque Specifications

Specified Torque for Standard Bolts

Provides specific torque values for standard bolts by class and size.

Charging System

Charging System Precautions

Safety and handling precautions for the charging system.

Charging System Troubleshooting

Lists common problems, possible causes, and remedies.

On-Vehicle Inspection

Procedures for inspecting battery, fusible links, and drive belt.

Alternator Components

Alternator Inspection and Repair

Procedures for inspecting rotor and stator components.

Cooling System

Cooling System Troubleshooting

Lists problems, causes, remedies, and page references for engine overheating.

EFI System

EFI System Precautions

General safety precautions before working on the fuel system.

Troubleshooting

Troubleshooting Hints

General hints covering electrical sources, fuel supply, ignition, and air induction.

Troubleshooting Procedures: Difficult Start/No Start

Flowchart for diagnosing difficult start/no start (engine won't crank).

Troubleshooting Procedures: Engine Often Stalls

Troubleshooting steps for engine stalling, covering diagnosis, fuel supply, and ignition.

Troubleshooting: Rough Idling and/or Missing

Steps for diagnosing rough idling, including vacuum leaks, ignition, and cold start injector.

Diagnosis System

Output of Diagnostic Codes

Procedures for obtaining diagnostic codes via check connector.

Diagnostic Codes (TCCS ECU w/o Air Flow Meter)

List of diagnostic codes, systems, diagnoses, and trouble areas.

Cancelling Diagnostic Code

Methods for cancelling diagnostic codes by removing fuses or battery terminal.

Troubleshooting with Volt/Ohmmeter

EFI System Check Procedure

Steps for performing voltage and resistance measurements on ECU wiring.

Voltage at ECU Wiring Connectors (TCCS ECU w/o Air Flow Meter)

Table of voltages at ECU terminals under various conditions.

Troubleshooting Flowcharts

Troubleshooting flowcharts for various ECU terminals and systems.

Fuel System

On-Vehicle Inspection: Fuel Pump

Procedures for inspecting fuel pump operation and fuel pressure.

On-Vehicle Inspection: Fuel Pressure

Steps for installing pressure gauge, measuring fuel pressure, and checking fuel hoses.

Injectors

Throttle Body

Electronic Control System

Engine Mechanical Troubleshooting

Troubleshooting: Engine Overheating

Troubleshooting chart for engine overheating, hard starting, and rough idling.

Troubleshooting: Hard Starting

Troubleshooting chart for engine not cranking or cranking slowly.

Troubleshooting: Rough Idling

Troubleshooting for rough idling, stalls, or misses.

Troubleshooting: Engine Hesitates/Poor Acceleration

Troubleshooting for engine hesitates and poor acceleration.

Engine Tune-up

Valve Clearance Adjustment

Steps for removing cylinder head cover and setting cylinder to TDC/compression.

Ignition Timing Adjustment

Procedures for warming up engine, connecting tachometer, and shorting terminals.

Cylinder Block Disassembly

Connecting Rod Thrust Clearance Measurement

Procedures for removing rear oil seal retainer and measuring thrust clearance.

Connecting Rod Cap Removal and Oil Clearance

Procedures for removing connecting rod caps and measuring oil clearance.

Piston and Connecting Rod Assembly Disassembly

Procedures for removing piston/connecting rod assemblies and cleaning carbon.

Cylinder Block Inspection

Cylinder Block Gasket Material Removal

Procedures for removing gasket material, cleaning, checking flatness, and inspecting for scratches.

Cylinder Bore Inspection

Procedures for inspecting cylinder bore diameter and removing cylinder ridges.

Piston and Connecting Rod Assemblies Disassembly

Piston and Connecting Rod Assembly Disassembly (Cont'd)

Steps for checking piston/pin fit and removing piston rings.

Piston Disassembly Procedures

Procedures for cleaning pistons and inspecting piston diameter/oil clearance.

Piston Ring Inspection

Procedures for inspecting piston ring groove clearance and end gap.

Crankshaft Inspection

Crankshaft Runout Inspection

Procedures for checking crankshaft runout and journal diameters.

Main Journals and Crank Pins Inspection

Procedures for measuring journal diameters and checking taper/runout.

Cylinder Head Removal

Cylinder Head Removal Procedures

Procedures for draining coolant, removing distributor, and removing exhaust manifold.

Component Removal for Cylinder Head

Steps for removing EGR valve, cold start injector pipe, delivery pipe, vacuum pipe, throttle body, and intake manifold.

Cylinder Head Component Removal

Procedures for removing water outlet, timing belt covers, spark plugs, and setting cylinder to TDC.

Cylinder Head Removal Steps

Procedures for disconnecting timing belt, removing pulleys, and removing cylinder head covers.

Cylinder Head Disassembly

Valve Lifters and Shims Removal

Procedures for removing valve lifters, shims, valves, and oil seals.

Cylinder Head Component Service

Cleaning pistons, block, combustion chambers, valve guide bushings, and cylinder head.

Cylinder Head Inspection and Cleaning

Inspecting cylinder head flatness, cracks, and cleaning valves.

Engine Mechanical Tune-up

Timing Belt Components

Timing Belt Installation

Compression Check (4A-GE)

Engine Compression Check Procedures

Procedures for warm-up, disconnecting connectors, removing spark plugs, and checking compression.

Ignition System

Ignition System Troubleshooting

Troubleshooting chart for engine start issues, rough idle, hesitations, dieseling, backfires, and overheating.

Spark Plugs Inspection

Distributor Installation

Lubrication System

Lubrication System Troubleshooting

Troubleshooting chart for oil leakage, low oil pressure, and high oil pressure.

Engine Oil and Oil Filter Replacement

Oil Pump Removal

Oil Pump Disassembly

Oil Seal Replacement

Oil Pump Assembly

Oil Pump Installation

Oil Cooler and Pressure Regulator Removal and Disassembly

Oil Cooler and Pressure Regulator Assembly and Installation

Service Specifications

EFI System Specifications

Starting System

Starting System Troubleshooting

Troubleshooting chart for engine not cranking, cranking slowly, starter issues.

Starter Inspection

Starter Assembly

Starter Performance Tests

CAUTION and performance tests for the starter (pull-in, hold-in, plunger return, no-load).

Starter Relay (AW) Inspection

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