TOYOTA 4A-F, 4A-GE ENGINE REPAIR MANUAL May, 1987Wz INTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL “To assist you in finding your way through this manuel, the Sec: tion Title and major heading are given at the top of every page. ‘An INDEX is provided on the 1st page of each section to guide ‘you to the item to be repaired. ‘At the beginning of each section, PRECAUTIONS are given ‘that pertoin to aff rapair operations contained in that section ‘Read these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the syatem problem and find the cause. The repair for each possible cause is referenced in the remedy col. lumn to quickly lead you to the solution. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Pulley Seat water Pump Pulley 1 won-reusable part \Woter Pump Suction Cover Rotor Gasket \Woter Purp BodyINTRODUCTION — How to Use This Manual IN Mustration: what 10 do and whore The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it © The task heading tells what to do. © The dotailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading’ what to do 3. DISCONNECT CONNECTING ROD FROM PISTON Using SST. press out the pin from the piston. 8ST 08221-25022 (09221-00080, 08221-00199, 08221-00140) Set part No. Comparient port No, Detail text: how to do it ()_ Install and alternately tighfen the cap nuts in several passes, Torque: 500 kg-cm (36 ft-Ib, 49 Nem) Specitication ‘This format provides the experienced technician with a FAST TRACK to the information needed. He can read the task hea ings end only refer to the detailed text when he needs it. Impor {ant specifications and warnings always stand out in bold type, REFERENCES References have been kept to a minimum, However, when they ‘are required, you are given the page to go to. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text in the applicable step. You never have to leave the procedure to ook up your specifications. All specifications are also found in Appendix A, spocifications, for quick reference. WARNINGS, CAUTIONS, NOTES: © WARNINGS are presented in bold type Possibility of injury to you or other peopl ‘© CAUTIONS are also presented in bold type and indicate there is a possibilty of damage to the components boing repaired, ‘© NOTES are separated from the text but do not eppear in bold type. They provide odditional information to help you effi- Ciently perform the repair. and indicate theNe INTRODUCTION — Abbreviations Used in This Manual ABBREVIATIONS USED IN THIS MANUAL AAP ‘SSM ssT STD sw Te Tvs Tvsv Twe us vsv Auxiliary Acceleration Pump ‘Air Conditioner Air Suction ‘Automatic Transmission Before Top Dead Center Choke Breaker Dash Pot Electronic Controtied Unit Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Exhaust (manifold, valve) Except Formed in Place Gasket Hot Idle Compensation Hot Air Intake Igrition Integrated Ignition Assembly Intake (manifold, valve Idle Speed Contro} Left-hand Left-hand Drive Long Life Coolant (Year Around Coolant) Multipurpose ‘Manual Tronsmission Oversized Positive Crankcase Ventilation Right-hand Right-hond Drive Research Octane Number Powar Steering ‘Special Service Materials Special Service Tools Standard Switch Top Dead Center Throttle Positioner TOYOTA-Variable Induction System Thermostatic Vacuum Switching Valve Three-way Catalyst Undersized Vacuum Switching Valve with WithoutEma ENGINE MECHANICAL — Description (4A-GE) DESCRIPTION 4A-GE ENGINE ‘The 4A-GE engine Is an in-line 4-cylinder 1.6 liter DOHC 16 vaive engineENGINE MECHANICAL — Description (4A-GE) The 4A-GE engine is an in-line 4-cylinder engine with the cylinders numbered 1-2-3-4 from the ‘ront. The crankshaft is supported by 5 bearings specifiod by the inside of the crankcese. These besrings are made of aluminum alloy ‘The crankshaft is integrated with 8 weights ‘hich are cast along with it for balancing. Oil holes: ‘2 built into the center of the crankshatt for sup- plying oil to the connecting rods, pistons and other ‘components. This engine's ignition order is 1-3-4-2. The cylinder head is made of aluminum alloy, with 7038 flow type intake and exhaust layout and with pent roof type combustion chambers, The spark lugs are located in the center of the combustion ‘chambers, The intake manifold has & independent long ports and utilizes the inertial supercherging effect to improve engine torque at low and medium speeds, Exhaust and intake valves are equipped with ‘negular pitch springs made oF oil tempered silicon chrome steel wire which are capable of folowing the valves even at high engine speeds. Both the exhaust side cam shaft and the intake side cam shaft are driven by a single timing belt. The cam joumal is supported at 6 places between the valve lifters of each cylinder and on the frant end of the cylinder heed. Lubrication of the cam eurnal end cam is accomplished by oil being sup- plied through the oiler port in the center of the camshat. Adjustment of the valve clearance is dono by means of an outer shim type system, in which valve adjusting shims are located above the valve ters. This permits replacement of the shims ‘mithout removal of the camshafts, The resin timing bolt cover is made in 3 pieces, A service hole is provided in the No belt cover for adjusting the timing belt tension, Pistons are made of highly temperature-resis- tant aluminum alloy, and a deprassion is built into the piston head to prevent interference with valves. Piston pins are the full-floating type, with the pins fastened to neither the piston boss nor the connecting rods. instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. ‘The No.1 compression ring is made of steel and the No.2 compression ring is made of cast iron. The oil ring is made of a combination of steal and stainless steel. The outer diameter of each piston ‘ing is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the oylinder wells when they are mounted an the piston. Compression rings No.1 and No.2 work to prevent the leakage of gas from the ‘ylinder and the oil ring works to scrape oil off the ‘ylinder walls to prevent it from entering the com- ‘ustion chamber. EM-5 ‘The eylinder block is made of cast iron. It has & covlinders which are approximately 2 times the length of the piston stroke. The top of the cylin: ders is closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the covlinder block contains a water jacket, through ‘which coolant is pumped to cool the cylinders. The oil pan is bolted onto the bottom of the ‘oylinder block. The oll pan is an oll reservoir made Of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient ol in the bot- tom of the pan even when the vehicle is tited. This dividing plate also provents the oil from making waves when the vehicle is stopped suddenly and thus shifting the oil away from the oil purnp suc- tion pipe.2 STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH T Mark ee Hexagon pot 47) 47 | Stud bot tend hom ‘need No. 5— st OC wom oe wa i Swed wiwasher No merk av root fines. | Clase at er atSTANDARD BOLT TORQUE SPECIFICATIONS: SPECIFIED TORQUE FOR STANDARD BOLTS: T Specified trave eines | Sameter | Pich Hexagon ange bolt koom te Nm 8 1 60 S2ina 59 8 125 | 190 943 14s wo 4 wo | 12s | 280 1926 290 ne ar 2 12s | 480 a 540 28 “ 1s 760 er as0 8 6 15 | 1180 ett - © y 6s senw 64 - 8 12s | 160 2 6 - 10 12s | 330 8 - st 2 12s | 600 488 - 1“ 1s 920 oo - 16 18 | 1400187 - | 6 1 80 ine 78 90 Teint 88 | i ® r2s | 188 419) wo er | 10 128 | 400 2 420 24 12 125) 720 so e10 8 wf oe | - [1280 9012 6 1 ne ° | 120 2 2 ® 12s | 200 1” 25 | 200 ne 10 12s 80 28 82 580 368 a 2 tas 870 20 95 | 1,050 78 108 “ 15 | 1800 108147) 1.700 288 16 15-2200 68s -FUEL SYSTEM @ INJECTOR @ COLD START INJECTOR INJECTOR SOLENOID COIL TERMINAL PLUNGER NEEDLE VALVE SPRING The injector performs the injection of fuel in accordance with a computer calculated injection signal. When a pulse from the computer is received by the solenoid coil, the plunger is pulled against spring tension. Since the needle valve and plunger are a single unit, the valve is also pulled off of the seat and fuel is Injected as shown by the arrows. Because the needle valve stroke is fixed, injection continues as long as the needle valve is open and fuel volume is controlled by the duration of the electrical pulse. COLD START INJECTOR SOLENOID call i TERMINAL 1 SPRING = PLUNGER A cold start injector, installed! in the center area of the air distribution chamber, is provided to improve starting when the engine is cald. This injector tunctions in ascardance with direc- tions from the start injector lime switch and only during engine cranking when the coolant tem- perature is below 35°C. The injector tip employs a special design to improve mist spray. When the start injector time switch signal is applied to the solenoid coil, the plunger is pulled against spring tension. Thus, the walve will open and fuel will flow over the plunger and through the injector tip. Once the engine has been started, current 1o the start injecter is cut off and injection Is terminated.AIR INDUCTION SYSTEM C aa AIR VALVE GATE VALVE FROM AIR CLEANER TO.AIR DISTRIBUTION ig CHAMBER HEAT CONL DIMETAL AT LOW TEMPERATURE The air valve is a fast idle device operated by a bimetal and heat coil to increase engine rpm when the engine is cold. GATE VALVE FROM AIH CLEANER HEAT COIL RIMETAL AFTER WARMEII UP OPERATION When starting a cold engine, the gate valve is open allowing air from the air cleaner to bypass the throttle valve and flow directly through the air valve to the air intake chamber. in the closed Thus, eventhough the throttle valve i position, intake air volume is increased and Idle speed will be slightly faster than normal (fast idle). When the engine is started, current begins to flow to the heat nil. As the bimetal is heated, the gate valve will gradually close and engine rpm will decrease. Once warmed up, the gate valve will be fully closed, preventing air flow, and idle speed will return to normal.CH CHARGING SYSTEM Page cH cH.2 . cH cH cH cHs PRECAUTIONS . ‘TROUBLESHOOTING CHARGING CIRCUIT ‘ON-VEHICLE INSPECTION ALTERNATOR ENGINE MAIN RELAYcH-2 CHARGING SYSTEM Proca ns. Troubleshooting PRECAUTIONS Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery w! ning. le the engine Is run- TROUBLESHOOTING Problem Possible cause Remedy Page Discharge warming light does not light with ignition ON and engine off Fuse blown Light bumed out ‘Wiring connection lose 1c rogulator fauty Check “CHARGE” and IGN” (AE ond AT) or "AM2" (AW) fuses Replace light Tighten loose connections Replace IC regulator CHT Discharge warming light doas not go out ‘with engine running Ibattery requires fre- quent recharging) Drive belt loose or wom Battery cables loose, corroded or worn | Repair or replace cables Fuse blown Fusible link blown ‘Adjust or replace drive bolt Ha CCheck “CHARGE” or ENGINE” fuse Replace fusible lin IC regulator or alternator Faulty Check charging system cH3 ‘Wiring foutty Repair wiring )CHARGING SYSTEM — Charging Circuit CHARGING CIRCUIT CHS AE and AT Battery aw Amy 161 ica Rs Ignition an 1 4 i a gine ae Lee A2 308 F704 (AB, OTs ! 7.BA (AT) 1 3 Charge ile ‘Warning € te 3 mass ™ - CHARGE 7.54 Aiarnator leon Sith . . AM 2 P re Bide 10a | Fuse AMO 7.50 Fusible d tink 1258 Battery Hh ‘Charge Warning Light Fuse CHARGE 5A * Alternator — gerCH-4 CHARGING SYSTEM — On-Vehicle Inspection lUrcer ever Lower Level Fusible Link Altern crankshatt Water Pump [Ie Caatt ator ON-VEHICLE INSPECTION 1, INSPECT BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL (@) Check the specific gravity of each cell ‘when fully charged at 20°C (68°F): 7.28 1.27 if vot within spectiestions, charge the battery 1b) Chock te electrolyte quantity of each cel \ isu, el with cstited (or puri) wote, 2. CHECK BATTERY TERMINALS AND FUSIBLE LINKS (a) Check that the battery terminals are not loose or cor- roded, (b) Check the fusible links for continuity 3. INSPECT DRIVE BELT (2) Visually check the belt for separation of the adhesive Fubber above and below the core, core separation ‘rom the belt side, severed core, separation of the rid, from the adhesive rubber, cracking or separation of ‘he ribs, torn of worn ribs or cracks in the inner ridges Of the ribs If the belt has any of the above defects, replace it. [b) Check the drive belt deflection of pressing on the belt ‘at the points indicated in the figure with 10 kg (22.0 'b,98 N) pressure. /e bolt doflaction: 4AF New belt 8.5 ~ 10.8 mm (0.335 ~ 0.413 in} Used belt 10.0 — 12.0 mm (0.39 ~ 0.47 in} 4A-GE Now belt. 4-5 mm (0.16 ~ 0.20 in) Used belt 6 — 7 mm (0.24 ~ 0.28 in) If necessary, adjust the drive belt deflectionCHARGING SYSTEM Hiae-————_sst8 leaasal daaaar|lasnah CORRECT WRONG ~~ WRONG Je Inspection (Reference) Using SST, check the drive belt tension, SST A 09216-00020 SST B 09216-00030 Drive belt tension: 4aF New belt 60-70 kg Used belt 40-55 kg 4A-GE ‘New belt 70 ~ 80 kg Used belt. 30-45 kg Noe: ‘© "New belt” refers to a belt which has been used less ‘than § minutes on a running engine. ed belt” refers to a belt which has been used on 2 running engine for § minutes or more. ‘© After installing the drive belt, check that it fits properly in the ribbed grooves, © Check with your hand to comtirm that the belt has not slipped out of the groove on the bottom of the crank pulley, © After installing the belt, run the engine for approx 5 minutes and recheck the deflection or tension. CHECK FUSES FOR CONTINUITY © CHARGE 7.5A (AE and AT), 6A (AW) © IGN 104 (AE), 7.54 (AT) © ENGINE 7.54 (AE), 10 (AT and AW) © AM2 7.58 (AW) VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES. (2) Check that the wring is in good condition. (0) Check that there is no abnormal noise from the alter- nator while the engine is running. INSPECT DISCHARGE WARNING LIGHT CIRCUIT (2) Warm up the engine and tum it off. (©) Tum off all eccessories. (c)_ Turn the ignition switch to ON. Check that the dis- ccharge warning light is lit () Start the engine. Check that the light goes out It the light does not operate as specified, troubleshoot the warning light circuitCHG CHARGING SYSTEM — On-Vehicle Inspection Disconnect Wire from Termual B Lote than 10 A 8 ae i 4 Termin! F Be Ss Wore than 0A % a etme meet z ‘CHECK CHARGING CIRCUIT WITHOUT LOAD NOTE: If 9 battery/siternator tester is available, connect ‘the tester to the charging circuit according to the manufacturer's instructions. @) Ifa tester is not avsilsble, connect a voltmeter and ammator to the charging circuit as follows: © Disconnect the wire from terminal B of the alterna- tor and connect the wire to the negative () ter- minal of the ammeter. © Connect the test lead from the positive (+) ter- ‘minal of the ammeter to terminal B of the alterne tor, © Connect the positive (+) lead of the voltmeter to terminal 8 of the alternator. © Ground the negative (-) lead of the voltmeter. (b) Check the charging cirevit 0s follows: With the engine running from idling to 2,000 rpm, ‘check the reading on the ammeter and voltmeter. Standard amperage: Less than 10 A Standard voltage: 13.9 — 16.1 V at 25°C (77°F) 13.6 — 14.3 V at 116°C (239°F) If the voltage reading is greater than standard voltage, replace the IC regulator. 1 the voltage reading is less than standard voltage, check the IC regulator and alternator as follows: © With terminal F grounded, start the engine and check the voltage reading of terminal B. © If the voltage reading is higher than standard voltage, replace the IC regulator. If the voltage reading is less than standard voltage, repair the alternator. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the hhigh beam headlights and place the heater fan con- ‘rol switch at Hl (b) Check the reading on the ammeter. Standard amperage: More than 30 A If the ammeter reading is less than 30 A, repair the alter- nator. (See page CH-7) NOTE: If the battery is fully charged, the indication will ‘sometimes be less than 30 A.CHARGING SYSTEM — Alternator CHT ALTERNATOR COMPONENTS, Bearing Cover Retainer Song Front Bearing 4 Rotor Rubber insulator “ SE Recitinr Hotor AY \ =D ar a he Brush Holder with Cover Porc neces Terminal Insulator Rectifier End Frame DISASSEMBLY OF ALTERNATOR 1. REMOVE REAR END COVER, (a) Remove the nut and terminal insulator. (b) Remove the three nuts and end cover,CHARGING SYSTEM — Alternator REMOVE BRUSH HOLDER AND IC REGULATOR Remove the five screws, brush holder and IC regulator, REMOVE RECTIFIER HOLDER {a) Remove the four screws and rectifier holder. (o) Remove the four rubber insulators, REMOVE PULLEY gsr. (a) Hold SST A with 2 torque wrench, and tighten SSTB clockwise to the specified torque SST 09820-63010 Torque: 400 kg-om (29 ft-lb, 39 Nem) (&) Check that SST A is secured to the rotor shaft (c}_ As shown in the figure, mount SST C in a vise, and install te lternator to SST C. 4d) To loosen the pulley nut tum SST A in the direction shown in the figure CAUTION: To prevent damage to the rotor shaft, do not loosen the pulley nut more that one-half of a turn, (e) Remove the alternator from SST C. {f) Turn SST B and remove STs A snd B. (9) Remove the pulley nut and pulley 5. REMOVE RECTIFIER END FRAME {a) Remove the four nuts. (b) Using SST, remove the rectifier end frame. SST 09286-46011 6. REMOVE ROTOR FROM DRIVE END FRAME SeatsCHARGING SYSTEM — Alternator cH-9 INSPECTION AND REPAIR OF ALTERNATOR Rotor 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- tween the slip rings, Standard resistance (cold): 2.8 - 3.0 0. If there is no continuity, replace the rotor. rn Continuity’ 2. INSPECT ROTOR FOR GROUND. Using an ohmmeter, check that there is no continuity be- ‘ween the slip ring and the rotor. Hf there is continuity, replace the rotor. 3. INSPECT SLIP RINGS. (@) Check that the slip rings are not rough or scored, W rough oF scored, replace the rotor. (0) Using calipers, measure the slip ring diameters. ‘Standard diam 14.2 - 14.4 mm (0.569 ~ 0.567 in) 14.0 mm (0.851 in) W the diameter is less than minimum, replace the rotor. Minimum dior Stator 1. INSPECT STATOR FOR OPEN CIRCUIT Using an chmmeter, check that there is continuity be- ‘ween the coil leads, If there is no continuity, replace the drive end frame assembly, INSPECT STATOR FOR GROUND Using an ohmmetor, check that there is no continuity be- ‘tween the coil leads and drive end frame, f there is continuity, replace the drive end frame assemb- Wy No continuityCH-10 CHARGING SYSTEM — Alternator Brushes 1, MEASURE EXPOSED BRUSH LENGTH Minimum exposed length: 4.5 mm (0.177 in) I the brush length is less than minimum, replace the brushes IF NECESSARY, REPLACE BRUSHES (@)_Unsolder and remove the brush and spring, (©) Run the wire of the brush through the hole in the brush holder, and insert the spring and brush into the brush hold fc) Solder the brush wire to the brush holder at the exposed length. Exposed length: 10.5 mm (0.413 in.) (d) Check that the brush moves smoothly in the brush holder. Cut off the excess wire (Apply insulation paint to the soldered point. Positive St Rectifier Terria) Rectifier 1, INSPECT POSITIVE SIDE RECTIFIER {a} Using an ohmmeter, connect one tester prove to the ositive stud and the other to each rectifier terminal (0) Reverse the polarity of the tester probes, (c) Check that one shows continuity and the other shows no continuity. If not, reploce the rectitier holder.CHARGING SYSTEM — Alternator CHAT 2. INSPECT NEGATIVE SIDE RECTIFIER (a) Connect one tester probe to each rectifier terminal {and the other to each rectifier negative termi (b) Reverse the polarity of the tester probes, fc} Check that one shows continuity and the other shows no continuity. If not, replace the rectifier holder. ings 1, INSPECT FRONT BEARING Check that the bearing is not rough or worn. 2. IF NECESSARY, REPLACE FRONT BEARING fo} Remove the four screws and bearing retainer. (0) Using a press and socket wrench, press out the front bearingCHAZ CHARGING SYSTEM — Alternator (€) Using SST and 2 press, press in a new front bearing into the drive end frame, ‘SST 09608-20012 (09608-00030) (d) Align the claws of the bearing retainer with the slots of the drive end frame. le) Install the bearing retainer with the four scrows. INSPECT REAR BEARING Check that the bearing is not rough or worn. If NECESSARY, REPLACE REAR BEARING (@) Using SST, remove the bearing cover and bearing ‘SST 09820-00021 (b) Using SST and 0 press, press in 3 new besring and the bearing cover. ‘SST 09285-76010CHARGING SYSTEM — Alternator CHAS ASSEMBLY OF ALTERNATOR (See page CH-7) 1. INSTALL ROTOR TO DRIVE END FRAME 2. INSTALL RECTIFIER END FRAME {a} Using a plastic-feced hammer. lightly tap in the end frame. (b) Install the four nuts 3. INSTALL PULLEY {a} install the pulley (0 the rotor shaft by tightening the Pulley nut by hand, (0) Hold SST A with a torque wrench, and tighten SST B. clockwise to the specified torque ‘SST 09820-63010 Torque: 400 kg-cm (29 ft-Ib,39 Nm) (fc) Check that SST A ts secured to the pulley sheft, |) As shown in the figure, mount SST C in a vise, and install the alternator to SST ¢. (fe) To torque the pulley nut tum SST A in the direction shown in the figure Torque: 1,125 kg-om (81 ft-lb, 110 Nem) (Remove the altornator from SST C. G@)_ Turn SST B end remove SSTs A and 8. 4. INSTALL RECTIFIER HOLDER (2) Install the four rubber insulators on the lead wires, (b) Install the rectifier holder with the four screws.CHARGING SYSTEM ~ Alternator 5. INSTALL BRUSH HOLDER AND IC REGULATOR (a) Place the brush holder cover to the brush holder () Install the IC regulator and brush holder to the rear ‘end frame horizontally as shown in the figure. NOTE: Make sure the brush holder's cover doesn't slip 10 one side during installation. (0) Tighten the five screws until there is a clearance of at least 1 mm (0.04 in) between the brush holder cover ‘connector, 6. INSTALL REAR END COVER (0) Install the end cover with the three nuts. (b} Install the terminal insulator with the nut 7. MAKE SURE ROTOR ROTATES SMOOTHLYCHARGING SYSTEM — Engine Mein Relay CHAS ENGINE MAIN RELAY INSPECTION OF ENGINE MAIN RELAY LOCATON: AE and AT In the engine compartment relay box. AW In the No.6 junction block of the front lug- ‘gage compartment. 1. INSPECT RELAY CONTINUITY |) Using an ohmmoter, check that ther batween terminals 1 and 3. (b) Check that there is continuity between terminals 2 and 4. fe} Check thet there is no continuity between terminals 4 and 5. It continuity is not as specified, replace the relay. is continuity 2, INSPECT RELAY OPERATION (a) Apply battery voltage across terminals 1 and 3. (b) Using an ohmmeter, check that there is continuity betwoen terminals 4 and 5 fc) Check that there's no continuity between terminals 2 and 4. If operation is not as sp ied, replace the relay.co-4 COOLING SYSTEM Page DESCRIPTION . : coz TROUBLESHOOTING ...... co-6 CHECK AND REPLACEMENT OF ENGINE COOLANT «os esesee Check of engine coolant . Replacement of Engine Coolant (AE and AT) - : co.6 Replacement of Engine Coolant (AW) co.7 WATER PUMP = €0-10 ‘THERMOSTAT - 60-18 RADIATOR . : co-18 ELECTRIC COOLING FAN . co-26 Radiator Cooling Fan (Ex. AW Europe) . 60.26 Radiator Cooling Fan (AW Europe) co.28 Engine Compartment Cooling Fan (AW) co-33co. COOLING SYSTEM — Description DESCRIPTION ‘This engine utilizes a pressurized water forced circulation cooling system which includes a thermostat eauip- ped with a mounted on the iniet side. AF Water Pump From Radiator Water inet Pipe Y ance Thermostat Water‘nlet Pipe / Water PumpCOOLING SYSTEM — Description co-3 The cooling system és composed of the water Jacket (inside the oylindr block end cylinder head), ‘adiator, water pump, thermostat, electric fan, hoses and other components, Coolant which is heated in the water jacket is pumped to the radiator, though whieh an electric fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where ‘cools the engine. The water jacket is 9 network of channels in the shell of the cylinder block and cylinder head ‘trough which coolant passes. It is designed 10 provide adequate cooling of the cylinders are com: bastion chambers which become the hottest dur- ing engine operation, RADIATOR Ex, MR, The radiator performs the function of cooling the coolant which has passed through the weter jacket and become hot, and is mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank, and a core which connects. the {wo tanks. The upper tank contains the inlet for Coolant from the water jacket and the filter inlet. iso has a hose attached through which excess coolant of steam can flow. The tower tank contains, the outlet for coolant and the drain cock The core contains many tubes through which coolant flows from the upper tank to the lower tank as well as cooling fins which radiate heat away from the coo- lant in the tubes. The air sucked through the radia {or by the electric fan, as well as the wind gener- ated by the vehicle's travel, passes through the radiator, cooling it’ Models with automatic transmissions include an automatic transmission uid cooler built into the lower tank of the radiator. A fon with an electrie motor is mounted behind radiator to assist the flow of air through the radia: tor The fan operates when the coolant tem- perature becomes high in order to prevent it from becoming too high. ‘The radiator performs the funetion of cooling the coolant which has passed through the wate Jacket and become hot, and is mounted in the front Of the vehicle. The radiator in the MR2 is different from that in other models, in that itis a cross flow ype in which the cootant flows horizontally. It includes side tanks and a core which connects them. The inlet for coolant from the weter jacket and the drain cock for draining out coolant are ‘ocated in the left side tank. The outlet for coolant and an air drain, whieh facilitates the supply of coolant to the engine, are located in the right side tank. The core contains many tubes through which ‘coolant flows from the left side tank to the right- Side tank as wall as cooling fins which radiate heat ‘away from the coolent in the tubes. Air sucked in by the electric fan, 08 well as the wind generated by the vehicle's travel, passes through the redi tor, cooling the coolant heated by the weter jacket 2s it passes through the tubes in the core, Models. with automatic transmission include an eutomatic transmission fluid cooler incorporeted into the cooling pipes. A fan with an electric motor is ‘mounted behind the radiator to assist the flow of air through the radiator. The fan operates when the coolant temperature becomes high in order to Prevent it from becoming too high. The radiator ‘cap is the seme as those used with ordinary vehi: cles, but due to the layout of the MRZ, itis located ‘on a coolant pipe in the engine space RADIATOR CAP. The radiator cap is a pressure type can which seals the radietor, resulting in pressurization of the. radiator 8s the coolant expands. The pressuriza~ tion prevents the coolant from boiling even when the coolant temperature exceeds 100°C (212°F) A relief valve (pressurization valve) and @ vacuum valve (negative pressure valve) are built into the radiator cap. The ralief valve opens and lets steam escape through the overtiow pipe when the Pressure generated inside the cooling system ‘exceeds the limit (coolant temperature: 110 — 120°C, 230 ~ 248°F, pressure: 0.3 - 1.0 kg/ om? , 43 ~ 14.2 psi , 23.4 ~ 98.1 KPa). The vacuum valve opens to alleviate the vacuurn which develops in the coolant system after the engine is stopped and the coolant temperature drops. The valve's opening allows the pressure in the cooling system to retun to the coolant in the reservoir tank. RESERVOIR TANK ‘The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric expansion when the coolant is heated, The coolant in the reservoir tank retums to the radiator when the coolant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be rep- lenished. WATER PUMP ‘The water pump is used for forced circulation of coolant through the cooling system. It is mounted (on the front of the cylinder block and driven by a V-ribbed belt0-4 COOLING SYSTEM — Description ‘THERMOSTAT ‘The thermostat has a wax type bypass valve and |'s mounted in the water inlet housing. The ther- mostat includes a type of automatic valve oper- ated by fluctuations in the coolant temperature. ‘This valve closes when the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the cir- culation of coolant. Wax inside the thermostat ‘expands whan heated and contracts when cooled, Heating tho wax thus generates pressure which ‘overpowers the force of the spring which keeps the valve closed, thus opening the valve. When the wax cools, its contraction causes the force of the spring to take effect once more, closing the valve, ‘The thermostat in this engine operates at a tem- perature of 82°C (180°F),COOLING SYSTEM — Troubleshooting £O-5 TROUBLESHOOTING Problem | Possible couse Remedy Page Engine overnests | Water pump drive belt oose or missing | Adjust or replace belt, cH Din, leaves or insects on radiator Clean raciator co-18 Hoses, water pump, thermostat housing. | Repair as necessary radiator, heater, core plugs or head gasket leakage Thermostat faulty Check thermostat co.18 Ignition timing retarded Sot timing Electric cooting system Faulty Inspect electic cooling system | 0.26 Rosiator hose plugged or rotted Replace hose ‘Water pump faulty Replace water pump 0.10 Radiator plugged or cap faulty Check radiator co-18 Cylinder head or block cracked or plugged | Repair as necessary NOTE: The thermostat is squipped with a by-poss valve. therefore, if the engine tends to overheat, removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency,cos COOLING SYSTEM — Check and Replacement of Engine Coolant FULL ‘Ab and AT Drain Cosi CHECK AND REPLACEMENT OF ENGINE COOLANT Check of Engine Coolant 1, CHECK ENGINE COOLANT LEVEL AT RESERVE TANK ‘The coolant level should be between the “LOW” and "FULL" lines. If low, check for leaks and add coolant up to the FULL fie 2. CHECK ENGINE COOLANT QUALITY ‘There should not be any excessive rust deposits or scales around the radiator (water outlet) cep or radiator (water ‘outlet filler hole, and the coolant should be free from ol If excessively dirty, replace the coolant Replacement of Engine Coolant (AE and AT) REPLACE ENGINE COOLANT (a) Remove the radiator cap. (&) Drain the coolant from the radiator and engine drain cocks, {c) Close the drain cocks Torque (Engine drain cock): 130 kg-om (9 ft-lb, 13 Nem} (9) Fill the system with coolant. Use a good brand of ethylane-glycol base coolant, mixed according to the manufacturer's directions. We recommend mote than 50% ethyleneglycol and alcohol But not more than 70%) be used for your system, Capacity (w/ Heater!: aA M/T Europe 5.2 liters (5.5 US ats, 4.6 Imp. ats) General 5.6 liters (5.9 US ats, 4.9 Imo. ats) aT 5.5 liters (6.8 US ats, 4.8 Imp. ats) 4n-cE 6.0 liters (6.3 US ats, 6.3 Imp. at (e) Install the radiator cap. (f) Start the engine and check for leaks. (G)_ Recheck the coolant level ond refill as necessary.COOLING SYSTEM — Check and Replacement of Engine Coolant co-7 Replacement of Engine Coolant (AW) COOLANT CIRCUIT Radiator Drain Cock Heater Air Drain Vaive Radiator Pipe Drain Cock Radistor Cap (Water Filer Cop] Water Init Air rain Valve DRAINAGE OF ENGINE COOLANT ae e en REMOVE SPARE TIRE AND FRONT LUGGAGE COMPARTMENT TRIM REMOVE SERVICE HOSE REMOVE NO.1 FUEL TANK PROTECTOR ‘SET HEATER CONTROL LEVER TO MAX HOT REMOVE WATER FILLER CAP DRAIN ENGINE COOLANT (2) Connect the sorvice hoses to drain cook, (6) Drain the coolant trom the radiator end engine drain cocks,‘of Engine Coolant fe) Drain the coolant from the two radiator pipe drain cocks. REFILL OF ENGINE COOLANT 1. CLOSE DRAIN CocKS Tight the radiator pipe, radiator and engine drain cocks. (Pp Torqu At Radiator pipe 170 kg-em (12 ftlb, 17 Nem) (ss) Engine 130 kg-cm (9 ft-lb, 13 Nem) — ~Y NN Se 2. CONNECT SERVICE HOSES (a) Connect the service hoses to the radiator and heater air drain valves, (b) Suspend the opposite end of the hose connected to ‘the radiator to the hood stay. (©) Suspend the opposite end of the hose connected to the heater air drain valve to the windshield washer tube. NOTE: De not close-off or pinch any of the tubes. 3. REFILL ENGINE COOLANT NOTE: Use a good brand of ethylene-glycol base coo- lant, mixed according to the manufacturer's directions. (2) Open the water inlet, radiator and heater sir drain valves about three tums. (b) Pour the coolant to the water (€)_ When the coolant begines to come out of the water inlet air drain valve, stop pouring and close the a drain valve, (d) Again, pour coolant into the water filer hole untilitis full (e) Check that the coolant levels in the suspended hoses come up to the level of the water filler nozzle. If the coolant levels in either hose does not come up to filler nozzle lever, check the hose for folds or obstructions. Repeat stops (d} and le) above. Capacityiw/ Hester): 12.4 liters (13.1 US gts, 10.9 Imp. ats)COOLING SYSTEM — Check and Replacement of Engine Coolant £0-9 = 4 % (Close the radiator and heater air drain valves, (@)_ Disconnect th service hoses. NOTE: When removing the service hoses, place 2 rag beneath the valve to catch any dripping coolant. (h) Fasten the radiator cop (water filler cap) to the first stop point, NOTE: Do not tighten the radiator cap completely (to the ‘second stop point) Start the engine and run at fast idle for about 3 minutes, and then turn it off If the level in the water filer hole fell, add coolant as before. Then repeat steps (h) and ii) above. 4) Completely tighten the radiator cap. ue (1) Fill coolant into the reservoir tank up to th mark INSTALL NO.1 FUEL TANK PROTECTOR INSTALL SERVICE HOSE NOTE: Thoroughly flush out remaining coolant in hoses. START ENGINE AND CHECK FOR LEAKS INSTALL FRONT LUGGAGE COMPARTMENT TRIM AND SPARE TIRE0-10 COOLING SYSTEM — Water Pump WATER PUMP COMPONENTS Water Pump Svetion Cover #0-Ring Seat Pulley Seat Water Pump Pulley } Bearing # Rotor # Gasket Water Pump Body {¢ Non-rousoble part REMOVAL OF WATER PUMP 1. DRAIN COOLANT (See page CO-6 or 7) 2. (4A-GE) REMOVE PS AND/OR A/C DRIVE BELT 3. LOOSEN WATER PUMP PULLEY AND REMOVE ALTERNATOR DRIVE BELT (@) Loosen the four water pump pulley boltsCOOLING SYSTEM Water By-pas Hose fater Pump cont (0) Loosen the lock bott and pivot nut (©) Move the alternator fully right, and remove the drive bolt (nF) REMOVE PS DRIVE BELT REMOVE WATER PUMP PULLEY Remove the four bolts and pump pulley. REMOVE WATER INLET PIPE {a) Disconnect the water inlet and water by-pass hoses from the inlet pipe. (6) Remove the two nuts and clamp bolt. (c)_ Remove the water inlet pipe and O-ring.0-12 COOLING SYSTEM — Water Pump 2 REMOVE OIL DIPSTICK GUIDE AND DIPSTICK Remove the mounting bolt and pull put the dipstick guide ‘and gauge. NOTE: After pulling out the oil dipstick guide, be sure to plug the oil pump body hole. REMOVE NO.3 AND NO.2 TIMING BELT COVERS 4A.F (See pag EM-69) 4A-GE (See page EM-102) REMOVE WATER PUMP Remove the three bolts and water pump. CAUTION: Be careful not to get coolant on the timing belt. INSPECTION OF WATER PUMP INSPECT WATER PUMP Turn the pulley and check that the water pump bearing moves smoothly and quietlyCOOLING SYSTEM — Water Pump co.13 Sst DISASSEMBLY OF WATER PUMP (See page CO-10) 1. REMOVE WATER PUMP SUCTION COVER fa) Remove the three bolts fo) Using a screwdriver, pry off the water pump suction cover. 2. REMOVE PULLEY SEAT Using SST and a press, remove the pulley seat from the ‘water pump bearing shaft SST 09236-00101 (09237-00010, 08237-00040) 3. REMOVE WATER PUMP BEARING (2) Using a gringing wheel, grind the water pump rotor as shown, CAUTION: De not grind water pump bearing shat. (b} Heat the water pump body to approx. 85°C (185°F) {6} Using SST and 8 press, remove the water pump rotor and bearing ‘SST 09236-00101 (09237-00010, 09237-00040) (d)_ Remove the seal set from the water pump body. CAUTION: Do not damage the water pump body. 4. REMOVE SEAL Using SST and o press, remove the seal SST 09236-00101 (09236-15010)co-14 Seat distance COOLING SYSTEM — Weter Pump ASSEMBLY OF WATER PUMP (Soe page CO-10) NOTE: Always assemble the water pump with & new seal Set, a new rotor end @ new bearing. 1. INSTALL WATER PUMP BEARING (@) Gradually heat the water pump body to approx. 85°C (185°), (0) Using SST and a press, install a new water pump bbearing into the water pump body. SST 09236-00101 (09237-00020) NOTE: The bearing end face should be flush with the body top surface INSTALL SEAL (a) Apply @ seal packing No. 1282-8 to a new seo! and pump body. Seal packing: Part No. 08826-00100 or ‘equivalent (o) Using SST and @ press, install the seal on the water pump bearing SST 09236.00101 (09237-00020) 3. INSTALL PULLEY SEAT Using SST end a press, install the pulley seat on the water pump besring shaft SST 09236-00101 (09237-00020) NOTE: As shown in the figure, the distance from the pulley seat to the instalation surface of the pump body should be as follows: Seat di 76.7 mm (3.020 in}COOLING SYSTEM — Water Pump. £0-15 4. INSTALL ROTOR, (a) Install a new packing and seat into the rotor. (bo) Apply @ litle LLC to the seal and rotor contact sur- face, le) Using @ press, install a new rotor on the water pump boring shaft NOTE: As shown in the figure, the distance from the rotor edge to the installation surface of the pump body should be 6.0 mm (0.236 in) 5. CHECK WATER PUMP After assembly make sure that the rotor rotates smoothly 6. INSTALL WATER PUMP SUCTION COVER Install the water pump suction cover on a new gasket with three bolts Torque: 95 kg-om (82 in-Ib, 9.3 Nem) NOTE: After instaling, make sure that the rotor is not in contact with the water pump suction cover.0-16 COOLING SYSTEM — Water Pump INSTALLATION OF WATER PUMP 1. INSTALL WATER PUMP Place a new O-ring on the block and install the pump with three bolts, Torque: 150 kg-em (11 ft-lb, 15 Nem) 2. INSTALL NO.2 AND NO.3 TIMING BELT COVERS 4A-F_ (See page EM-94) AA-GE (See page EM-121) 3. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK {a) Install a new O-ring on the oil dipstick guide. (b) Apply smalt amount of engine oil to O-ring. {c) Push in the oil dipstick guide with the O- ring 4d) Install the mounting bolt. 4, INSTALL INLET PIPE (a) Install the inlet pipe and a new O-ring to the wete pump with the two nuts Torque: 200 kg-om (14 ft-lb, 20 Nem) (b) Install the inlet pipe clamp bolt.COOLING SYSTEM — Water Pump ce ‘Water By-pase Hose] 10. " 17, (c) Connect the water inlet and water by-pass hoses to the inlet pipe, ‘TEMPORARILY INSTALL WATER PUMP PULLEY. Install the water pump pulley and temporarily tighten the four bolts. ar) INSTALL PS DRIVE BELT INSTALL ALTERNATOR DRIVE BELT (a) Place the ative belt on the each pulley and set up the drive belt. () Tighten the four bolts of the water pump pulley. (4a-Ge) INSTALL PS AND/OR A/C DRIVE BELT ADJUST DRIVE BELT (See page CH-4) REFILL WITH COOLANT (See page CO-6 or 8) START ENGINE AND CHECK FOR LEAKSCOOLING SYSTEM — Thermostat rrr Gost tote in oy TY ie Ag OEY ew THERMOSTAT REMOVAL OF THERMOSTAT 1 DRAIN COOLANT (See page CO-6 or 7) REMOVE WATER INLET HOUSING COVER AND THERMOSTAT Remove the two nuts, the housing cover ond thermostat from the water inlet housing. INSPECTION OF THERMOSTAT NOTE: The thermostat is numbered according to the valve opening temperature, {a) Immerse the thermostat in water and heat the water ‘gradually (b) Check the vaive opening temperature. Valve opening temperature: 80 — 84°C (176 — 183°F) If the valve opening temperature is not within specifica ton, replace the thermostat. () Check the valve lift. Valve lift: 8 mm (0.31 in) or more at 95°C (203°F) If the valve lift is less than specification, replace the ther mostat. (@) Check that the valve spring is tight when the ther- mostat is fully closed. If necessary, replace the thermostat INSTALLATION OF THERMOSTAT PLACE THERMOSTAT IN WATER INLET HOUSING Install 8 new gasket to the thermostat and align the jiggle valve of the thermostat 2s shown in the water inlet hous- ing INSTALL WATER INLET HOUSING COVER Install the water inlet housing cover with the two nuts. REFILL RADIATOR WITH COOLANT (See page CO-6 or 8) START ENGINE AND CHECK FOR LEAKSCOOLING SYSTEM — Radiator c0-19 RADIATOR CLEANING OF RADIATOR Using water or steam cleaner, remove any mud and dint from the radiator core. CAUTION: If using # high pressure type cleaner, bo careful not to deform the fins of the radistor core. If the cleaner nozzle pressure is 30 ~ 35 kg/cm? (427 — 498 psi, 2, 942 — 3,432 kPal, keep a distance of at east 40 — 50 cm (15.75 — 19.69 In) between the radiator core and cleaner nozzle. Radiator Cap Tester| INSPECTION OF RADIATOR 1. CHECK RADIATOR (WATER OUTLET) CAP Using » radiator cap tester, pump the tester until the relief , valve opens. Check that the valve opens between 0.75 kg/ ©) | Gat8''pu'ba nr and 198 nglometa 8 pat. 168 | kay racaror cap \, A Check that the pressure does not drop rapidly when ese pressure on the cap is below 0.6 kg/em? (8.5 psi, 59 kPal. either check is not within limits, replace the cap. 2. CHECK COOLING SYSTEM FOR LEAKS {a) Fil the radiator with coolant and attach a radiator cap, tester. [b) Warm up the engine. le) Pump it to 1.2 kg/em? (17 psi, 118 kPa), check that pressure does not drop. W the pressure drops, check for leaks from the hoses, radiator or water pump. If no external leaks are found, check the heater core, block and head. Radiator Cap. TestercO-20 COOLING SYSTEM — Rediator COMPONENTS —# Tonk Plate $0-Ring Core Subsssembly DISASSEMBLY OF RADIATOR (AE and AT) 1. REMOVE TANK PLATE (a) Raise the claws of the tonk plates with SST in the umerical order shown in the figure. ‘SST 09230-00010 NOTE: Be careful not to damage the core plateCOOLING SYSTEM tor 2, 3. (b} Pull the tank plates outward. REMOVE TANK AND O-RING (a) Pull the tank upward. (b) Remove the O-ting. tam REMOVE OIL COOLER FROM LOWER TANK (@) Remove the two nuts, spring washers, plete washers and oil cooler (b) Remove the O-ring from the oil cooler.0-22 COOLING SYSTEM — Redietor O-Ring 01 Cooler Core Plate Ho-Ring WRONG: a oe ASSEMBLY OF RADIATOR (AE and AT) (See page CO-20) 1 4 am INSTALL OIL COOLER TO LOWER TANK {@) Clean the O-ring contact surface of the lower tank and oil cook (©) Install new O-ring to the oil cooler. {c) Install the oil cooler with the O-rings to the lower tank (a) Install the plate washers, spring washers and nuts INSPECT CORE PLATE Inspect the core plate for damage, Note: If the sides of the core pl reassembly of the tonk will © Therefore, first correct any deformation with pliers of like object. Water leakage will result ifthe bottom of the core plate groove is damaged or dented Therefore, repair or replace if necessary. INSTALL NEW O-RING AND TANK NOTE: © Clean the tank and core plate. groove are deformee, 2 impossible © Take out any twists INSTALL TANK PLATE Install the tank plates from both ends in the direction of the arrows. Insert to where the portions shown by the arrows contact with the tankCOOLING SYSTEM — Rodi Tank Plate Guide Block Stopper ST. 60-23 STAKE CLAW OF TANK PLATE la) Set the punch of SST to “LOW”. SST 09230-00010 (b) Stoke the claws of the tank plates with SST in the ‘numerical order shown in the figure, ‘SST 09230-00010 CAUTION: If the bottom of the core plate is staked ith the SST on the guide block stopper, it may result in water leakage, SST 08230-00010 Nore: '® Stake with just enough pressure to leave a mark on the Claw, The staked plate height (H) should be as follows Plate height: 9.08 — 9.43 mm (0.3675 — 0.3713 in) © Do not stake the areas protruding around the pipes. brackets or tank ribs.co-24 COOLING SYSTEM — Radiator © The points shown in the illustration connot be staked with the SST. Use a pliers or like object ond be careful not to damage the core plates. 6. INSPECT FOR WATER LEAKS {a} Tighten the drain plug. (b) Plug the inlet and outlet pipes of the radiator with sst. ‘SST 08230-00010 (c) Using a radiator cop tester, apply pressure to the radiator. ‘Test pressure: 1.5 kg/em? (21 psi, 147 kPa) (d)_ Inspect for water leaks. NOTE: On radiator with resin tanks, there is a clearance between the core plate and tank plate where 2 minute _amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before performing the water leak test, first switch the Clearance ‘ediator around in the water until all air bubbles disappesr PAINT TANK PLATE NOTE: If the water leak test checks out okay, allow the radiator to completely dry and then paint the tank plates,COOLING SYSTEM — Radiator aw co-25 INSTALLATION OF RADIATOR INSTALL RADIATOR Place the radiator in installed position and install the two supports with the two bolts. NOTE: After installation, confirm that the rubber cushion, (A) of the support is not depressed.50-26 COOLING SYSTEM — Electric Cooling Fen ELECTRIC COOLING FAN Radiator Cooling Fan (Ex. AW Europe! SYSTEM CIRCUIT Ignition ite {aan Fanible Link FAN 308 (ae RADIATOR FAN 30 an RAD FAN 204, (aw) sete ; Re ay aN a on a) & Ye Engine Main Relay en ae COMPONENTS TT SST ¢ a c S4 ‘ Fan Motor Fan Shroud Fen Motor Fan ShroudCOOLING SYSTEM — Electric Cooling Fan co-27 9 |) AE IOAF ON-VEHICLE INSPECTION Low Coolant Temperature {below 83°C (181°F)) 1 TURN IGNITION SWITCH ON Check that the fan does not rotate. If it rotates, check the fan relay and temperature switch, ‘and check for a separated connector or severed wire bet- ween the relay and temperature switch, DISCONNECT TEMPERATURE SWITCH CONNECTOR Check that the fan rototes. IW it does not, check the fan relay, fan motor, ignition relay ‘and fuse, and check for 8 short circuit between the fan relay and temperature switch. AE (48-GE} and AT aw 3. 4, CONNECT TEMPERATURE SWITCH CONNECTOR High Coolant Temperature (above 90°C (194°F}) START ENGINE @) Raise engine coolant to above 80°C (194°F). (o) Check that the fan rotates. It it does not, replace the temperatu switchco-28 COOLING SYSTEM — Electric Cooling Fan ‘Ohmmetor No continuity Ameneter INSPECTION OF ELECTRIC COOLING FAN 1, INSPECT TEMPERATURE SWITCH LOCATION: AE and AT On the water inlet housing. AW On the radiator let side. (a) Using an ohmmeter, check that there is no continuity when the coolant temperature is above 93°C (19978), (b) Check that there is continuity when the coolant tem: erature is below 83°C (181°F) If continuity is not as specified, replace the switch. 2. INSPECT ENGINE MAIN RELAY (AE and ATI OR FAN MAIN RELAY (AW) (See procedure Engine Main Relay on page CH-18) 3, INSPECT COOLING FAN RELAY LOCATION: AE and AT In the engine compartment relay box. AW In the No.5 junction block of the front lug- ‘gage compartment. ‘A. Inspect relay continuity (2) Using an ohmmoter, check that there is continity between terminals 1’ and 2. (b) Check that there is continuity between terminals 3 and 4. Hf continuity is not as specified, replace the relay. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2 (B) Check that there is no continuity between terminals 3 ‘and 4. If operation is not as specified, replace the relay. 4. INSPECT FAN MOTOR {a) Connect the bettery and ammeter to the fan motor connector. 0} Check to s00 that the motor rotates smoothly, and current is 2s follows: Standard amperage: AE and AT 3.2-4.4A aw 68-748COOLING SYSTEM — Electric Cooling Fan co.28 Radiator Cooling Fan (AW Europe) SYSTEM CIRCUIT Fusibte nk HEAD 80a, Fusible Uns 1258 ~ ro ignwon | Fan Wain ‘Switen |_Reloy $ Fuse AMD 7.54, Fuse = DS FAN cooling Fan 30a, ‘Computer {rer} — No.2 Cooling Fan COMPONENTS (See page CO-26)COOLING SYSTEM — Electric Cooling Fan ON-VEHICLE INSPECTION Low Coolant Temperature (below 85°C (185°F)) 3 ‘TURN IGNITION SWITCH ON Check that the fan does not rotate. If it rotate, check the fan rolay and temperature switch, ‘and check for a separated connector or sovared wire bet ‘ween the relay and temperatura switch. DISCONNECT TEMPERATURE SWITCH CONNECTOR ‘Check that the fan rotates It it does not, check the fan relay, fan motor, ignition relay ‘and fuse, and check for a short circuit between the fan relay and temperature switch CONNECT TEMPERATURE SWITCH CONNECTOR High Coolant Temperature {above 90°C (194°F)) START ENGINE (a) Reise engine coolant to above 90°C (194°. (b) Check that the fan rotates. I it does not, replace the temperature switch. INSPECTION OF COOLING FAN COMPUTER CIRCUIT INSPECT COOLING FAN COMPUTER CIRCUIT TI2 3 LOCATION! HD In the right side of the front compartment 4{5 2 LHD In the left side of the front compartment. Disconnect the cooling fan computer, and check the con- rector on the wiring hatness side as shown in the chert x below. ‘hock fr ‘Tener connection ondtion Specifies veiw | vores 1 = Geouns arian $20 On ‘ay wotage Contoity 2 = Grows = Coney ‘ota iprten SW ON [ vote ‘ony - | Contnaty Aopen 135 48 fovmtaee 5-7 90% 1947) ‘Aspro 1.19 WAL 25 20s) Apron 108 KahCOOLING SYSTEM — Electric Cooling Fan £0.31 INSPECTION OF ELECTRIC COOLING FAN COMPONENTS 1. INSPECT WATER TEMPERATURE SENSOR LOCATION: On the radiator left side. Using an ofmmeter, measure the resistance between the terminals, Resistanci ‘Approx. 1.35 k‘) at 85°C (185°F) Approx. 1.19 kM at 90°C (194°F) ‘Approx. 1.06 ki) at 96°C (203°F) If resistance is not as specified, replace the sensor. 2, INSPECT NO.1 COOLING FAN RELAY {See procedure Cooling Fan Relay on page CO-28) LOCATION: In the No.S junction block of the front lug ‘gage compartment. 3. INSPECT NO.2 COOLING FAN RELAY LOCATION: In the No.6 junction block of the front lug- ‘gage compartment. ‘A. Inspect relay continuity la) Using an ohmmeter, check that there is continuity between terminals 2 and 6. (bo) Check that there is continuity between terminals 1 and 3. (e) Check that there is no continuity between terminals 1 ‘and 4. If continuity is not as specified, replace the relay. Continuity “)_ B. Inspect relay operation (2) Apply battery voltage across terminal 2 and 6, (b) Using an ohmmeter, check that there is no continuity between terminals 1 and 3. fc) Check that there is continuity between terminals 1 ‘and 4. '¥ operation is not as specitied, replace the re NY. Battery60-32 COOLING SYSTEM — Electric Cooling Fan INSPECT NO.3 COOLING FAN RELAY LOCATION: In the No.S junction block of the front l- Os 2 Pl | [No continuity ~~ Canty ‘A. Inspact relay continuity La (@) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (6) Check that there is no continuity between terminals 2 and 4, continuity is not as specified, replace the relay, [continuity ~~~ | & Inspect relay operation aa (a) Apply battery voltage across terminal t and 3. (b) Using an ohmmeter, check that there is continuity between terminals 2 and 4. If operation is not as specified, replace the relay. 6. INSPECT FAN MAIN RELAY (See procedure Engine Main Relay on page CH-15) LOCATION: In the No.5 junction block of the front lg- ‘gage compartment 6. INSPECT COOLING FAN MOTORS fa) Connect battery and ammeter to the fan motor cor rector. (&) Check that the fan motor rotates smoothly. and check the reading on the ammater. Standard amperage: 8.8 - 10.8 ACOOLING SYSTEM — Electric Cooling Fan c0.33 Engine Compartment Cooling Fan (AW) SYSTEM CIRCUIT Cooling Fan Cooling Fan Worning Light Computer onl0-34 COOLING SYSTEM — Electric Cooling Fan ON-VEHICLE INSPECTION Low Temperature (Below 64°C (147°F)} 1. TURN IGNITION SWITCH “ON” Check that the fon stops, If it does not, check the cooling fan relay and compar: ment temperatura sensor, and check for a separated cor actor ar severed wire between the cooling fan relay ard compartment temperature sensor. 2. DISCONNECT COMPARTMENT TEMPERATURE SENSOR CONNECTOR Check that fan rotates. It not, check the cooling fan relay, fan moter, engine msin relay and fuse, and check for a short circuit between the cooling fan ralay and compartment temperature sensor 3. CONNECT COMPARTMENT TEMPERATURE SENSOR CONNECTOR High Temperatu START ENGINE (a) Raise the compartment temperature to above 80°C (176°) fo) Check that the fan rotates. IF not, replace the compartment temperature sensor. (Above 80°C (176°F)) INSPECTION OF COOLING FAN COMPUTER CIRCUIT INSPECT COOLING FAN COMPUTER CIRCUIT LOCATION: In the right side of the rear engine compart L 3]4 ment s [e! Disconnect the cooling fan computer, and check the com actor on the wiring harness side as shown in the chan below. rT ever conection Condon eecinea wae vena” 2= ened “re sr On I votoue = Gowns - tary vase ve . seo uaeh oon 6270 a wre ore 760 nop. 2958 1 Vonage T= Goud = Ne vl Vota = Gowns ‘goon S78 OW eat voteCOOLING SYSTEM — Electric Cooling Fan c0-35 INSPECTION OF ELECTRIC COOLING FAN COMPONENTS 1. INSPECT COMPARTMENT TEMPERATURE SENSOR LOCATION: On the cylinder head rear plate Using on ohmmeter, measure the resistence between the terminals Resistance: ‘Approx. 627.0 0 at 64°C (129°F) Approx. 298.5 {2 at 80°C (176°F) If resistance is not as specified, replace the sensor. 2. INSPECT COOLING FAN RELAY (See procedure Cooling Fan Relay on page CO-28) LOCATION: In the No.5 junction block of the front lug- ‘gage compartment 3. INSPECT ENGINE MAIN RELAY (See procedure Engine Main Relay on page CH-15) LOCATION: In the No.2 junction block of the engine compartment, 4, INSPECT COOLING FAN MOTOR, {a) Connect battery and ammeter to the fan motor con- nectar, lb) Check that the fan motor rotates smoothly, and check the reading on the ammeter. Standard amperage: 3.1— 4.3 AFi-1 EFI SYSTEM SYSTEM DESCRIPTION PRECAUTIONS .. INSPECTION PRECAUTIONS TROUBLESHOOTING ...... DIAGNOSIS SYSTEM . TROUBLESHOOTING WITH VOLT/OHMMETER FUEL SYSTEM Fuel Pump Cold Start Injector Fuel Pressure Regulator . Injectors ...... . AIR INDUCTION SYSTEM .....-..-..0.05 Air Flow Meter (w/ Air Flow Meter) Throttle Body settee Auxiliary Ale Valve es..seeceee ELECTRONIC CONTROL SYSTEM ... Location of Electronic Control Parts. EFI Main Relay .... Circuit Opening Relay : Solenoid Resistor and injector Rotay Cold Start Injector Time Switch .. Water Temperature Sensor Vacuum Sensor (w/o Air Flow Meter) (Manifold Absolute Pressure Sensor) Variable Resistor (w/o Air Flow Meter) Intake Air Temperature Sensor (w/o Air Flow Meter) . ‘Oxygen Sensor (w/ TWC! Electronic Controlled Unit (ECU) Fuel Cut RPM. High-temperature Line Pressure Up System (Europe! fauas FI-109 Idle-up System sees F100FL2, EFI SYSTEM — System Description SYSTEM DESCRIPTION | ‘wie Air Flow Meter lgeition Switch AIC Compressor Fuel Tank \eFrBGLOF Check Engine Shock Worring Light Conner Battery ecu ust sv Testope) Vacuum Sensor mas Intake Cleaner air Temp, Switch Pressure I ate-up Regulton ise N\ Injector — Cold Start ws ss Auxitory ‘air Valve Theotte Position (tusvsv Cold Stor Injector “Tene Switch Water Temp, Switch Sensor To Vacuum Reservor Tank[wir Flow Meter fu rater FT Fuel Pressure Regulator EFI SYSTEM — System Description FL3. SYSTEM DESCRIPTION (Cont'd) coores, OW] Shu ‘1 Battery Intake ir Temp. Ignition me Got ss / ae Cleaner Flow Meter ____Auxtiary Throttle Ar Valve Position Sensor To Vacuum Rosarvoir Tank “Cold Stan Inctor \ Time Switch Water Temp, SensorFL EFI SYSTEM — System Description ‘The EFI system is composed of three basic sub- system: Fuel Induction, Air Induction and Electronic Control System. FUEL SYSTEM Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pumo. The injectors inject a metered quantity of fuel into the in manfold m accordonce with signale from the ECU (Electronic Control Unit AIR INDUCTION SYSTEM ‘The air induction system provides sufficient sir for engine operation ELECTRONIC CONTROL SYSTEM The 4A-GE engine is equipped with @ Toyote Computer Control System (TCCS) which centrally controls the EFI, ESA, Diagnosis systems, etc. by ‘means of an Electronic Control Unit (ECU-formerly EFI computer) employing a microcomput By means of the ECU, the TCCS controls the following functions: 1. Electronic Fue! Injection (EFI) The ECU receives signals from verious sen- sors. indicating changing engine opersting conditions such as: Intake manifold absolute pressure (w/o Air flow moter Intake air volume (w/ Air flow meter) Intake air temperature Coolant temperature Engine rpm Acceleration/deceleration Exhaust oxygen content (w/ TWC) ete. These signals are utilized by the ECU to determine the injection duration necessary for ‘an optimum air-fuel ratio. 2. Electronic Spark Advance (ESA) ‘The ECU is programmed with data for ‘optimum ignition timing under any and all ‘operating conditions. Using data provided by sensors which monitor various engine func- tions (rpm, coolant temperature, etc.) the microcomputer (ECU) triggers the spark at precisely the right instant. (See IG section) 3 Diagnosis, The ECU detects any malfunctions or abnor akties in the sensor network and lights » ‘check engine warning panel, At the same time, the trouble is iden- tified and a diagnostic code is recorded by the ECU. The diagnostic code can be read by the number of blinks of the check engine warning light when terminals T and EY are short-circuited. The diagnostic codes we refer to the later page (See page FI-25 or 26) Fail-Safe Function In the event of the sensor malfanctioning, 2 back-up circuit will take over to provide minimal driveability, and the check engine warning light will light‘Cheek Connector EFI SYSTEM Procautior Inspection Precaution FILS. PRECAUTIONS 1. Before working on the fuel system, disconnect the ‘cable from negative (=) terminal af the battery. NOTE: Any diagnostic code retsined by the computer, will be erased when the battery terminal is removed, ‘Thorefore, if necessary, read the diagnosis betore remov- ing the battery terminal 2. Do not smoke or work on open flame when working on ‘the fuel system, Keep gasoline off rubber or leather parts. INSPECTION PRECAUTIONS MAINTENANCE PRECAUTIONS 1. CHECK CORRECT ENGINE TUNE-UP (See page EM-34) 2. PRECAUTIONS WHEN CONNECTING GAUGE (a) Use the battery as the power source for the timing light, tachometer, ete. (©) Connect the test probe of a tachom IGS of the check connector. LOCATION: See page FI-89 {0 terminal (Reference (AT and AW)) Connect the test probe of a tachometer to the nega- tive (=) terminal of the ignition coil 3. IN EVENT OF ENGINE MISFIRE FOLLOWING PRECAUTIONS SHOULD BE TAKEN (a) Check proper connection of battery terminals, ete, (b] Handle high-tension cords carefully. (e) After repair work, check that the ignition coil ter- rminals ond all other ignition system lines are recon- nected securely (d) When cleoning the engi ly careful to protect the: compartment, be especial- ctrical system from water. 4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR (a) Do not allow oxygen sensor to drop or hit a object (B} Do not allow the sensor to come into contact with water.EFI SYSTEM wspection Precaution IF VEHICLE 1S EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, GB, ETC.) ‘The ECU has been designed so that it will not be affected by outside interference. However, if your vehicle is equipped with CB radio transceiver, etc. (even one with about 10 W output, it may, at times, affect upon ECU operation, especially if the’ antenna’ and feeder are installed nearby. Therefor, observe the following precautions: 1. Install the antenna as far as possible from the ECU. The ECU is located under the radio (AE and AT), center the rex luggage compartment (AW), so the antenna should be installed at the rear side of the vehicle 2. Keep the antonna feeder 28 far away as possible from the ECU wires ~ at least 20 cm (7.87 in} ~ and, especially do ‘not wind them together. 3. Check that the jeder and antenna are properly adjusted 4. Do not equip your vehicle with a powerful mobile rade system. AIR INDUCTION SYSTEM 1. Separation of the engine oil dipstick, oil filer cap, PCV hose, ete. may cause the engine to run out of tune, 2. Disconnection, looseness or cracks in the parts of the it induction system between the throttle body and oylindr head will allow air suction and cause the engine to run out of tune. ELECTRONIC CONTROL SYSTEM | 1. Before tomoving EF wing connectors. tarminals at. | fst dscannoet to power by other turing the ign Sonic OFF oF ksconnosting the batty terminate | 2 When installing the bottery, be especially careful not t| incorrectly connect the positive (4) and negative (| cables, 3. Do not permit parts to receive @ severe impact during | removal or installation. Handle ali EFI parts carefuly, especially the ECU 4 Do not be careless during troubleshooting as there are humerous transistor circuits and even slight terminal con- tact can cause further troubles. 5. Donot open the ECU cover. 6. When inspecting during rainy weather. take care to pre vent entry of water. Also, when washing the engine com- partment, prevent water from getting on the EFI parts ane wiring connectors. 7. Parts should be replaced as an assembly.EFI SYSTEM — In Fi Care is required when pulling out and inserting wiring con- nectors. (@)_ Release the lock snd pull out the connector, pulling ‘on th connectors (b} Fully insert the connector and check that itis locked. When inspecting a connector with a volt/ohmmeter. (@) Carefully take out the water-proofing rubber if itis a water-procf type connector. (©) Insort the test probe into the connector from witing side when checking the continuity, amperage or voltage (€) Do not apply unnecessary force to the terminal (d) After checking, install the water-proofing rubber on ‘the connector securely. Use SST for inspection or test of the injector, cold start Injector or its wiring connector. SST wio Air flow met 09842-30050 (A) wi Air flow meter 09842-30050 (A) and 09842-30070 (C) ind 09842-30060 (8!Fe. EFI SYSTEM — Inspection Precautions FUEL SYSTEM 1. When disconnecting the high fuel pressure line, # large Pag amount of gasoline will spill out, 50 observe the following j procedure. (2) Puta a container under the connection. (©) Slowiy loosen the connection {0} Disconnest the connection. {4} Plug the connection with ¢ rubber plug. 2. When connecting the flare qut oF union bolt on the high pressure pipe union, observe the following procedure: (Union Bolt Type) (o} Always use 2 new gasket. (©) Tighten the union bolt by hand {c} Tighten the union bolt to the specified torque. Torque: 300 kg-em (22 ft-1b, 29 Nem) (Flare Nut Type) lal Apply @ light cost of engine oil the flare end tighten ‘he flare nut by hand of RR. (b) Using $8, tighten the flare nut to specified torque Lay Sy 4 SST 09631-22020 SB Torque: 310 kg-em (22 ft-lb, 30 Nem) ab NOTE: Use a torque wranch with a fulcrum length of 30 om (11.81 in) a 3. Observe the following precautions when removing snd z 7 sencor ree conn instaling the injectors Ni => (le) la) Never reuse the O-ring. (©) When placing @ new O-ring on the injector, take care Grommet not to damage itn any way. e fc} Coat a new O-ring with spindle oil or gasoline before ho installing ~ never use engine, gear or brake cil Delivery Pipe Dane. 4. Install the injector to delivery pipe and cylinder head es Pee shown in the figure. O-Ring Grommet rector —— InsvatorEFI SYSTEM ~ Inspection Precautions FL9 Check Connector 6. Check that there are no fuel leeks after performing any maintenance on the fuel system, (2) With engine stopped, turn the ignition switch ON. (0) Using a service wire, short terminals +B and FP of the check connector. LOCATION: See page FI-89 (c)_ When the fusl return hose is pinched, the pressure within high pressure line will rise to approx. 4 kg/cm? (57 psi, 392 kPa). In this state, check to see that there are no leaks from any part of the fuel system, CAUTION: Always pinch the hose. Avoid bending as it may cause the hose to crack.#10 EFI SYSTEM — Troubleshooting TROUBLESHOOTING TROUBLESHOOTING HINTS 1 G Engine trouble are usually not caused by the EFI system, ‘When troubleshooting, always first check the condition of the other systems. (a) Electronic source © Battery ‘© Fusible links © Fuses {b) Body ground le) Fuel supply © Fuel leakage © Fue! filter © Fuel pump (d}_ Ignition system Spark plugs © High-tension cords © Distributor © Ignition coit Igniter le) Air induction system © Vecuum leaks (Emission control system © PCV system © EGR system (w/ Air flow meter! (@) Others © Ignition timing Idle speed otc ‘The most frequent cause of problems is simply a bad con- ‘tact in wiring connectors. Always check that connections ore secure, When inspecting the connector, pay particular attention 19, the following points (2) Check to see that the terminals are not bent (©) Check to see that the connector is pushed in com: pletely and locked (©) Check to see that there is no signal change when the connector is slightly tapped or wiggled. Sufficiently troubleshooting for other causes before rep- lacing the ECU, 98 the ECU is of high quality and expenEFI SYSTEM — Troubleshooting FLAY | 4 Use a vottiohmmeter with high impedance (10 kQ/V Digits! Type. Analog Type minimum) for troubleshooting of the electrical circuit (See page FI-29) TROUBLESHOOTING PROCEDURES SYMPTOM — DIFFICULT TO START OR NO START (ENGINE WILL NOT CRANK OR CRANKS SLOWLY) CHECK ELECTRIC SOURCE |__Tveattery { BAD | 11) Connection (2) Gravity-Drive belt—charging system (3) Voltage 2. Fusible link OK CHECK STARTING SYSTEM ———-T ignition switch BAD | 2. Starter | 3. Wiring/Connection SYMPTOM — DIFFICULT TO START OR NO START (CRANKS OK) CHECK DIAGNOSIS SYSTEM Diagnosis code(s) (See page FI-28 or 26) Check for output of diagnosis code, junction (See page FI-22) codets} Normal code CHECK FOR VACUUM LEAKS IN AIR 1 Oil filer cap INTAKE LINE BAD | 2 Oil dipstick 3 Hose connections 4. PCV hosels) 5.EGR system — EGR valve stays open To CHECK IGNITION SPARK 1 High-tension cords (See page IG-19) BAD | 2 Distributor 3. Ignition coil igniter [* ‘CHECK IGNITION TIMING | ___Jignition timing ~ Adjust 1, Short terminals T and 1 of the check NO”) (See page EM-37) connector. 2. Check ignition timing, Standard: 10° BTDC @ idle Tox CONTINUED ON PAGEFFI2Fitz EF! SYSTEM — Troubleshooting T 0% cONTIWED FROM PAGE F-11 ‘CHECK FUEL SUPPLY TO INJECTOR 4 Fuel in tank 2 Fuel prossure in fuol line {1) Short terminals +8 and FP of the Fuel line — Leakage ~ deformation Fuse Circuit opening relay (See page FI-91) Fuel pump (See page FI-65), CHECK FUEL PUMP SWITCH IN AIR. FLOW METER Check continuity between terminals FC ‘ond E1 while measuring plate of air flow meter is open check connector. Fuel filter (2) Fuel pressure at fuel hose of fuel Fuel pressure regulator filter con be felt. (See page FI-67) (See page FI-76) L® (w/ AIR FLOW METER) ‘Air flow meter (See page F1-82) OK ‘CHECK SPARK PLUGS Standard: 1.1 mm (0.043 in) NOTE: Check compression pressure and valve clearance if necessary 1. Spark plugs 2. Compression pressure Minimum: 10.0 kg/er (142 psi, 981 kPa) at 250 rpm 3. Valve clearance (Cold) Standard: IN 0.15 ~ 0.25 mm (0.006 ~ 0.010 in} EX 0.20 ~ 0.30 mm {0.008 ~ 0.0012 in 1. Injectors ~ shorted or leaking 2. Injector wiring ~ short circuited 3. Cold start injector ~ leakage (See page FI-72) 4, Cold start injector time switch (See page F-95) OK 1 ‘CHECK AUXILIARY AIR VALVE | ___J Aunaliary air valve (See page Fi-87) 2. Water hoses 3. Air hoses Lo CHECK EF! ELECTRONIC CIRCUIT 7. Wiring connections USING VOLT/OHMMETER, 2. Power to (ECU) (See page Fi-29) (1) Fusible links, (2) Fuses (3) EFI main relay Air flaw meter (w/ Air flow meter) \Vecuum sensor (w/o Air flow moter) Water temp. sensor Air temp. sensor Injection signal ciecuit (1) Injector wiring {2) Solenoid resistor (w/o Air flow meter @) ECUEFI SYSTEM yubleshooting SYMPTOM — ENGINE OFTEN STALLS (CHECK DIAGNOSIS SYSTEM Diagnostic code(s) (See page FI-25 or 26) Check for output of diagnostic code, Malfunction (See page FI-22) codels) Normal code CHECK FOR VACUUM LEAKS IN AIR __] 1 OF filer ap INTAKE LINE ‘BAD "| 2. Oil dipstick 3. Hose connections 4, PCV hosals) 5. EGR system — EGR valve stays open 1 CHECK FUEL SUPPLY TO INJECTOR |__| 1. Fuel line — leakage ~ deformation 4. Fuel in tank Bap | 2-Fuses 2.Fuel pressure in fuel line 1} Short terminals +8 and FP of the check connector. (2} Fuel pressure at fuel hose of fuel 3. Circuit opening relay (See page FI-91) 4. Fuel pump (See page FI-65) 6. Fuel filter © Fuel pressure regulator titer [See page FI-67), (See page F-75) Tor CHECK AIR FILTER ELEMENT ——+[Eiement — Clean or replace BAD Tex CHECK IDLE SPEED (AND IDLE CO lle speed — Agjust CONCENTRATION} NO] See page EM.39 or 42) Standard: 800 rpm OK CHECK IGNITION TIMING | Ignition timing ~ Adjust 1, Short terminals T and E1 of the check NO | Gee page EM-37 ‘connector. 2. Check ignition ti Standard: ing 10° BTDC @ idle Tor (CHECK SPARK PLUGS Standard: 1.1 mm (0.043 ind NOTE: Check compression prossure and valve clearance if necessary. Spark plug Compression pressure Minimum: 10.0 kg/em= (142 psi, 981 kPa) at 260 rpm 3. Valve elearance (Cold) Standard: IN 0.16 ~ 0.25 mm (0.006 ~ 0.010 in) EX 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) Te ‘CHECK COLD START INJECTOR (See page FI-72) BAD 1. Cold siart injector 2.Cold start injector time switch. (Sve page FI-95) }>* CONTINUED ON PAGE Fi-14F44 [ ox _coWTRED Ro PAGE F-¥8 EFI SYSTEM — Troubleshooting ‘CHECK AUXILIARY AIR VALVE 1. Auxiliary air valve (See page FI-87), BAD] 2: Water hose 3. Air hoses ‘OK ‘CHECK FUEL PRESSURE + 1 Fuet pump (See page F-65) (See page FI-67), BAD | 2 Fuel fiter 3. Fuel pressure rogulator (See page FI-75) L* CHECK INJECTORS. Tnlection condition (See page FI-77) BAD OK ‘CHECK EFI ELECTRONIC CIRCUIT 7, Wiring connections USING VOLT/OHMMETER BAD | 2 Power to ECU (See page FI-28) (1) Fusible links 2) Fuses {G) EF main rolay 3, Air flow meter (w/ Air flow meter) 4. Vacuum sensor (w/o Ait flow meter) 5. Water temp. sensor 6 Air tomp. sensor 7 Injection signal circuit 41) Injector wiring 12) Solenoid resistor (w/o Air flow meter 8) ECU SYMPTOM — ENGINE SOMETIMES STALLS CHECK DIAGNOSTIC SYSTEM Check for output of diagnostic code ‘See page FI-22) Malfunction codels) iagnostic(s] (See page FI-25 or 26) Normal code (w/ AIR FLOW METER) Check that there is a signal change when the connector or relay is slightly tapped or wiggled. CHECK AIR FLOW METER BAD (See page FI-82) OK ‘CHECK WIRING CONNECTORS AND 1. Connectors RELAYS: BAD “| 2 EFI msin reley (See page FI-801 3. Circuit opening relay (See page F-91)EFI SYSTEM ~ Troubleshooting FI-A5 SYMPTOM — ROUGH IDLING AND/OR MISSING ‘CHECK DIAGNOSIS SYSTEM Diagnostic codels) Check for output of diagnostic code Malfunction | (Sea page Fi-28 or Fi-26) (See page FI-22) code(s) [Normal code CHECK FOR VACUUM LEAKS IN AIR JT oF titer cop INTAKE LINE BAD) 2 Oil dipstick 3. Hose connections 4. PCV hose's) 5.EGR system ~ EGR valve stays open To CHECK AIR FILTER ELEMENT | —___[Etement = Clean or replace BAD T OK [CHECK IDLE SPEED (AND IDLE CO [late speed — Adjust CONCENTRATION) NO Standard: 800 rpm < (CHECK IGNITION TIMING -fignition timing = Adjust (See page Ew-37) 1-Short terminals T and E1 of the check No connector 2. Check ignition timing Standard: 10" BTOC @ idle | Lo (CHECK T-VIS INTAKE AIR CONTROL —___.[1 VV tor air control valve VALVE NO "] 2. Vacuum leaks Check that the air contral valve is closed. Lo [CHECK SPARK PLUGS 1. Sperk plogs Standard: 1.4 mm (0.043 in) NO | 2. Compression pressure NOTE: Check compression pressure and Minimum: 10.0 kg/em? valve clearance if necessary (142 psi, 081 kPal at 260 rem ' 3. Valve clearance (Cold) | Standard: IN 0.16 - 0.25 mm (0.006 ~ 0.010 in) EX 0.20 ~ 0.30 mm (0.008 ~'0.012 in) | OK (CHECK COLD START INJECTOR |____I¥- Gord start injection (See page FI-72) BAD | 2 Cola start injector time switch (See page FI-95) [0K CONTINUED ON PAGE F-16FS EFI SYSTEM — Troubleshooting | 0K CONTINUED FROM PAGE F-15 (See pege FI-98) ‘CHECK FUEL PRESSURE | -[1-Fuet pump (See page FI-65) (Gee page FI-67) BAD "| 2 Fuel filter 3. Fuel pressure regulator (See page FI-75) L& ‘CHECK INJECTORS Injection condition (See page FI-77) BAD L& ‘CHECK EFI ELECTRONIC CIRCUIT |__Ji- Wiring connections USING VOLT/OHMMETER BAD | 2. Power to ECU (See page FI-29) (1) Fusibie links (2) Fuses (3) EFI main relay 3. Ale flow mater {w/ Air flow meter) 4, Vacuum sensor (w/o Air flow meter) 5. Water temp. sensor 6 Air temp. sensor 7- Injection signal circuit (2) Injector wiring (2) Solenoid resistor (w/o Air tlow meter (@) ecu 8. Oxygen sensor w/ TWO) OK 1 (w/o AIR FLOW METER) [Variable resistor CHECK VARIABLE RESISTOR BAD SYMPTOM — HIGH ENGINE IDLE SPEED (NO DROP} ‘CHECK ACCELERATOR LINKAGE - —-[Tinkege — Seok _ BAD r 1 ‘CHECK AUXILIARY AIR VALVE |__T'auniiary ir vaive — Always open (See page FI-87) BAD Lo ‘CHECK AIR CONDITIONER IDLE-UP “ir valve for et conditioner — Leakage ciRcUIT BAD Le ‘CHECK DIAGNOSIS SYSTEM L [Diagnostic coaels) (See page FI-25 or 26) Check for output of diagnostic code ‘Malfunction (See page FI-22) code(s) [Normal code Throttle body CHECK THROTTLE POSITION SENSOR F (See page FI-84) ‘BAD ] OK CONTINUED ON PAGE FI-17EFI SYSTEM — Troubleshooting i OK CONTINUED FROM PAGE FI-16 FLAT ‘CHECK FUEL PRESSURE (See page FI-67) BAD Fuel pressure regulator ~ High pressure L™* ‘CHECK COLD START INJECTOR (See page FI-72) BAD Cold start injector — Linkage L« [CHECK INJECTORS (See page FI-77 Injectors — Leakage, Injection quantity T* BAB [CHECK EFI ELECTRONIC CIRCUIT USING VOLT/OHMMETER {See page FI-28) BAD 1. Wiring connection 2. Power to ECU (1) Fusible links (2) Fuses @) EFI main relay 3. Air flow meter (w/ Air flow meter) 4. Vacuum sensor (wv/o Air flow meter) 5. Water temp. sensor 6. Air temp. sensor 7. Injection signal circuit (1) Injoctor wiring (2) Solenoid resistor (w/o Air flow meter) @ ECU SYMPTOM — ENGINE BACKFIRES-Lean Fuel Mixture CHECK DIAGNOSIS SYSTEM [ Matfunction’ Diagnostic codeis) (See page FI-25 or 26) Check for output of diagnostic code. (See page FI-22) code(s) [Normal code CHECK FOR VACUUM LEAKS IN AIR. 1. Oil filer cap) INTAKE LINE BAD "| 2. Oil dipstick 3. Hose connections 4, PCV hosels) 5. EGR system — EGR valve stays open L& (CHECK IGNITION TIMING Ignition timing — Adjust 1. Short terminals T and E1 of the check NO (See page EM-37) connector 2, Check ignition timing. Standard: 10° BTDC @ idle 1 [CHECK IDLE SPEED (AND IDLE CO 1 Idle speed — Adjust CONCENTRATION) NO 2 Idle CO concentration — Adjust |!See page EM-39 or 42) ] OK CONTINUED ON PAGE Fi-18FL18. | 9k CONTINUED FROM PAGE F-17 EFI SYSTEM — Troubleshooting ‘GHECK COLD START INJECTOR 1. Cold star injection {See page F-72) BAD | 2 Cold start injector time switch {S00 poge Fi-95) TOK i ‘CHECK FUEL PRESSURE 7 7 -Foet pump Gee page F861 (See page F-67) BAD] 2’ Fuel hiter 3. Fuel pressu {See poge T* CHECK INJECTORS |____.Tinjectors — Clogged {See page F-77) BAD 1% CHECK EFI ELECTRONIC ciRcUTT—_|___.[7 Wing connections USING VOLT/OHMMETER BAD "|2. Power to FCU (See poge Fi-29) (1) Fibs (2) Fuse (9) EFI main ceiay 3. Ai flow meter bw Airflow meter) 4. Vacuum sensor (w/o Ale low mete] ©. Water temp. sensor 6. Air temp. sensor 7. Throtle position sensor 8 injection signal circuit, (1) Injector wiring {2) Fuel cut RPM iSee page F-108) i) ECU 9. Oxygen sensor (w/ TWC) 1 ‘OK (w/o AIR FLOW METER) |__| Variable resistor CHECK VARIABLE RESISTOR BAD (Sea page F198) SYMPTOM — MUFFLER EXPLOSION (AFTER FIRE)-Rich Fuel Mixture-Misfire CHECK DIAGNOSIS SYSTEM . _[ Diagnostic code(s) See page F-25 or 26) Check for output of ciegnostic code. | Malfntion (See page Fi-22) codets) I ‘Normal CHECK IGNITION TIMING Ignition uming — Adjust 1 Short terminals T and E1 of the check NO | Gee page EN-37) connector 2. Check ignition timing Standard: 10" BTDC @ idle | ‘OK CONTINUED ON PAGE F-19EFI SYSTEM — Troubleshooting | 0k CONTINUED FROM PAGE FI-18 Fl CHECK IDLE SPEED (AND IDLE CO 1 Wie speed - Adjust CONCENTRATION) NO "| 2. Idle CO concentration ~ Adjust (Gee page EM-39 or 42) OK t ‘CHECK COLD START INJECTOR 1. Cold start injector (See page FI-72) BAD | 2. Cold start injector time switch, (See page FI-95) OK 4 (CHECK FUEL PRESSURE | Fuel pressure regulator (Ses page FI-67), BAD Lo (CHECK INJECTORS (See page FL-77) | ____ [injectors ~ Leakage Lx BAD CHECK SPARK PLUGS | _____[1 Spark plugs Standard: 0.11 mm (0.043 in} NO "| 2. Compression pressure NOTE: Check compression pressure and Minimum: 10.0 kg/em! valve clearance if necessary. (142 psi, 981 kPa) at 250 rpm 3. Valve clearance (Cold) Standard: IN 0.15 ~ 0.25 mm (0.006 — 0.010 ind EX 0,20 ~ 0.30 mm (0.008 - 0.012 in) OK t (CHECK EFI ELECTRONIC CIRCUIT L [1 Throttle position sensor USING VOLT/OHMMETER BAD "| 2 Injection signal circuit {See page FI-29) (1) Injector wiring (2) Fuel cut RPM (Seo page FI-108) 3) Solenoid resistor (w/o Air flow meter! (a) Ecu 3. Oxygen sensor (w/ TWC) SYMPTOM — ENGINE HESITATES AND/OR POOR ACCELERATION (CHECK CLUTCH OR BRAKES. — fi clutch = stips BAD | 2. Brakes ~ Drag OK 1 CHECK FOR VACUUM LEAKS IN AIR —__.7 oir fier cap INTAKE LINE BAD | 2. Oil dipstick 3. Hose connections 4. PCV hosels) 5.EGR system ~ EGR valve stays open ‘OK CONTINUED ON PAGE FI-20Fi20 EFI SYSTEM — Troubleshooting | 0K CONTINUED FROM PAGE F-t9 ‘CHECK AIR FILTER ELEMENT ~[Eiement — Clean or replace L* ‘CHECK DIAGNOSIS SYSTEM Diagnostic codes) (See page FI-25 or 26) Check for output of diagnostic code. (See page FI-22) Malfunction’ [_Nomet code ' ‘CHECK IGNITION SPARK 1. High-tension cords (See page IG-19) 2 Distributor 3. ignition coil, igniter OK 1. Short terminals T and E1 of the check connector 2. Check ignition timing, Standard: 10° BTDC @ idle ‘CHECK IGNITION TIMING L Ignition timing — Adjust (See page EN-37) CHECK FUEL PRESSURE |_____[7Fuet pump (See page Fi-65) 1 {See page FI-67) 2. Fuel filter 3. Fuel pressure regulator (See page FI-78) L* ‘CHECK INJECTORS Injection condition (See page FI-77) OK ‘CHECK SPARK PLUGS Standard: 1.1 mm (0.043 in} NOTE: Check compression pressure and valve clearance if necessary, 1. Spark plugs 2. Compression pressure Minimum: 10.0 kg/em? (142 psi, 981 kPal ‘at 250 rpm. 3. Valve clearance (Cold! Standard: IN 0.18 ~ 0.26 mm (0.006 ~ 0.010 in) EX 0.20 - 0.30 mm (0.008 = 0.012 in} LK Chock its air control vaive open with engine running at Approx. 6,000 rpm (w/o TWO), 4,350 rpm (w/ TWC) or above. ‘CHECK T-VIS AIR CONTROL VALVE | __ [1 VSv tor air control valve 2 Vacuum leaks ‘OK CONTINUED ON PAGE FL-21 'EFI SYSTEM — Troubleshooting EFI SYSTEM — Troubleshooting [ 0k CONTINUED FROM PAGE F120 (CHECK EFI ELECTRONIC CIRCUIT |___]7 Wiring connections: USING VOLT/OHMMETER BAD Power to ECU {See page FI-29) (1) Fusible links, (2) Fuses (3) EFI main relay Air flow meter (w/ Air flow meter) Vacuum sensor (w/o Air flow meter) Water temp. sensor Air temp. sensor Throttle position sensor Injection signal circuit (1) Injector wiring (2) Solenoid resistor (w/o Air flow mater) (3) ECUFL22 EFI SYSTEM — Diagnosis System 2p "pe ‘Service Vi Check Connector DIAGNOSIS SYSTEM DESCRIPTION The ECU contains a built-in self-diagnosis system by which troubles with the engine signal network ae detected and a check engine warning light on the instru- ment panel flashes. By analyzing various signals as shown in the later table (See page F'-26 or 26) the ECU detects system malfunc- tions which are related to the various operating parameter sensors or actuator. The ECU stores the failure code associated with the detected failure until the diagnosis ‘system is cleared by removing the fuse stop 15A (AE), EF: 15A (AT) or AM2 7.5A (AW) with the ignition switch OFF ‘The check engine warning light on the instrument pane! informs the driver that a malfunction has been detected The light goes out automatically when the malfunction hhas been cleared CHECK ENGINE WARNING LIGHT CHECK 1, The check engine warning light will come on when the ‘gnition switch fs placed at ON and the engine is not tun ning. 2. When the engine is started, the check engine warning light should go out. 1 the light remains on, the diagnosis system has detectee ‘a malfunction or abnormality in the system. OUTPUT OF DIAGNOSTIC CODES To obtain an output of diagnostic codes. proceed as follow: 1. Initiat conditions (a) Battery voltage 11 volts or more () Throttle vaive fully closed (throttle position sensor IDL points closed) (e) Transmission in neutral position (8) Accessories switched OFF le) Engine at reach normal operating temperature 2 Tumthe nition switch to ON. Do not start the engine 3. Using a service wire, short terminals T and E1 of the check connestor. LOCATION: See page FI-89 4, Read the diagnostic code @s indicated by the number of flashes of the check engine warning light.EFI SYSTEM — Diagnosis System FL23 os on oF 45 (Seconds) low Code No.2 Code No.4 Code No. 2 os ore | _p (Seconds) UUW (Seconds) Code No. 21. Code No. 32 Code No. 21 o5 45 Diagnostic Codes (See page Fi-25 or 26) (TCS ECU w/o Air Flow Meter) lo) Normal System Operation (code No.1) (normal func~ tion) © The light will blink every 4.5 seconds, (©) Malfunction Code Indication ‘© The light blink a number of times equal to the mal- function code indication with a 2.5 second interval between each indication. © After all the codes have been output, there wil be ‘9.4.5 second pouse and they will all be repested 9s long a8 terminals T and E1 of the check connector are shorted. NOTE: In the event of » number of trouble codes, indica- tion will begin from the smaller value and continue in order to the larger (TCS ECU w/ Air Flow Meter) {a} Normal System Operstion (no malfunction) © The light will alternately blink on and OFF for 0.25 second intervals. (b) Malfunction Code Indication © In the event of a malfunction, the light will blink ‘every 06 seconds. The first number of blinks will ‘equal the first dight of @ 2-digit diagnostic code and, after 2 1.5 second pause, the 2nd number of blinks will equal the 2nd. If there are two or more codes, there will be a 2.5 second pause between each. © After all the codes have been output, there will be ‘94.5 second pause and they will all be repeated 2s Jong as the terminals T and E1 of the check con- nestor are shorted. NOTE: In the event of a number of trouble codes, indica tion will bogin from the smaller value and continue in order to the larger. After the diagnosis check, remove the service wie.a EFI SYSTEM — Diagnosis System CANCELLING DIAGNOSTIC CODE ‘After repair of trouble area, the diagnostic code retained in memory by the ECU must be cancelled out by removing the fuse STOP 15A (AQ), EFI 15A (AT) or AMZ 7.5A (AW), located in the engine compartment relay box, for 10 seconds or more, depending on ambient temperature (the lower the temperature, the longer the fuse must be left out) with the ignition switch OFF NoTE. © Cancetaon can iso ba done by removing the bey ive (=) terminal, but in this case, other memory Systems (clock, ete) wil lso be canceled out © If the diognostic code is not cancelled out, it will be retained by the ECU and appear along with a new code in the event of future trouble. © Ifitis necessary to work on engine components requir- ing ramoval of the battery terminal, a check must first bbe made to see if @ diagnostic code is has been recorded After cancellation, road test the vehicle to check that 2 normal code is now read on the check engine warning light. If the same diagnostic code appers, it indicates that the ‘trouble area has not been repaired thoroughly.EFI SYSTEM — Diagnosis System DIAGNOSTIC CODES (TCCS ECU w/o Air Flow Meter) Code Number of No CHECK ENGINE System Diagnosis Trouble area , blinks ON : This appears when none of 1 I I i i Norma! the other codes (2 thru 11) - OFF ronan are identified. . : a 1. Vacuum sensor circuit f n 2 ul ut lL . aoe nal ven cuneee diana. 2. Vacuum sensor 9 one 3. ECU 1. Ignition circuit 3 {| Wi Wu. fla Ignition No signal from igniter (+B, IGF, IGT} signal four times in succession. { 2. Igniter FIO? 3. ECU / 1. Water temp. sensor 4 TUL! iW LI Water temp. | Open or short circuit in circuit sensor signal | water temp. sensor signal. 2. Water temp. sensor Es 3. ECU © No NE, G signal to ECU 1. Distributor circuit within several seconds : 2. Distributor 6 UL {ULLJ|| RPM signat | after engine is cranked. 3. Igniter | @ No NE signal to ECU when : a i : : 4. Starter signal circuit the engine speed is above 1 5. ECU raeas 000 rpm a 1. Throttle position Throttle Open or short circuit hd 7 JUUUUUUL__ UU position in throttle position er circurt . ; 2. Throttle position sensor sensor signal | sensor signal. 3. EC F intake air Open or short circuit 1. Intake air temp. sensor TULL UL temp. sensor | in intake air : circuit signal temp. sensor signal. , 2. ECU FiGk4? Vehicle speed sensor signal ® Engine rpm is between 2,000 — 5,500 rpm. Water temp. is 80°C {176°F) or more. Manifold pressure is a certain value or more and vehicle speed continues at O km/h for seconds or more. . Vehicle speed sensor circuit Vehicle speed sensor . ECU 1. Starter relay circuit (AW) No STA signal to ECU when 2. IG switch circuit 10 JUL} Starter signal | vehicle stopped and engine (starter) i over 800 rpm. 3. IG switch peas 4. ECU ; 1. Air con. switch . Air conditioner switch ON. 2. Throttle position sensor 1 i f i j I jl l ll . ; idle switch OFF or shift circuit " ! UU J Switch signal position in D range during 3. Throttle position sensor diagnosis check. 4. Neutral start switch | 5. ECUFiL26 EFI SYSTEM — Diagnosis System DIAGNOSTIC CODES (TCCS ECU w/ Air Flow Meter) ‘during diagnosis check ‘Neutral start switch ecu. ode cutcenane | 5 ater Dingnos “rouble area = blinks _ earns | Toute area This appeors when none of = | BF) ormar ‘the other codes (12 thru 51) - - fa sresgentied | No NE, G signal ECU win) Dstibulorcreut 2) SUL RPM signal | seversi seconds after engine | 3 eee uit | IG T8 mae 's cranked, A ECU Wo WE signal ECU win 3 JUL RPM signal | severe seconds after engine | Some os 12, above os techs 1.500 rom 1 itr droit funn ition | No signal trom igniter 4 = 5 | Bre IGF) ed signet times in succession. | 2. Igniter Fise oa ecu" Oxygen 1. Oxygen sansor ereut a) UL serooe Oxygen sensor signal 2. Oxygen sensor - ” signe! nu 3.ECU 1. Water temp sensor JULI | water temp. | open or snort crew in water| "Creu 22 ‘sensor signal | temp. sensor signal (THW). Water temp, sensor F63 Inake er FILA. | FE Bor | Open or shor cit in intake 2 ML | tyme, SF tomp soncr signa (THAD, | 2. Intake air tmp, sensor | Fr62 con 3 ecu + tector 2 TULIUNUUL. | ton signsr | Oryaen sensor signal continues | 3 Goyer emp se ‘anal | soncte leon conan, | 3 Water temp sensor — ____| 8: Oxygen sensor ‘Onygen soaor onl cortinoes 26 ficnsionot | Qryag seem eral cosns | Same os 25, above - ‘© Open cieuit n VC, VS, VE | 1. Airflow meter creut ay | UU | Bee iont | 4 SE 2 A fw meter ‘nae 3t_| « Short akeul in Ve. Secu Tote 1 thos position a1 | SUL | position Seen. ce anort reat in tht0t- | 2. throtle position FL? ya] 9001 3. ECU ‘Engine rpm is between ] 21800 "5.300 mm” | 1. Vehicle speed sensor a DIVULIUL | venice sec | # Water tmp ie 80°C ercuit, - Sensor signal |” {176'F) ormore 2. Vehicle speed sensor ‘© Basi nection duration is | 3 ECU a Scertin value of more 7 1 Sie: Fam AT saner | NOSTA signal ECU when | 2.6 switch cheut aa | IUINLIVUL | sumer | Setietgdad nae” | ? Goose rss | ‘nong over 800 rpm 3.Ieemen | a a eou) 1. Ale con. awiteh | s | Avconaong:awtcn on, | 2 Tt poxton ese witch | fle snitch OFF of sft posi. | ~ ekout se UL Ses thon etnr than for range | 3. Trvote postion sensor : 5EF! SYSTEM — Diagnosis System, INSPECTION OF DIAGNOSIS CIRCUIT RE ee 15a nin ny ecu. Fusile frit Fuse check froin Unk GAUGE neck Erinn att 75n Waring Ua 8a, ate || ~ chock Connector on ar 7 Fuse rou FTN Wa Sarr Fosile ay Unie ase +8 Foeibe Fusbic ‘creck Epne]*2" te Gn rack Engh aur AM Warang tion 80a fon w chook Coanector law ecu Fusi| 50 Eliiae vs 1 Ho opel hack Engine | 78 TUR GACT SAS Woring taht (Sears Boney creck Connector roFL28 EF! SYSTEM — Diagnosis System. ves ‘Does check engine warning light come on when ignition switch is at ON? “| System Normal NO) ves Does check engine warning light come on when ECU terminal W is grounded to the body] oK Check wiring between ECU terminal E1 and body ground. “| Try another ECU. NO [=> Check bulb, fuse and wiring between ECU and| ignition switch Repair or replace. BAD Repair or replace, ves Doas check engine warning light go off pl when the engine is started? System Normal i) 1 ‘check wiring between ECU and check aa engine warning light. Repair iG Is there diagnostic code output when check connector terminals T and Et are short circuited? ‘Try another ECU, YES NO Does check engine warning light go out after repair according to malfunction code? Further repair required YES System OK Cancel out diagnostic code.EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FL29 TROUBLESHOOTING WITH VOLT/OHMMETER NOTE: The following troubleshooting pro- cedures are designed for inspection of each sepa- rate system, and therefore the actual procedure may vary somewhat. However, troubleshooting should be performed refering to the inspection methods described in this manual Before beginning inspection, itis best to first make a simple check of the fuses, fusible links and the condition of the connectors. The following troubleshooting procedures are based on the supposition that the trouble lies in either @ short or open circuit in component out- side the computer or a short circuit within the computer. HW engine trouble occurs even through proper ‘operating voltage is detected in the computer con- rector, then it can be assumed that the ECU is faulty and should be replaced. LOCATION OF FUSES AND FUSIBLE LINKS RE STOP 15 _GAUGE 758 i IGN 100 LHD. GAUGE 754 stor 154, a lon 10a EFI 18AFL30 EFI SYSTEM — Troubleshooting with Volt/Ohm LOCATION OF FUSES AND FUSIBLE LINKS (Cont'd) aT 2g0} EFit6a aw Be GAUGE Europe) -TURN-GAG (thers) Fuse __ Ae 16A Sosa COR eA. esi tk Fuse Odea 75h 1258EFI SYSTEM — Troubleshooting with Volt/Ohmme! FL34 EFI SYSTEM CHECK PROCEDURE NOTE. © Perform all voltage measurements with the connectors, connected. © Verity that the battery voltage is 11 V or more when the ignition switch is at “ON”. Using a voltmeter with high impedance (10 kf/V minimum), measure the voltage at each terminal of the wiring connectors. Terminals of ECU (TCCS ECU w/o Air Flow Meter) Symbol Terminal Name ‘Symbol Terminal Name £01 | ENGINE GROUND T | CHECK CONNECTOR £02 ” ENGINE GROUND {OL THROTTLE POSITION SENSOR No.10_| INJECTOR THA | INTAKE AIR TEMP. SENSOR | No20 | INJECTOR vee | VACUUM SENSOR sta | STARTER SWITCH Pim | VACUUM SENSOR it | IGNITER vta | THROTTLE POSITION SENSOR a “ENGINE GROUND: THW WATER TEMP. SENSOR “FU | FUEL PRESSURE VSV £2 | SENSOR GROUND vase | IDLE-UP sv SPD | SPEED SENSOR st | T-vis vsv FC | CIRCUTT OPENING RELAY VAF VARIABLE RESISTOR AG A/C MAGNET SWITCH ~ vF___| CHECK CONNECTOR “SEL | SENSOR GROUND ce | pistaeuTor BaTT | BATTERY £21 SENSOR GROUND - w ‘WARNING LIGHT ” G | DISTRIBUTOR a1 | MAN RELAY Ne | DISTRIBUTOR +5 | MAINRELAY (GF | IGNITER * EuropeFL32 EFI SYSTEM — Troubleshooting with Volt/Onmmeter Voltage at ECU Wiring Connectors (TCCS ECU w/o Air Flow Meter) 1 1 INo) Terminals |STD voltage (Vi Condition See page| +8 | 1) ne 10-14 Ignition S/W ON re33 2) eart-er | 10-14 - rege tot ~ €2 45-55 “Throttle valve open 05 or less Thwottle valve fully closed 3| via-e2 tanition SW ON fap 35-55 ‘Throtle valve fully open vee-e2 | 45-55 - j “°° a] icr-e1 07-10 Cranking or ishng rar s| sta-e e-14 ranking F139 6 | No 10 fo" o-14 Ignition S/W ON fiat No. 20 E02 a| weer o-1 No trouble (Check engine warring light off) and mag engine runing PIM ~ 2 33-39 8 Igation SW ON read vec-€2 | 45- 55 9| ta-e2 | 20-28 Intake ai temp. 20°C (68°41 ras to) THw-€2 | 04-08 | Ignition SW ON Coolant tomp. 80°C (176°F) ras ni we-er 5-14 Air conditioning ON nar s 1 [ECU TerminaleEFI SYSTEM ~ Troubleshooting with Volt/Onmmeter F133 No. | _ Terminals Troubl Condition ‘STD voltage 1 -E1 | No voltage 1G s/won 10-14 EFiMain Relay ecu Peaepoe Ta Fuze IGN 140A (AE 75A (AT) Voltmeter [aye voltoge between ECU terminals +8 or +81 ond E1. (Pus srw on) I ‘Check that there i voltage between ECU terminal +B or +481 and body ground. (IG S/W ON} No I ‘OK [gy cheek wing betweon ECU terminal E1 and body [ground ]o« yee ' Try another ECU. oF replace, eck fuses, fusible inks and] BAD Check fuses, fsibie links an | BAD. mapair or replace. ignevon switen, [™ ‘Check EFI main relay 800 Treo ‘See page F1-90) rt OK ‘Check wiring between EFI mein] BAD, relay and battery, | PA°.| Repair or replace.34 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter Wo |” Temas | Trout Conon S10 verge 2 | earr-e1 | No voiege = 1o-14v cou IL Fusite Link § ALT 804 tae) sR (ar) 1.258 IAW) Fuse Stor EFL IBA (AT) AN 758 (AW) 15 (AD sae Df No voltage between ECU termninals BATT and E71 sen} Voltmeter v lee | | [Check that thor ie voltoge between ECU terminal BATT ana |® ody around \ No [0K [gy check wiring between ECU terminal ET end baoy {® ground OK I BAD Try another ECU. Repair or replace. ‘Check fuse and fusible ink | 2A2L Replace, OK BAD, ‘Check wing between ECU Repair or replace terminal and battery.EFI SYSTEM — Troubloshooting with VolOhmmeter FL-35 Terminals Trouble Condition STD voltage WL — Ez ‘Throttle valve open as—65v 3) vra—ez | overage [1a s/w ow Tle valve fully closed (055 V or lest Throttle vaive fully open a5 -55V vec =e? | - = 45-55V ecu Throttle Position Sensor aS © tL - E2 [qp Thee f no voltage betweon ECU terminals IDL and E2 (IG S/W ON) [Throttle valve open) I gy Check that there is voltage between ECU end body ground. @ S/W ON) NO OK (Check wiring between ECU terminal E1 end body around. I BAD Repoir oF replace, Refer to No.1 fap Se ees) =} Repair or replace OK [qycheek trot positon a sensor (See page FI-84) BAD OK 1 Repair of replace Check wiring between ECU and throttle postion sensor,| | throttle position sensor. OK Try another ECUFL36 EFI SYSTEM ~ Troubleshooting with Voit/Ohmmeter, a © VTA~E2 [gp There 1 no specified voltage at ECU terminals VTA and £2 [us sw on I [jp check that there is voltage berm ® and vody ground. (1G S/W ON) ECU torminal +81 oF +8 No | OK [Check wiring between ECU terminal E1 end body around! Teao Repair or replace Refer to No.1 (See page F1-33) | 8AO_Trensir or repioce OK [Check throtte position sensor |_BAD IB ee hace thse) Repair or replace ‘see page F184] Toe ‘Check wiring between ECU end | _ BAD throttle position sensor. T To« z Try another ECU. * vec ~ £2 [ap These is no voltage between ECU terminals VCC and €2 Pug siw ond I ‘Check that there is volage between ECU terminat +8 or +8 {and body ground. {1G S/W ON) _ I OK NO [gp check throtte postion eter 10 No. 1 sensor (See page F184) (Seo page FI-33) [pao Tox ‘Check wiring between ECU and thretle Repair or replace. pai or ree Position sensor ]o« Tsao another Repair or replace Try another ECU, [rexEFI SYSTEM — Troubleshooting with VolOhmmeter_ F387 ie.[ Terminals | __Trouble 51D vot 4 | torr | No voltage 07-10 KE and AT ecu To Tachometer Fusbe te ate onion Cot ecu ‘To Tachometar af he ema oe Engine | Ignition CoilFL38 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter | ecu [gpNe voltage between ECU terminals IGT and ET tating) I [q check that there is voltage between ECU torminat IGT and ‘body around. (tating? ECU | NO ]o« ‘Check wiring between jaecuremna er aod sowy | 240. Ras or ground. repiace. Jo« Tey another ECU, ‘Chock fuse, fusible ink, ignition | BAD Switch and starter relay (AW. [* Check aistributor (See page 16-23) |®A°_ [Repair or replace [x eck wing belwoon ECU wi Check wing barwoen ECU and | 6AD.| peng or enlace. ox (See page 16-23) _ } ®P Ropar or replaceEFI SYSTEM — Troubleshooting with Volt/Ohmmeter F138 [ve I Trouble ‘Condition T ‘STD voltage 5 Wo vat Cranog =a i and AT i —___Seing —_}___ ecu ton Swen meee rust J Lai (Terminal 50) AW ~ fu mf a0 griton Sitch suaner rane | | i ora 1.288 (Teeminal 50} To Circuit Opening RelayFL40 EFI SYSTEM — Troubleshooting with VolvOhmmeter [glo votage between ECU terminals STA and EY Da srw star) (Check wiring between ECU terminal STA and ignition switch terminat ST1 (AE and AT) or ST2 (AW) BAD, OK ‘BAD ‘chock starter | OK ‘operation Repair or replace [gp Chek wring between ECU terminal ET and body ‘ground [* ] BAD rea Tapa | ted L Tat im ae] ay ‘wiring, ignition switch and starter Repair or replace. ‘Voltmeter @) | reloy Aw). 0K [g Check that there is voltage at STA (60) terminal of storter P [aa srw start) STD voltage: 6 - 12 V OK NO STA \ {Terminal 50) \\ Check winng between ignition switch Check starter. terminal ST1 (AE and AT) ot ST2 (AW! and starter terminal STA (50)jaw Fusible Linke 7258 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter Fiat Ne. Terminals Trouble Condition ‘STD voltage ‘No. 10 _ €01 @ /No-19_ £01) Wo voltage IG Swon 9-14v [AE and AT Ignition Switen ama| 162 Fusible Unk M2 308, FB) Solenoid Resistor wat De ad da ecu Ignition Switch awe, Fuse aM 162 Tea 1 = Battery Solenovs . fT Injector ecuFaz, EFI SYSTEM — Troubleshooting with Volt/Ohmmeter fo ve No. 10 @ Onmmeter E01 and/or £02. (IG S/W ON) [@DNe voltage between ECU terminals No. 10 andor Na. 20 ana minal +8 and body Yround. STD voltage Check that there apcied volagebetwoon solenoid resto \2 tert o-14v OK I NO | ‘Check fuse, fusible ink, wining ignition switch and starter relay (AW). BAD | Repsir or replace, [gy Check resistance of magnetic col in each Replace [Pinjector. STD resistance: Approx. 2.312 resistor OK BAD ~———_ Replace injector [ ‘Check wiring between ECU and resistor. Replace or replace wiring ox Tey another ECU,fo | Terminals | Wrouble STD volage Wo Vo iss eng wari 7) wer | weet —— vy nee @ eos a cra es {AW LHO Corea TURN-GAG 758 (aw Others) ‘Combination Meter Voltmeter [gy check thet the is vakage between ECU terminal W and ? body ground. no] O8 aul fs ecu, @ \o« I BAD Tiyan Fer ovnace |] Choc ace and cc sage wang ior oY Ba [Trononecou J Fue ows sone Tracking bowen EG | 840 _[pepar or ‘terminal W and fuse. ooFas, EFI SYSTEM — Troubleshooting with Volt/Ohmmeter No] Terminale PIM — F2. vee - 62 Trouble ‘Condition ‘STD voltage i ow 33-39V No voltage iG sjwon aoe nemo 45-55V ecu Vacuum Sensor Manifold Absolute) Pressure Sensor) ( (Das s/w on No voltage ai ECU tecrinats PIM or VCC and £2 +81 and body ground. (IG S/W ON) [qycheck that there is votage between ECU terminal +8 or NO. OK 1 body ground. ‘Check wiring between ECU terri Et ane BAD Repair or replace Rofer to No. 1. Gee page F1-93) | SAP Repair or repice OK 1 ‘Check wiring between ECU anc Repair or roplace OK t “Tey another ECU,EFI SYSTEM — Troubleshooting with Volt/Ohmmeter, Fas No.| _Terminais Trouble ‘Conaition ‘STD voltage o | THa-e2 No voltage 1G S/W ON Intake sir temp. 20°C (68°F) | 20-28 Air Temp. Sensor — a [ D]_ [Ne voltage between ECU terminals THA ond £2 UG s/w ON fou Twa Voltmeter 27 \@ Check that there is voltage between ECU terminal +B or 481 and body ground. 16 S/W ON) OK NO Rater to No.1 {Sen page FL-33) Check wing between ECU terminal EY and body ground OK PAD [pobeck temp sensor enlace |® (See poae F1-100) Repair Or recta BAD ox ‘ : epiace or ‘heck wing between ECU and tome. sensor ae tern. sensor OK BAD ‘ “ry nother ECU, amesEFI SYSTEM — Troubleshoot Vott/ohmme No. | Terminale Trouble Condition ‘STO voltage 10/ THW-E2 | Novoltege | 1G S/WON Coolant temp. 80°C (176°) 04 -o8v ecu Water Temp. Sensor THW. Uwe 2 — TD] [fre vonage between ECU vorminals THW ond EZ (us sw om Votimeter [qycheok thot there ie voltage between ECU terminal +8 or +81 J and body ground. 16 S/W ON! | oK rr veal Refer to No.1 See page ‘Cheek wiring between FCU terminal EY and body ground, OK BAD + She water. sensor epow or replace Seepage F-96) | AL BAD T= Tasioce waver Cheat wkng batwean ECU and water temp conor oop inane I “Try enother ECU. Repair or replaceEFI SYSTEM — Troubleshooting with Volt/Ohmme! FLA? No.| Terminals Trouble: ‘Condition ‘STD voltage nu] Acer No voltage Air conditioning ON B-14v ecu we Amplifier AIC Compressor Eu {aie conditioning ON} apo voltage between ECU terminals A/C and E1. | ‘Check that there is voltge between ECU terminal A/G and ” body around. NO OK ‘Cheek wiring between ECU terminal ET and body ground. OK ‘BAD ‘ Try anather ECU. Repair or replace ‘Check wiring | 0k | between ECU ‘Check compressor runaing Teeth Ale acd) NO amplifier BAD Repair or replace ecu @ 4 ‘Check that there i voltage Ohmmeter between amolitier terminal and [PAD | Repair or reptace, body ground, OK 1 heck wiring between amoltior | BAD TA. tace, and ECU or compressor. fo LRepae ox centF149 EFI SYSTEM Terminals of ECU roubleshooting with Volt/Ohm (TCCS ECU w/ Air Flow Meter) Symbol Terminal Name Symbot Terminal Name £01 ENGINE GROUND €2 SENSOR GROUND: £02 | ENGINE GROUND Ge | osTRIBUTOR No10 | INJECTOR ox | oxyGen sensor No20 | INJECTOR G__| DISTRIBUTOR sta | STARTER SWITCH vec | VACUUM SENSOR IGT | IGNITER VTA _| THROTTLE POSITION SENSOR VF | CHECK CONNECTOR NE | DISTRIBUTOR E1 | ENGINE GROUND THW | WATER TEMP, SENSOR sm | Tvs vsv ve | AIR FLOW METER Feu | FUELPRESSURE SV; «21_—|«SENSORGROUND = “vase | TMs vsv vs | AIRFLOW METER w | WARNING GAT ste | STOP UGHT swiTcH HT | OXYGEN SENSOR THA | INTAKE AIR TEMP. SENSOR 1 | CHECK CONNECTOR spo | SPEED SENSOR RIP | FUEL CONTROL SWITCH BATT | BATTERY IDL | THROTTLE POSITION SENSOR +81 | MAIN RELAY Ac | AIC MAGNET SWITCH +a | MAIN RELAY IGF | IGNITER ~ [ECU TerminalsEFI SYSTEM — Troubleshooting with Volt/Ohmmeter Fag Voltage at ECU Wiring Connectors (TCCS ECU w/ Air Flow Meter) No] Terminals | STD voltage (V} Condition See vege +8 1] Bycet | to-18 Ignition SW ON F560 2] gatr~e1 10-14 = Ft wou -e2 10-14 Throttle valve open | 08 or less Throttle valve fuly closed 3) vra-e2 Ignition SW ON F152 35-55 Throttle valve fully open vee - £2 45-85 - 4) er-e1 07-10 Cranking oF ding fsa 8] sta-et e-14 ranking F158 6 | No t0_ cor e-14 Ignition S/W ON F.s8 No. 20 £02 | wee a 'No trouble (Check engine warning light off) ang hes engine running ve -e2 61-108 7 I ; 25-54 | lgnion SW ON | Measuring pat tty closed fue Vs ~e2 62-88 Measuring plate fully open 39-58 Idling 9| THA-e2 2-28 Intake aie temp, 20°C (68°F) F62 ro] tHw-€2 | 04-07 | ignition WON | Coolant temp. 80°C (176°F) F.63 in} weer 5-14 Air condoning ON Fee60. EFI SYSTEM — Troubleshooting with Volt/Ohmmeter, me Trouble Conaion BID valose + 1) Emer | wo voltage 16 S/W on 10-14v fee FN olay cu 3 2 Be" ps [etn fon ies he OE |g AM 30a eA satery [cpio voltage between ECU terminals +8 or +B and FT Ps sw on} [ay check that there is voltage between ECL terminal +8 or +81 and body ground. (1G S/W ON) mo | 0K | eck wring batneen ECU trial Eb bod Soom " ra a iG co Thy enor £0 Tao ce Volemetar Check fuses, fusible links and | BAD ignition ewiteh, | BAP. | Repair or replace. OK a a (Check EFI main relay BAD, - (Soe page FI-90) pone Ox ‘heck wing between EFI man] BAD (Oo senan relay and battery. Rens piEFI SYSTEM — Troubleshooting Volt/Ohmmeter No] Termine Trouble Condition ‘STO voltone 2)| BATT—E1 | No voltage = wav ECU. Fosibe ink Euae Galisoatan — STOP 164 AB) SesRiaT EFLISATAT) OSS avn AM? 754 AW) ID No voltage between ECU terminals BATT and E1. [jp cheat ot veo wage Poteon FOU tia BATT and 2 paar sauna OE Bp check ang baiwoon EGU oni 1 an by [> ground. Tor oD [Lirroinereeu Taps oc Chet tse ona se tae} 28? Rene ox el ee ou 9] po = maar aa i nigFiz EFI SYSTEM — Troubleshooting with Volt/Ohmmeter_ [No.| Terminele | Trouble Conaition ‘STO voltage WoL e2 ‘Throttle valve open 10-14 Throttle vaive fully closed 05 V or loss 3) vane maxenaye | 1 aha ow ‘Throttle valve fully open 35-58V | vec = E2 = 45-55 Thiotte Postion Sensor IDL — E2 O [jp There is no voltage between ECU terminals IDL and €2. UG S/W ON [Throtte valve open [& Check tat tere valiage bviweon EGU imine +87 or #8 tnd body ground S/W ON! nO OK ‘ hock wing between ECU vernal EY ard body rod oo Repair roca fuer Na sap {See page Fi-b0) Ropoir or replace OK | FeneGaewe ©} [5 check avon pon Pry (@ saaor. See page FLeA) Ofmmeter ae BAD EF | Repat or epics | [ cheek winng between EGU and thot poston soar | [thot poston sensor ‘seo page Fi-84}| Try another ECU,EFI SYSTEM — Troubleshooting with Volt/Ohmmeter © VTA — £2 F153 [jp There i no speciied voltage at ECU terminals VTA and €2. ua s/w ON) fq) Sheck that there i vokage between ECU termine! #B1 or +B 2 and body ground. UG S/W ON) NO) r ‘Check wiring between ECU terming! ET and body ‘ground = Repair or replace Refer to No. 1. (See page #50) | 242 Tapas or replace, pe [q Check throttle position sensor |_BAD. Orr eran, Ropair or replace, OK (Check wiring between ECU ond | BAD throttle postion sensor Repair oF repla Tox “ey anova ECU * vec ~ £2 a There is no voltage between ECU terminals VEC and E2 ‘Yaa srw ony (Check that there fs vorage between ECU terminal 481 or +8 and body ground. (IG S/W ON) Tox NO [qcneek throtte position Refer to No. 1 sensor. (Sue page Fi-84) (See page F1-50) [= OK Check wiring between ECU and throwle Repair orrepvce- | | position sensor. OK BAD Repair or replace Try enother ECU. neFL 64 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter No] Terminal Trouble Conaton STD volte @| tere | No voltage ting 07-10 AE and AT oe ecu lantion Sten ane ice Furie tine ane Soe loniion Cot ECU Ignition Switeh Ignition CoilEFI SYSTEM — Troubleshooting with Volt/Ohmmeter F155. oO ecu Voumeter Sect a or voageBetwean ECU erin GT and ® ody ground Wang) nO ox 4 Theck wing beiween | Ba0.| Repavr or ECU terminal Et and body |=™) Fens ace. ground i “rey another EU 4 Cc BAD Gheck fuse, fusible nk, geition | BAO. cectace switch and starter relay (AW). Repair or rol ‘OK : BAD, Check distibutor (Gee page 1G-23l] ~—~|_Repair of replace TOK ‘Check wiring betwoen ECU and bottor. is Repair or repace. sap Tar gamer ow pe 20) } SAP “Ropar epeeEFI SYSTEM Trou hooting with Volt/Ohmmeter No.| Terminals Trouble T Condition STD voltage S| STA-E1 | Novottage Cranking é-1v ‘AE ond AT cou Ignition Switon AMIE AIST! Fuse Fuse Basa gon Pestle D aut 808 sia {Ferminal 50) saven| To Cheat Opening Relay aw AM] st2 Fuse AM lgnition Switch 75a Fusible Link 1258 FE Jeatery Starter Relay Starter STA (orminal 501 To Circuit Opening Relay ecuEFI SYSTEM oubleshooting with Volt/Ohmmeter Q [ip No voltage betwoen ECU terminals STA and EV ug siw START) Chock starter] oy [ Check wing between ECU terminal operation. | SE.) STA and ignition switch terminal ST1 (AE and AT) or STZ (AW). [BAD fox [ead Repair or replace, ground [Cheek wing between ECU verminsl EY and body Tor 1 BAD Try enother ECU. Repair or replace 1 ‘Check fuse, fusible inks, battery, ‘Torr 501\ \ ‘wiring, ignition switch and | PAD _| repair or repiace. starter relay (AW, [OK [g Check that thre is votage at STA (50) terminal of starr ue srw START) STD voltage: 6-12 OK nO ‘Check wiring between ignition switch STA Check starter. terminal ST1 (AE and AT) or ST2 (AW? and starter terminal STA (60).FL58. EF! SYSTEM — Troubleshooting with Vol/Ohmmeter fusble [Sy Lak i ‘AM2 308] | Battery AW nition Switen aa A} Fusible Unk, Injector 1258 Flay No. | Terminals Trouble Condition ‘STD voltage Ne. 10 _ £01 _ 6 [No 30_ £01 No voltage 16 s/won o-14v ‘AEandAT Ignition Seiten oo io ecu one ECU,EFI SYSTEM — Troubleshooting with Volt/Ohmmeter F159 GD]. [pre voteae tween ECU emia No 10 adoro. 70a fo and/or €O2 1a S/W On) Check that jalage between ECU terminal No. 10 {2 andor No. 20 and body ground NO. I* (Check wiring betwoon ECU terminal EOT andlor 02 and body ground, i BAD + Try another ECU. Repair or replace 4 heck fuse, fusible ink, BaD *)_ Repair or replace. _! g) Check resistance of magnetic collin each injector. a » STO resistance: Approx. 13.8 0 @ (OK [BAD Ohmmeter Replace injector. ‘Check wiring between ECU BAD terminal No. 10 and/or No, 20 *]_ Repair or replace. and battery.EFI SYSTEM — Troubleshooting with Volt/Ohmmeter Trouble No vattage ‘Condition ‘STD voltage No trouble (check engine warning light off) ‘and engine running. ® uy GAUGE 7.50 (ey GAUGE 158 ‘Combination Meter ‘Check Engine Warning Ught Feu [No voltage between ECU terminals W and £1 © tain [a Check thot thee voltage betwen ECU to body ground pe OK ‘Check wiring between ECU terminal EY end body ground OK BAD —t— sy another FCU Repair or replace ‘Check fuse and check engine warning light. OK BAD 1 “Try another ECU L Fuse blows again t ‘check wiring between ECU BAD terminal W and fuse. Repair or replaceEFI SYSTEM — Troubleshooting with Volt/Ohmmeter FL i eam toa = aoe ve - ez | - 51-108 | 1800 on iss do ivan | "BEB ‘VS - E2 Mo voltage Measuring plate fully open 62-88V fe 1 oe is [a Ne specie vottage st ECU terminals VE or VS ond E2 LP tue sw ON [Eiseswon | [ay Cheek hat there votage between ECU terminal +8 or 461 nd body ground. 1 S/W ON) jox r Refer to No. 1 (See page FI-50) otmeter Check wiring between ECU terminal EV and body sound Ao [OK BAD [wie 1 ‘Chock ai flow meter a cra a tow Repair or replace AD iE 1 Replace ai (Check wing betwoan ECU and a bnmeter flow mete flow moter re BAD 4 Try snother ECU Rear o pace (Soe page FI-82)FL62 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter No.) Terminals Trouble Condition 9) THA-e2 No voltage | 1G S/W ON Intake air temp. 20°C (68°F) c ‘Air Temp. Sencor (Air Flow Meter {© ac sw on Ne voltage between ECU terminals THA and £2, {See page F-821 check ho rats vote two ECU eral +B 75 2 body ground. (1G S/W ON} oe meant Se ge F.80) ECU i) SS ee Tox BAD i Chea won ie —, revo 2 oe = % su | Faace aro) [Check wing tween ECU nd a metowwee O] | twee ee | 7 was [-—pom=y] | Ty monet Ter orEFI SYSTEM — Troubleshooting with Volt/Ohmmeter FL63 a Ta — ae wef ti =e | Roving ieanvon) coumamnwoenen | etary bande Uwe} D]_ [qe voltage between ECU terminals THW and £2. sara ® ody ground. Wa S/W ON) OK, Ne Refer to Not {See page FI-50) Check wiring between ECU terminal ET and body Tox [eo { ogee sa enor or pce Tes Te > ®) | Reptace water ‘Check wiring between ECU and water : lx [osFL64 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter_ [No] Terminals Trouble Condition STD voltage av 11) Ac—e1 | No voltage ‘Air conditioning ON 5 ecu ac ‘Ampitier AVG Compressor [Fe vette betwoen ECU terminals ATG ond ET [Pair condoning OW Check that there volge betoeen ECU torinal AIC and Vanimete 2 body ground. INO Pe wis ‘Check wiring between ECU terminal E7 and body wa [acres OK BAD Try another CU epa or enc Check wing ‘Check compressor running. OK between ECU termine! A/C ond nO smote BAD : apa or ropa. ee. a cr . ck that the Qt - eck thal there & volage cnmmo | PEE Se eg [ote ore tenet ver” body ground = = a ‘heck wing batweon amp ]_BAD noes _and ECU oF compressor Repair or repleRoliet Vaive: a Armature Bearing oumuer EFI SYSTEM — Fuel System F165 FUEL SYSTEM Fuel Pump ek ae vee courier Neer Casing Magnet Impotir | ___impeter t mer AE and AT fuse a wee} Fuel Pomp Ignition Seiten Sonnector mal cuit | Fawalg [sr Spening Foo ink |AM2{ ane ti” lave | tan ‘1 Seow oasng ft — STAT FIT [in ae ron FC { | Air Flow Mater) FR oneny Van aw te 4 ToeCU - tolEFI SYSTEM — Fuel System aw EFA Mai lay vat + oO re BEEP Felton i Shack \-) Ignition Switch | Connector 34] iso Circuit 3S st Srening an fae eee Pai ow nec") ere re eft (wv) Air Flow Meter) ie yoo Air Flow Meter) Ito ecuEFI SYSTEM — Fuel System F67 Check Conndetor elamire Service Wire ON-VEHICLE INSPECTION 1, INSPECT FUEL PUMP OPERATION (2) Tum the ignition switch ON, NOTE: Do not start the engine. (b} Using a service wire, short terminals +8 and FP of the check connector. LOCATION: See page FI-89 (c) Check that there is pressure in the hose from the fue! filter. NOTE: At this time, you will hear fuel return noise. (id) Remove the service wire (e) Turn the ignition switch OFF. {f there is no pressure, check the following parts: ‘© Fusible links © Fuses © EFI main relay © Circuit opening relay © Fuel pump ‘© Wiring connections 2. INSPECT FUEL PRESSURE {a} Check the battery voltage above 12 volts. (©) Disconnect the cable from the negative (=) terminal of the battery (c) Disconnect the cold start injector connector. ()_ Put a suitable container or shop towel under the cold start injector pipe. (e) Remove the two union bolts, four gaskets and cold start injector pipe, NOTE: Slowly loosen the union bolt.FL68 EFI SYSTEM — Fuel System (1) Install SST (pressure gaugel to the delivery pipe with now two gaskets and union bolt SST 09268-45011 Torque: 160 kg-em (11 ft-lb, 16 Nim) (@)_ Wipe off any splattered gasotine. (h) Reconnect the battery negative 4 cable. @ Using a service wire, short terminals +8 and FP of the check connector. LOCATION: See page FI-89 (Turn the ignition switch ON. (K) Measure the fuel pressure. 2.7 = 3.4 kg/om (38 — 44 psi, 265 — 304 kPa! Hf pressure is high, replace the fuel pressure regulator. IF pressure is low, check the following parts: © Fuel hoses and connection © Fuel pump © Fuel filter ‘© Fucl pressure regulator (Remove the service wire. (im) Start the engine. (n) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. fo) Measure the fuel pressure at idling, Fuel pressure: 2.7 ~ 3.1 kg/er (38 — 44 psi, 265 - 304 kPa)EFI SYSTEM — Fuel System F-69 (p) Reconnect the vacuum sensing hose to the fuel pressure regulator. {@)_ Measute the fuel pressure at idling Fuel pre 2.4 = 2.3 kg/em®? (30 — 33 psi, 206 — 226 kPa} if pressure is not os specified, check the vacuum sensing hose end fuel pressure regulator. () Stop the engine. Check that the fuel pressure remains 1.5 kg/cm? (21 psi, 147 kPal or more for 5 minutes after the engine is tuned off. If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (3) After checking fuel pressure, disconnect the battery negative (=) cable and carefully remove the SST to prevent gasoline from splashing, SST 09268-45011 (Install the cold start injector pipe with new four ‘gaskets and two union bolts. Torque: 150 kg-om (11 ft-lb, 15 Nem) (4) Reconnect the cold start injector connector. () Reconnect the cable to the ne the battery (w) Check for fuel teakage. (64 terminal of70 EFI SYSTEM — Fuel System REMOVAL OF FUEL PUMP Fuel Pump Bracket # Non-reusable part Fuel Pump Fuel Pump iter + Clip So ——-Rubber Cushion DRAIN FUEL TANK WARNING: Avoid smoking and open flame when working on the fuel pump. REMOVE FUEL TANK REMOVE FUEL PUMP BRACKET FROM FUEL TANK {a) Remove the five bolts. (b} Pull out the pump bracket REMOVE FUEL PUMP FROM FUEL PUMP BRACKET (a) Remove the two nuts, disconnect the wires from the fuel pump, (©) Pull off the bracket from the lower side of the fuel pump, {fc} Remove the fuel pump from the fuel hose.EF! SYSTEM — Fuel System FLT 1 2 ~ 7 mm (0.08 -0.38 in) Hose i= = Clip 0 - 3mm ~ 0.12 ind REMOVE FUEL PUMP FILTER FROM FUEL PUMP } Remove the rubber cushion (e) Remove the clip, and pull out the pump filter. INSTALLATION OF FUEL PUMP (See page FI-70) 1, INSTALL FUEL PUMP FILTER TO FUEL PUMP. 2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET (a) Insert the outlet port of the fuel pump into the fuel hose. (b} Install the rubber cushion to the lower side of the fuel pump. (c) Push the lower side of the fuel pump together with the rubber cushion into the pump bracket. 3. INSTALL FUEL PUMP BRACKET fa) Place the pump bracket with a new gasket on the fuel tank. (b) Install and torque the five bolts. Torque: 35 kg-om (30 in-tb, 3.4 Nem) 4 INSTALL FUEL TANK ‘CAUTION: * Tighten the fuel tank mount bolts, ete. to the specified torqu # Tighten the pipe union and flare nut (hose) to the ‘specified torqu © Push in the pipe and insert-type hose to the specified position, and install the clip to the ‘specified location. If rousing the hose, reinstall the clip at the original location. 5. REFILL FUELFELIZ EFI SYSTEM — Fuel System Cold Start Injector Connector Terminal / i Point a al ON-VEHICLE INSPECTION INSPECT RESISTANCE OF COLD START INJECTOR (a) Disconnect the cold start injector connector (6) Using on ohmmeter, measure the resistance between the terminals. ao If the resistance is not as specified, replace the {fc} Reconnect the cold start injector connector. injector, REMOVAL OF COLD START INJECTOR 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. DISCONNECT COLD START INJECTOR CONNECTOR 3. REMOVE COLD START INJECTOR PIPE (e] Put a suitable container or shop towel under the injector pipe. {b) Remove the two union bolts, four gaskets and injec- tor pipe NOTE: Slowly loosen the union bolts. 4, REMOVE COLD START INJECTOR Remove the two bolts, injector and gasket.EFI SYSTEM — Fuel System FI-73 INSPECTION OF COLD START INJECTOR J sor tuner 3 ser wone)| "INSPECT INJECTION OF COLO START INJECTOR ise) WARNING: Keep clear of sparks during the test. Ganka < —_ (@) Install SST (two unions) to the injector and delivery pipe with new gaskets and the union bolts. SST 09268-41045 (} Connect the unions with SST those). SST 09268-41045 (6) Connect $ST (wire) to the injector. SST 09842-30050 (d} Puta container under the injector. {e} Reconnect the battery negative (2) cable (9 Turn the ignition switch ON. NOTE: Do not start the engine. @) Using @ service wire, short terminals +8 and FP of the check connector. LOCATION: See page FI-89 Union Bott | SST (Wire) (h) Connect the test probes of the SST (wire) to the bat- tery, and check that the fuel spray Is #5 shown, ‘SST 09842-30050 CAUTION: Perform this wi time. in the shortest po INSPECT LEAKAGE {@) Inthe condition above, disconnect the test probes of SST (wire) from the battery and check fuel leakage from the injector ‘SST 09268-30050 Fuel drop: One drop or less per minute (b) Disconnect the battery negative (=) cable. (Remove SST and the service wire. SST 09268-41045 ond 09842-30020FL74 EFI SYSTEM. Fuel System INSTALLATION OF COLD START INJECTOR 1, INSTALL COLD START INJECTOR Install a new gasket and the injector with the two bolts Torque: 78 kg-cm (65 in-Ib, 7.4 Nem) 2, INSTALL COLD START INJECTOR PIPE Install the injector pipe with new four gaskets and the two union bolts. Torque: 150 kg-cm (11 ft-b, 16 Nem} 3. CONNECT COLD START INJECTOR CONNECTOR 4, CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 6. CHECK FOR FUEL LEAKAGE (See page FI-9)EFI SYSTEM — Fuel System FI-75 Fuel Pressure Regulator FROM PPE es TORETURN HOSE (PIPE) DELveRY Fuel Pressure Regulator kl) Vacuum Sensing Hove Fuel Return Hose sas Fuel Refurn Pipe Fuel Return Hose, sass] ON-VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page FI-67) REMOVAL OF FUEL PRESSURE REGULATOR 1, DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. DISCONNECT VACUUM SENSING HOSE DISCONNECT FUEL RETURN HOSE (AE AND AT) (OR PIPE (AW) {a} Put 2 suitable container or shop towel under the pressure regulator. (b) (AE and AT) Loosen the clip, and disconnect the return hose. NOTE: Slowly disconnect the return hose. fe) aw) Loosen the flare nut, and remove the return pipe NOTE: Slowly loosen the flare nutFL76. EFI SYSTEM — Fuel System Dativery Pipe es O-Ring [AE and AT 4 REMOVE FUEL PRESSURE REGULATOR Remove the two bolts. and pull out the pressure regulator. INSTALLATION OF FUEL PRESSURE REGULATOR 1 INSTALL FUEL PRESSURE REGULATOR [a1 Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. (b) Install the pressure regulator with the two bolts Torque: 75 kg-om (66 in.-Ib, 7.4 N-m) ‘CONNECT FUEL RETURN HOSE (AE AND AT) OR PIPE (AW) (AE and ATH Install the return hose with with the clip. caw) Install the return pipe with the flare nut, Torque: 300 kg-om (22 ft-lb, 29 N-m) CONNECT VACUUM SENSING HOSE CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY CHECK FOR FUEL LEAKAGE (See page FI-9)EFI SYSTEM — Fuel System FL77 Injectors Connector Terminal Fue. ON-VEHICLE INSPECTION 1, INSPECT INJECTOR OPERATION Check operation sound from each injector. lo) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm. (b) If you have no sound scope, you can check the injec tor transmission operation with your finger. | no sound or an unusual sound is heard, check the wiring connector, injector, resistor or injection signal from ECU. 2, INSPECT INJECTOR RESISTANCE (a) Disconnect the injector connector. (b} Using an ohmmeter, measure the resistance between the terminals. tan wo Alt flow meter Approx. 2.3 0 w/ Air flow meter Approx. 13.8 (1 If the resistance is not as specified, replace the injector. (el Reconnect the injector connector.Fi78 EFI SYSTEM — Fuel System REMOVAL OF INJECTORS 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. REMOVE COLD START INJECTOR PIPE (Gee steps 2 and 3 page FI-72) 3. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 4. DISCONNECT INJECTOR CONNECTORS DISCONNECT HOSE FROM FUEL RETURN PIPE 6. REMOVE FUEL INLET PIPE (2) Remove the inlet pipe mount bolt () Remove the union bolt, two gaskets and init pipe. 7. REMOVE DELIVERY PIPE AND INJECTORS. (a) Remove the three bolts and delivery pipe together with the four injectors, CAUTION: Be careful not to drop the injectors, when removing the delivery pipe. 0) Remove the four insulators and three spacers from the cylinder head (cl Pull out the four injectors from the delivery pipe. INSPECTION OF INJECTORS Pressure a 1, INSPECT INJECTOR INJECTION Pan vehick \8 WARNING: Keep clear of sparks during the test. \ & (2) Disconnect the fuel hose from the fuel fker outa (8) Connect SST fanion and hose) tothe fue iter out with new poskets and the union bot gst NS /oisconnest 5. st SS SST 09268-41045 e NOTE: Use the vehicle's fel fier. Union ol ‘FuniHose New Gasket Fue! FilterEFI SYSTEM — Fuel System F179 Prossure _ Regulator Ko (Hose) Wrion) New Gasket Vinyl Hose [7887 tose) 5p" (clamp) 3ST (Union) (Check Conriector. > ES {ec} Install a new O-ring to the pressure regulator {id} Remove the pressure regulator. (See page F1-75) fe) Connect SST (union and hose) to the pressure regulator with two bolts. ‘SST 09268-41045 (#) Connect the fuel retum hose (AE and AT) or pipe @) Install a new O-ring to the injector. (hi Connect SST those) to the injector. with SST (union), ‘and hold the injector and SST (union) with SST {olompy. ‘SST 09268-41045 i) Put the injector into the graduated cylinder. NOTE: Install the a suitable vinyl hose onto the injector 10 prevent gasoline from splashing out §) Reconnect the battery negative (2) cable. (k) Tum the ignition switch ON. NOTE: Do not start tne engine. 4) Using 8 service wire, short terminals +B and FP of the check connector. LOCATION: See page FI-89 Gm) Connect SST (wire) to the injector and battery for 15, seconds, and measure the injection volume with @ graduated cylinder. Test each injector two or three times. ‘SST 09842-30060 (w/o Air flow meter) (09842-30070 (w/ Air flow meter) Volume: w/o Air flow meter 4a — 49 cc (2.7 ~ 3.0 cu in) per 18 sec. w/ Air flow mets 48 — 53 cc (2.9 ~ 3.2 cu in) per 16 sec. Difference between each injector 5 ce (0.3 cu in) or loss If the injection volume is not as specified, replace the injector.F-80 EFI SYSTEM ~ Fuel System 2. INSPECT LEAKAGE [a) In the condition above, disconnect the test probes of SST (wire) from the battery end check the fuel leakage from the injector. ‘SST 09842-30060 (w/o Air flow meter! 09842-30070 (w/ Air flow moter Fuel drop: One drop or less per minute. T (b) Disconnect the battery negative (=) cable (c)_ Remove SST and the service wire, SST 09268-41045 O-Ring | INSTALLATION OF INJECTORS 1. INSTALL INJECTORS AND DELIVERY PIPE (2) Install a new grommet to the injector. Ir (} Apply a tight coat of gasoline to a new O-ring and We instal it to the injector. Grommet (€)_ While turning the injector left and right, install it to in ri ofng CORRECT the dolivery pipe. Install the four injactors. ine > Th (@) Place the four insulators and three spacers in position fon the cylinder head, (@) Place the injectors together with the delivery pipe in position on the cylinder head. f) Check that the injectors rotate smoothly. NOTE: If injectors do not rotate smoothly, the probable couse is incorrect installation of O-rings. Replace the O- ringsEFI SYSTEM — Fuel System Fi-81 {g) Install and torque the three bolts. Torque: 176 kg-cm (13 ft-lb, 17 Nem} INSTALL FUEL INLET PIPE Install 2 new gasket, the inlet pipe and a new gasket with the union and mount bolts. Torque: 300 kg-em (22 ft-lb, 29 Nem) CONNECT FUEL RETURN HOSE CONNECT INJECTOR CONNECTORS CONNECT VACUUM SENSING HOSE INSTALL COLD START INJECTOR PIPE (See step 2 and 3 on page FI-74) 7. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 8. CHECK FOR FUEL LEAKAGE (See page Fi-9)Fi82 EFI SYSTEM — Air Induction System AIR INDUCTION SYSTEM Air Flow Meter (w/ Air Flow Meter} POTENTIOMETER MPENSATION Piate eae m To AIR « a INTAKE Return Spring NF cnaicen an Tom. / > » Sensor ain CLEANER ~t SIDE Measuring Air By-pass Passage FROM E R Piste — IntaKe, tahoe Measurng Plate | CHAMBER ‘Ac By-pass Passage SIDE yset ead Compensation Plate E1Fce2 vevevs Wa THA ' reetea Fa on =q-- = ON-VEHICLE INSPECTION INSPECT RESISTANCE OF AIR FLOW METER (a) Disconnect the air flow met (6) Using an ohmmeter, measure the resistance between each terminal connector. 40 (104) 60 (140), Whe resistance is not as specified, replace the air low meter. ()_ Reconnect the air flow meter connector. REMOVAL OF AIR FLOW METER 1, DISCONNECT AIR FLOW METER CONNECTOR 2. DISCONNECT AIR CLEANER HOSE 3. REMOVE AIR FLOW METEREFI SYSTEM. Fo Sooo oeom vs INSPECTION OF AIR FLOW METER INSPECT RESISTANCE OF AIR FLOW METER Using an ohmmeter, measure the resistance between each termi I by moving the measuring plate. Measuring Plate Berween Fo-et vs -€2 sistance | Messurng plate Re opening Infinity iy olosed Other than ° closed position 20— 400, Fully closed 20 - 3,000 Fully open NOTE: Resistance between E2 and Vs will change in @ wave pattern as the measuring plate slowly opens. Hf the resistence is not as specified, replace the meter. INSTALLATION OF AIR FLOW METER 1. INSTALL AIR FLOW METER 2. CONNECT AIR CLEANER HOSE 3. CONNECT AIR FLOW METER CONNECTOREFI SYSTEM — Air Induction System Throttle Body “Throttle Position Sensor ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY (2) Check that the throttle linkage moves smoothly, lb) Check the vacuum at N port © Start the engine. © Check the vacuum with your finger. 2. INSPECT THROTTLE POSITION SENSOR (@) Disconnect the sensor connector. (b) Insert a fecler gauge between the throttle stop screw and stop lever. () Using an ohmmeter, measure the resistance between each terminalEFI SYSTEM — Air Induction System F186 je 4 we vTa vec Gearance between | ay teverond step sceow | F208 | stance cv ° oo via = & | 300~ @00 036 014) | wl = E2 | 2.900 ores 0890023) | DL =e? | nay rote vate fl : VIA =€2 | 2:00 10, ‘opened position 0,000) 7 No Clesrance ‘Trrotie Stop Serow = veo | 3000 7000 (d) Reconnect the sensor connector. REMOVAL OF THROTTLE BODY 1. DRAIN ENGINE COOLANT 2 (am DISCONNECT THROTTLE CABLE FROM THROTTLE LINKAGE 3. DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE 4, DISCONNECT AIR CLEANER HOSE 5. DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 6. REMOVE THROTTLE BODY {a} Disconnect the following hoses: © PCV hose © Water hoses © Air hose © Emission control vacuum hoses (b) Remove the two bolts, two nuts, throttle bedy and gasket. 7. IF NECESSARY, REMOVE AIR VALVE FROM THROTTLE BODY (See step 2 on page FI-87) INSPECTION OF THROTTLE BODY 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cl cast parts, (b) Using compressed apertures. CAUTION: To prevent deterioration, do not clean the throttle position sensor. sner, clean the clean all the passages and 2. INSPECT THROTTLE VALVE Check that there is no clearance between the throttle stop ‘Screw and throttle lever when the throttle valve is fully closed.EFI SYSTEM — Air Induction System (0.47 mm Feeler Gauge a 3, INSPECT THROTTLE POSITION SENSOR (See step 2 on page FI-84) 4, IF NECESSARY, ADJUST THROTTLE POSITION SENSOR {a} Loosen the two mount screws of the sensor. lb) Insert 9 0.47 mm (0.019 in) feeler gauge, between the throttle stop screw and stop lever. (c) Connect the test probe of an ohmmeter tothe te- rminals IDL ond E2 of the sensor. (@) Gradually turn the sensor clockwise until the ohm. meter deflects, and secure it with the two screws fe} Recheck the continuity between terminals IDL and 0.35 men or 058 am & ‘Gouge og £2, Clearance berween 7 lever and stop screw Continuity YOL ~ £2) mn 6) 036 0.018) Continuity 059 (0.023) No continuity INSTALLATION OF THROTTLE BODY 1. INSTALL AIR VALVE TO THROTTLE BODY (See step 1 on page FI-88) 2. INSTALL THROTTLE BODY (} Install a new gasket and the throttle body with te two bolts and two nuts Torque: 220 kg-cm (16 ft-lb, 22 N-m) (©) Connect the following hoses: © PCV hose © Water hoses: Air hose ‘© Emission control vacuum hoses 3. CONNECT THROTTLE POSITION SENSOR CONNECTOR 4. CONNECT AIR CLEANER HOSE 6. CONNECT ACCELERATOR CABLE TO THROTTLE LINKAGE 6 AM CONNECT THROTTLE CABLE TO THROTTLE LINKAGE 7. FILL WITH ENGINE COOLANT (See page CO-3 or 5)EFI SYSTEM — Air Induction System Auxiliary Air Valve | Idle Speed Adjusting Screw | Throttle Body ce Sal FROM , An cueaner T™ Auxiliary Air Valve \ ‘Ausiiary Ar Valve Coolant fui Air Flow Meter ON-VEHICLE INSPECTION Se Ne SPX INSPECT AIR VALVE OPERATION (wla Air Flow eto) te) Remove theo cleaner hose (b) Check the engine rpm by closing the air port on the tattle bed, At low temp. (Coolant temp.: below 80°C (176°F)) © Tho engine RPM shou drop. After warerup © Check hat engine RPM doesnot drop more than 00pm. Wf operations not as specie, replace the ave (wi Ale Flow Meter {eck te engine om by fly screwing inthe ile speed sctosting eee Atiow temp. (Coolant temp. below 80°C (176°) wen the le apens acting sere in, the tnaine rom shoul tnd 09 ter warm-up ‘¢Whon th ile speed adhsting sew it in the beget thou drop bolow ido speed dua stop If operation is not as specified, replace the air valve. REMOVAL OF AIR VALVE 1, REMOVE THROTTLE BODY (See steps 1 to 6 on page FI-85) 2. REMOVE AIR VALVE FROM THROTTLE BODY Remove the five screws, air valve, gasket and O-ringFLe8 EFI SYSTEM — Air Induction System INSTALLATION OF AIR VALVE 1. INSTALL AIR VALVE TO THROTTLE BODY (2) Place new gasket and O-ring on the throttle body. (0) Install the air valve with the five screws, 2, INSTALL THROTTLE BODY (See steps 2 to 8 on page FI-86)Electronic Control System Fi-89 ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts Solenoid Resistor (CHO w/o Ar Flow Moter Fuol Pressure VSV (Europe) Vacuum Sensor \w/o Air Flow Meter) cu cold Start Circuit Opening Relay Injector - Solenoid Resistor ‘Teme Switch BHD wio Arr Flow Meter) ‘Check Connector = Variable Resistor (wo Air Flow Moter) ALL Proce / Intake Air Tomo. Sensor {wie Air Flow Meter! EFI Main Reloy : — Vacuum Sensor ‘Oxygan’ Sensor a (w/o Air Flow Meter) w! Two) Cold Start Injector Water Temp. Sensor lote-up vsv. Oxygen Sensor (w! TWO) Intake Air Temp. Sensor (w/o Air Flow Meter) iar) Water Tom Sensor Relay ~Solonoid Resistor (w/o Air Flow Meter) Variable Resistor (w/o At Flow Meter) Me ‘Vacuum Sensor ws, C We Bean bisetor cow Suter Crt Ovaing Relay mise geen ‘Oxygen Sensor (wl Two)F180 EFI SYSTEM — Electronic Contro! System EFI Main Relay EFI Main Relay ECU Fuse. EFI 158 7A (aT) INSPECTION OF EFI MAIN RELAY (AE) 1. INSPECT RELAY CONTINUITY la) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 ond 4, continuity is not as specified, replace the relay. 2. INSPECT RELAY OPERATION (a) Apply battery voltage across terminals 1 and 2. {0} Using an ohmmeter, check that there is continuity between terminals 3 and 4. Hf operation is not as specified, replace the relay. INSPECTION OF EFI MAIN RELAY (AT and AW) (See procedure No.3 Cooling Fan Relay on page CO-32)EFI SYSTE! To To ignition Switch (ST1) (Others) M. tronic Control Sys Circuit Opening Relay Starter Relay (AW) ‘Check D Connector} | Fe To ECU (STA) TOFCU I+8) [ ae] TOF Mam Reta | oo +8 To ECU fFC} FF Gi (wio Air Flow Meter) Fuel Pump Switch (a Cirouit Opening Relay Fe ir Flow Meter L INSPECTION OF CIRCUIT OPENING RELAY (AE w/o Air Flow Meter, AT and AW) 1. INSPECT RELAY CONTINUITY (2) Using an ohmmeter, check that there is continuity, between terminals STA and E1. (©) Check that there is continuity between terminals 8 and FC (€) Check that there is no continuity between terminals 8 and FP. If continuity is not as specified, replace the relay. 2. INSPECT RELAY OPERATION (6) Apply battery voltage across terminals STA and ET () Using an ohmmeter, check that there is continuity between terminals 8 and FP. (2) Apply battery voltage across terminals B and FC. (d} Check that there is continuity between terminals 8 and FP. Mf operetion is not as specified, replace the relay.FL92 EFI SYSTEM — Electronic Control System Continuity INSPECTION OF CIRCUIT OPENING RELAY (AE w/ Air Flow Meter) 1, INSPECT RELAY CONTINUITY No continuity ay Using an ohmmeter, check that there is continuity between terminals STA and E1 tb) Chock that there is continuity between terminals 8 and FC (el Check that there is no continuity between termir and FP. ~ Hf continuity is not continu 5B 8 specifi |, replace the relay, 2. INSPECT RELAY OPERATION (2) Apply battery voltage across terminals STA and E1 () Using an ohmmeter, check that there is continuity between terminals B and FP. () Apply battery voltage across terminals B end FC. () Check that there is continuity between terminals B ‘ond FP. UV operation is not as speci 1d, replac he cola. Continuity LalEFI SYSTEM — Electronic Control System FL93 Solenoid Resistor and Injector Relay 7E (w/o Air Flow Mi jeter) and AT (w/o Air Flow Meter) Ignition Switch ama] 32 FE] Solenoid Resistor E&Y 6 fusible No. 20) No. 10 tin AN? 308 Injector a -——8 ecu Ignition Switch | | AMaf— 62 Fuse vg TSR jc 11258 Reley ‘AW (w/ Air Flow Meter) Fuse aM Fusible 7.5A Linke 1288 [eatery ——— ecu, Ignition Switch alas } Injector Rely ctorEFI SYSTEM — Electronic Control System INSPECTION OF SOLENOID RESISTOR (w/o Air Flow Meter) INSPECT SOLENOID RESISTOR RESISTANCE Using an chmmeter, measure the resistance between ter minal 8 and other terminals (No.10, No.20), Resistance: 2~3 2 each If the resistance is not as specifi replace the resistor, a No. 10 +8 No.20 INSPECTION OF INJECTOR RELAY (AW) (See procedure No.3 Cooling Fan Relay on page CO-32)EFI SYSTEM — Electronic Control System FL-05 Cold Start Injector Time Switch To ignition Switch (ST1) (AE and ATI To Starter Relay (AW) To ECU (STAD "ole Start injector Tene Switch INSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT COLD START INJECTOR TIME SWITCH Using an chmmeter, measure the resistance between each terminal Resistance: STA-STJ 20 ~ 40 © below 30°C (36°F) 40 — 60 1 above 40°C (104°F) STA-Ground 20-800 if the resistance is not as specified, replace the switchF986 EFI SYSTEM — Electronic Control System Water Temperature Sensor 40) 20 19) WATER TEMP. SENSOR . 3 gai 2 2 Bo Boa # o8| oa] Thermistor 02 4066-80 100 130 5 (San BBnGandtontronstauss TEMPERATURE °C (°F INSPECTION OF WATER TEMPERATURE SENSOR INSPECT WATER TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals, Resistance: Ret If the resistance is not as specified, replace the sensor. iro 10 chart,EFI SYSTEM Electronic Control System 7 Vacuum Sensor (w/o Air Flow Meter) (Ma ‘old Absolute Pressure Sensor) vacuum “Chamber ecu Vacuum Sensor Manitold Absolute Pressure Sensor) 2 int vee 1. Vacuum INSPECTION OF VACUUM SENSOR INSPECT POWER SOURCE VOLTAGE OF VACUUM ‘SENSOR (a) Disconnect the vacuum sensor connector. (b) Turn the ignition switch ON. (6) Using a voltmeter, measure the voltage between ter- minals VCC and £2 of the vacuum sensor connector. Voltage: 4-6 V INSPECT POWER OUTPUT OF VACUUM SENSOR {2} Tum the ignition switch ON ) fonnect the vacuum hose of the intake chamber side. (e) Connect a voltmeter to terminals PIM and E2 of the ECU, and measure and record the output voltege under ambient etmospheric pressure. (d) Apply vacuum to the vacuum sensor in 100 mmHg (3.94 inHg, 13.3 kPa) segments to 500 mmHg (19.69 intig, 66.7 kPa) {6} Measure voltage drop from step (c) above for each segment. Voltage drop Applied T vaewm | 100 | 200 | 300 | 400 | S00 mmbg | 394) /7.87)]/11.81) 15.75)) 1968 (ta) (1397 |'267?|(400/|\s3)) 667 kPa voltage drop ¥ 1 (03-08 07-09] 1-1.) 18-17 18-24EFI SYSTEM — Electronic Control System Variable Resistor (w/o Air Flow Meter) Variable Resistor veo var 2 INSPECTION OF VARIABLE RESISTOR ecu 1, INSPECT VOLTAGE OF VARIABLE RESISTOR (a) Using a voltmeter, measure the voltage between ECU terminals VCC and E2 Voltage; 4-6V (b} Measure the voltage between ECU terminals VAF ang 2 while slowly turning idle mixture adjusting screw first fully counterciockwise, and then fully clockwise {e) Check that the voltage changes smoothly from 0 V to approx. 5 VEFI SYSTEM — Electronic Control System Fi INSPECT RESISTANCE OF VARIABLE RESISTOR (a) Disconnect the variable resistor connector. (b} Using an ohmmeter, measure the resistance between the terminals VEC and E2 Resistance: 4-6 kn. (c) Turn the idle mixture adjusting screw fully coun- terclockwise. {) Connect an chmmeter to terminals VAF and £2 Turn the adjusting screw fully clockwise end check that the resistance value changes from approx. 5 k 2 10.0 & accordinglyL100 EFI SYSTEM — Electronic Control System Intake Air Temperature Sensor (w/o Air Flow Meter) INTAKE AIR TEMP, SENSOR RESISTANCE KO? = ‘Thermistor 309-9080 8010-120 (4) (62) (8)(104K140K1 76X2 124248) TEMPERATURE °C (*F) reser INSPECTION OF INTAKE AIR TEMPERATURE SENSOR INSPECT RESISTANCE OF INTAKE AIR TEMPERATURE SENSOR Using an ohmmeter, measure the resistance betweon the terminals, Resistance: Refer to chart If the resistance is not as specified, replace the sensor,(check Connector VF Warm up the oxygen sencor with the engine at 2,500] ‘pm for approx. 90 seconds. ‘Short terminals T and €7 of the check connector, ‘And maintain engine speed at 2,500 rpm 1 System Oxygen Sensor (w/ TWC) INSPECTION OF OXYGEN SENSOR 1. WARM UP ENGINE ‘Allow the engine to reach normal operating temperature 2, INSPECT FEEDBACK VOLTAGE (VFI Connect the positive (*#) probe of a voltmeter to terminal robe to ter- Of the check connector, and negative minal £1. Perform the test es follows: Foplace the ECU. Zero ogoin! After replacing [the oxygen sensor F101 (Check the number of times the voltmeter needle fluctuates in 10 seconds Loss then 8 times ‘Warm up the oxygen sensor with the engine at 2.500] ‘pm for approx. 80 seconds. And maintain engine at 2,500 rom, (Check the number of times the voltmeter needle fluctuates in 10 seconds. Loss thon 8 ti 8 times or mot [Biimes ormora | Unshort terminals T and ET of the check connector And maintain engine speed at 2,500 tam Measure voltage Treen foneials VF and EY [ow R relevant diagnostic code @ ® CONTINUED ON PAGE FI-102 Zero02 EFI SYSTEM lectronic Control System CONTINUED FROM PAGE FI-101 ® = @® Repair the relevant diagnostic code Mtfunction cadets) [B+ cose 21) | Reed and record diagnostic codes. (See page Fi-26) i Normal code’ and cove 21 | | ‘Unshort terminals T and €1 of the check connector. ‘Ang maintain engine at 2,500 rom ‘Measure voltage between terminals VF and ET lov BV —b + Disconnect the PCV hose, “Measure voltage between terminals VF and E71 ‘More than OV Disconnect the wator temp. sensor connector and connect resistor with a resistance of 4 — 8 KGL or another coded water temp. sensor. ‘Short terminals T and E1 of the check connector. Warm up the oxygen sensor with the engine at 2.500 «pm for approx. 930 seconds. And maintain engine speed at 2,500 rpm. | Measure voltage betwoen terminsls VF and ET lov sv —-Replace the onygen sensor ) (Repair (ver team){FI SYSTEM. sctronic Control System FI-103 INSPECT HEATER COIL RESISTANCE OF OXYGEN SENSOR Using an ohmmeter, measure the resistance between the torminals +B and HT. Resistance: 5.1- 6.3.2 the resistance is not as specified, replace the sensor.F104 EFI SYSTEM — Electronic Control System, Electronic Controlled Unit (ECU) INSPECTION OF ECU NOTE: The EFi circuit can be checked by measuring the resistance and voltage at the wiring connectors of the ECU, 1. INSPECT VOLTAGE OF ECU Check the voltage between each terminal of the wiring connectors. © Turn the ignition switch ON. ‘© Measure the voltage at each terminal NOTE: ‘© Perform all voltage measurements with the connector. ‘connected. ‘© Vority that the battery voltage is 11 V or more when the Ignition switch is ON. Voltage at ECU Wiring Connectors (TCCS ECU w/o Air Flow Meter) Condon “Ts vote] So-e lnton Sw OX i BATT — Et - - 10-14 io Tht valve pen as—55 Thott ave fly coed G8 cies WTA ~ 2 ‘ontion Siw ON Throttle valve fully open 35-55 = 45-55 - Cranking or idling 07-10 coming oni | No. 10 _ cor fo 30 _ Fat lption SW ON wre No trouble (Check engine warning light off) and engine running 9-14 Pim ~ €2 33-39 Ignition S/W ON vec = 2 45-55 THA - €2 Intake air temp. 20°C (68°F) [20-28 THW — £2, Coolant tamp. 80°C (176°F 04-08 AC —€1 | Ignition S/W ON _Ait conditioning ON ees) Check connector T ~ £1 not shor 45-55 Toe re—ee oer Check connector T — £1 short 0.5 oF less ‘aing o-3 STH -e1 7 ‘Approx. §,000 rpm or more 10-14EFI SYSTEM — Electronic Control System F1-105 Voltage at ECU Wiring Connectors {TCCS ECU w/ Air Flow Meter) Terie Conaion B10 vonage Boe ‘ion WON 10-14 BATT - ET = ~ 10-14 ‘OL =e Tht vave open 1o=8 Trt vt uy sel as eres via =2 | taivon sow : . vote valve fal open 36-68 vec 2 = a5-58 AGT - E1 Cranking or idling 07-10 sane renting en te 19 cor ition SW ON ent8 w - et No trouble (Check engine warming light off) and engine running "9-14 [" 2 - 51-108 laiton SW on Teasing ise Fly Sond 25-54 woe Messi Bate fal open e288 ‘ai 38-88 twa vate av np 206 BA 2-28 hw =e Coot we. 80°C A7OF oa 07 wena fir contoring ON so 18 lniton SW OW Check comectarT ~ Et not shor tot rat ‘Check connector T - E1 short 0.5 or less —| Falcone! SW NORMAL vo-14 | weet Fuel control S/W SUPER 05 oF less weoa b tava o-8 ooo £380 rpm or more 10-4 ECU Terminals 2 [ ox [vee106, EFI SYSTEM — Electronic Control System INSPECT RESISTANCE OF ECU CAUTION: © Do not touch the ECU terminals. ‘© The tester probe should be inserted into the wiring connector from the wiring si Check the resistance between each terminal of the wiring connectors. ® Disconnect the connectors from the ECU. © Measure the resistance at each terminal Resistance of ECU Wiring Connectors (TCCS ECU w/o Air Flow Meter) Terminals Condition Resistance (0) | poe Thweitle valve open [laity “Thiottle valve fully elosed 2,300 or less via ee Lo “Throttle valve fully open _ {3800 — 10.000 “Throttle valve fully closed 200 ~ 800 “vec - 2 7 13,000 - 7.000 THA = €2 Intake air tormp. 20°C (68°F) - 2,000 ~ 3,000 THW = £2 Coolant temp. 80°C (176°F) [200 = 400 e-69 - = 140 - 180 “we-colo™~—CSCOOCOCSTC‘“‘C™‘CS;SCO#NAO= 180 ECU Terminals coi "3 [sr] [esEFI SYSTEM — Electronic Control System F107 Resistance of ECU Wiring Connectors {TCCS ECU w/ Air Flow Meter) ECU Terminals Termin Coin Fess we = Tea va und 2300 ee Thott a nen 3.300 - 10.009 VTA - E2 = Tova ay lve 200 = 00 were : 3.000 = 7.000 Tres ite arcade vs ~ £2 ___Messuring plate fuly closed sing te ty oan 20 = 3000 a = 700 300 Tae vie sir 20 18 Bia00~ 009 iw = 2 coo one 00% 076" + 300= 400 oo - om 1 wos = 140 10EFI SYSTEM — Electronic Control System_ RPM Fuel Cut RPM INSPECTION OF FUEL CUT RPM. WARM UP ENGINE Allow the engine to reach normal operating ternperatue. INSPECT FUEL CUT RPM. (2) Disconnect the connector from the throttle position {o) Short terminals IDL and £2 of the wiring connector. 0) Gradually raise the engine rpm and check that there is fluctuation between the fuel cut and fuel retum points NOTE: The vehicle should be stopped. Fuel cut rpm: w/o Air flow meter 1,800 rpm w/ Air flow meter 1.400 rpm M/T (idle-up VSV OFF) 1,600 rpm M/T (idto-up VSV ON) 41.600 rpm A/T Fuel return rpm: w/o Air Flow Meter 1,400 rm w/ Air Flow Meter 1,200 rpmEFI SYSTEM — Electronic Control System, High-temperature Line Pressure up System (Europe) To Circuit Opening Relay To EFI Main Relay ‘Continuity Fuel Prossure VSV fear} Water Temp. Sensor INSPECTION OF HIGH-TEMPERATURE LINE PRESSURE UP SYSTEM 1, INSPECT WATER TEMPERATURE SENSOR (See page FI-96) INSPECT FUEL PRESSURE VSV ‘A. Inspect VSV for open Using an ohmmeter, check that there is continuity be- tween the terminals Resistance (Cold): 33 - 39 0 If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity be- ‘ween each terminal and the body. If there is continuity, replace the VSV.F110 EFI SYSTEM — Electronic Control System ©. Inspect VSV oper (a) Check that air does not flow from pipe E to pipe F ion (b} Apply battery voltage across the terminals. (c) Check that air flows from pipe E to the filter. f operation is not as specified, replace the VSV.EFI SYSTEM — Electronic Control System Fan Idle-up System Idle-up vsv To tgnition Switch (AE ang AT) To Starter Relay aw Voltmeter | Continuity Ohmmeter INSPECTION OF IDLE-UP SYSTEM 1, INSPECT BATTERY VOLTAGE OF IDLE-UP VSV (a) All accessories switched off. (b) Using a voltmeter, check that it indicates battery voltage during cranking and for ten seconds after starting 2. INSPECT IDLE-UP VSV ‘A. Inspect VSV for open circult Using an ohmmeter, check that there is continuity be- tween the terminals Resistance (Cold): 37-44 0 If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity be- tween each terminal and the body. 1K there is continuity, replace the VSV.FL2, EFI SYSTEM — Floctroni¢ Control System f" No Air 4 oF ZG fy ( Se Inspect VSV operation {2} Check that sir flows from pipe E to pipe F. {b) Apply battery voltage across the terminals. fc) Check that air flows from pipe E to pipe F. f operation is not as specified, replace the VSV.2AL_— Troubleshooting (4A-GE) $$ SRE MECHANICAL = Troubleshooting (4A-GE)_ M14. TROUBLESHOOTING (4A-GE) ENGINE OVERHEATING Possible or Remedy Poge Cooling system faulty Troubleshoot coating system | CO-5 laconect ignition timing Reset timing ©M.37 HARD STARTING Problem Possible cause Remedy Page Engine will not erank | Starting system faulty Troubleshoot starting system | ST-2 for cranks slowhy Engine will ot star’ | No fuel supply to injsctor ‘Troubleshoot EFI system FLO hare to stort No fuel in tank lerank OK) © Fuel pump not working Fuel fine clogged or leaking | EFl system problems Repair es necesssry Ignition problems Perform spark test |icrs © Ignition coi Igniter © Distributor Spark plug faulty Inspect plugs 16-20, 21 High-tension cord disconnected or Inspect eords 16-20 broken Vacuum leaks Ropar as necessary Pov EGR line (w/ EGR system) Intake manitois (Air intake chamber) Intake air control valve Throttle body © Brake booster line Puling i air between air flow meter | Repair es necessary ‘and throttle body Low compression Check compression em.a7 ROUGH IDLING Problem Possible cause Remedy Rough ide, salls or | Spark phag faulty Inspect plugs 16-20, 21 misses High-tension cord faulty Inspect cords 16-20 Igaition wiring faulty pect wiring Ignition problems © ignition col Inspect coil © lgniter Inspect igniter © Distributor Inspect distributor Incotre’ igition timing Reset timing M37 Incorrect valve clearance Adjust valve clearance £M.25EM.A2 ENGINE MECHANICAL — Troubleshooting (4A-GE) ROUGH IDLING (Cont'd) Problem Possible cause Remedy Page ‘Rough ile, sts or | Vseuur lasks Repair necessary rmisses (Cont'd) © PCV line 18 EGA line fw EGR system) 1 take manifold © Aicintoke chamber Untake air control valve) © Throttle body © Brake booster tine Puling in air etweon air low meter Repair as necessary and throttle body Incorrect idle speed Adjust ile speed ew-39, 42 EFI system problems. Repair 08 necessary GR valve faulty (Check EGR valve Engine overheats ‘check cooling systom cos Low compression |_ Cheek comoreston eM.a7 ENGINE HESITATES/POOR ACCELERATION Problem Possible couse Remedy Page Engine hestotos/ ‘Spark plug faulty Inspect plugs 16-20, 21 poor acceleration tHign-tension cotd fouty Inspect cords 1-20 vacuum leaks Ropair as necessary © PCV line © EGR line 1 lotake manifold (Ar intake chamber) |© lotake sr contro valve '¢ Throtto body (© Brake booster line Puting in ar between airflow as necessary ‘meter and throttle body Incomect ignition tiring Reset timing M37 Incorrect valve clearance ‘Adjust valve clearance EM.35 Fuel system clogged ‘Check fuel system ‘ir cleaner clogged ‘Check air cleaner eM.34 EFI system problems Repair as necessary Engine overheats ‘Check cooling systern cos Low compression ‘check compression ema?ENGINE MECHANICAL — Troubleshooting (4A-GE) ENGINE DIESELING Problem Possible couse Remedy Page Engine cessing EF system problems Repair ae necessary {tums wnen priton | incorec gion ting a0 tii : ‘switch is tumed off] ‘sr o Reset tem) EMST EGR syst faulty (w/ EGR system! | Check EGR system AFTER FIRE, BACKFIRE Problem Possible cause Remedy Page Mutter explosion | Ovceeration fus!eut system aiwoys oft | Check EFI (uel eu system {fatter fire! on DP system always: ‘Check DP system deceleration only " = . Mutter exsiosion | Air cnaner clogged Check ar cleaner e.g {after fire! all the time | er system problem. Repair as necessary Incorrect fnition timing Reset ming ema Incorrect valve clearence ‘Agust valve clearance FM.35 Engine backfires EF eystem problem Repair ae necessary Vacuum tak Check hoses and repo as | * PCV noses © intake manifold tai intake chembed | take air contol valve © Throte body © brake booster ine Putin in aie between ai tow meter | Repair as necessary and trol body Insuticient fue flow Troubleshoot fue system Incorrect ignition timing Reset timing ems? Incorrect valve clesronce Adjust valve clearance M36 Carbon deposits in combustion Inspect evince head ewei0s chambers EXCESSIVE OIL CONSUMPTION Problem Possible cause Remedy | Exces8ve ol 1 tak Repair as necessary consumption PCV line clogged Check PCV system Paton ring worn oF damaged Check Hg ewa7 Vetve stem and guide busing worn | Chock valves and guide eM-107 burnings Valve stem ci sa! worn or damages | Check Ot sealsEM14. ENGINE MECHANICAL ‘Troublesho: EM14_______ENGINE MECHANICAL — Troubleshooting (@A-GE)___ EXCESSIVE FUEL CONSUMPTION Vacuum leaks © PCV ine 1 EGR line (w/ EGR system) 1 tntake manifold (Ae intake chamben) 1 lotake control valve 18 Thvotte body 1 Brake booster ine EFI system problems Problem Possible cause Remedy Page Poor gasoline milsage ) Fuel Weak Repair as necessary Air cleaner clogged ‘check si cleaner ema Incorrect igition timing Reset timing [M37 EFL system problems Repair 2s necessary 1 injector faulty 1 Deceteration fucl cut system faulty Idle speed to high ‘Adjust idle speed ew.39, 42 ‘Spark plug faulty Inspect plugs 16-20, 21 EGR systom always on Check EGR system Low compression Check compression em.a7 Tiees improperty inflated Inflate tes to proper prossure ‘Clutch slips Troubleshoot elutch Brakes drag |_Trosbisnoot brakes UNPLEASANT ODOR Problem Possible cause Remedy Page Unplessant odor Incorrect idle speed ‘Adjust ile speed em.39, 42] Incerreet ignition timing Reset timing M37 Repair as necessary Reptir as necessaryEM.34 ENGINE MECHANICAL — Engine Tune-up (4A-GE} ENGINE TUNE-UP (4A-GE) INSPECTION OF ENGINE COOLANT {See stops 1 and 2 page CO-6) INSPECTION OF ENGINE OIL (See steps 1 and 2 on page LU-5) INSPECTION OF BATTERY (See stops 1 and 2 page CHA) ‘Standard specific gravity: "1.25 — 1.27 when fully charged at 20°C (68°F) Tye INSPECTION OF AIR FILTER 1. INSPECT AIR FILTER Visually check that the element is not excessively dirty damage or oily: 2. CLEAN AIR FILTER Clean the element with compressed air. First blow from the back thoroughly. Then blow off the front of the element, INSPECTION OF HIGH-TENSION CORDS Correct electrode gap: 1.1 mm (0.043 in) Recommended spark plugs: ND Q20R-U11 NGK BCPREY11 Platinum Tipped Type (See page 10-21) ‘Maximum electrode gap: 1.3 mm (0.051 in! Correct electrode gap of new plu 1.1mm (0.043 in) Recommended spark plugs: ND Pater NGK BCPREEPI1 INSPECTION OF ALTERNATOR DRIVE BELT (See step 3 page CH-4) Drive belt deflection: ‘New belt 4 — 5 mm (0.16 ~ 0.20 in) Used bolt 6 ~ 7 mm (0.24 ~ 0.28 in} Drive belt tension (Reference) New belt 70 ~ 80 kg Used belt 30 — 45 kgENGINE MECHANICAL — Engine Tune-up (4A-GE) EM-35 ADJUSTMENT OF VALVE CLEARANCE NOTE: Adjust the valve clearance while the engine is cols. 1. REMOVE CYLINDER HEAD COVER (See page EM-102) SET NO.1 CYLINDER TO TDC/COMPRESSION (2) Tum the crankshaft pulley and align its groove with the timing mark “0” of the No.1 timing belt cover (AE or AT) or timing pointer (AW). (b) Chock that the valve lifters on the No.1 cylinder are loose and vaive lifters on the No.4 are tight. If not, turn the crankshaft one revolution (360°) and align ‘the mark as above. ADJUST VALVE CLEARANCE () Check only those valves indicated as shown, © Using a feeler gauge, measure the clearance bet- woon the value lifter and camshaft '© Record the valve clearance maasurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): oss) Intake 0.16 — 0.25 mm (0,006 — 0.010 in.) Exhaust 0.20 ~ 0.30 mm (0.008 — 0.012 in} (0) Tum the crankshaft one revolution (380°) end align the mark as above, (See procedure step 2) (c) Check only the valves indicated as shown, Measure the valve clearance, (See procedure step (a) () Remove the adjusting shim, ‘© Turn the crankshaft to position the cam love of the camshaft on the adjusting valve upward © Using SST (A), press down the valve lifter and place SST (8) between the camshaft and valve lifter. Remove SST (A) SST 09248-55010 NOTE: Before pressing down the valve lifter, position the notch toward the spark plug.EM.36 ENGINE MECHANICAL — Engine Tune-up {4A-GED ‘@ Remove the adjusting shim with @ small screwdriver and magnetic finger. (e) Determine the replacement adjusting shim size following Formula or Charts: © Using a micrometer. measure the thickness of the shim which was removed, © Calculate the thickness of @ new shim so the valve clearance comes within specified value T cscs Thickness of used shim A... Measured valve clearance N11) Thickness of new shim Intake N= T+ (A — 0.20 mm (0.008 in.) Exhaust N= T+ (A 0.25 mm (0.010 in.) Select @ new shim with a thickness as close as possible to the calculated values. NOTE: Shims aro available in seventeen sizes of 0.05 imam (0.0020 in}, from 2.50 mm (0.0984 in} to 3.30 mm (0.1299 in). (Install @ new adjusting shim. © Place a new agjusting shim on the valve iter. © Using SST (A), press down the valve lifter and remove SST Gi. ‘SST 09248-55010 (@)_ Recheck the valve clearance. REINSTALL CYLINDER HEAD COVER (See page EM-1211 Adjusting Shim Selection Using Chart (See pagk EM-19 and 20)ENGINE MECHANICAL — Engine Tune-up (4A-GE) EM-37 ADJUSTMENT OF IGNITION TIMING 1. WARM UP ENGINE Allow the engine {0 reach normal operating temperature. 2. CONNECT TACHOMETER (AE, AT and AW) Connect the test probe of a tachomet the check connector LOCATION: See page FI-89 Check Connector to terminal IG= of, eference (AT and AW) Connect the test probe of a tachometer to the negative (61 terminal of the ignition coil ‘CAUTION: © NEVER allow the tachometer terminal to touch ‘ground as it could result in damage to the igniter and/or ignition coi me tachometers are not compatible with this |. we recommend that you confirm ity of your until before using. [Reference (AT and AW! sx 3. SHORT TERMINALS T AND E1 Using a service wire, short termi connector. LOCATION: See page FI-89 Check Connector Is T and E1 of the check - 4. ADJUST IGNITION TIMING la) Using a timing light, check the ignition timing, Ignition ti 10° BTDC @ idle {} Loosen the two hold-down bolts, and adjust by tuen- ing the DISTRIBUTOR. (c) Tighten the hold-cown bolts, and recheck the igni- tion timing, Torque: 200 kg-cm (14 ft-lb, 20 Nem)M38 ENGINE MECHANICAL — Engine Tune-up (4A-GE) 5, UNSHORT TERMINALS T AND Et Remove the service wire from the check connector. 6. FURTHER CHECK IGNITION TIMING Ignition timing: 16° BTDC or more @ idleENGINE MECHANICAL — Engine Tune-up (4A-GE) EM-329 ADJUSTMENT OF IDLE SPEED (w/ TWC) 1. INTIAL CONDITIONS (2) Engine at reach normal operating temperature (©) Air cleaner installed (c) All pipes and hoses of sir induction system con- nocted (2) All vacuum lines connected NOTE: All vacuum hoses for EGR systems, ete. should bbe properly connected. (el EFI system wiring connectors fully plugged (Ignition timing set correctly @) All accessories switched OFF (h) Transmission in “N” range START ENGINE CONNECT TACHOMETER (See page EM-37) CHECK AIR VALVE OPERATION (See page FI-87) 5. ADJUST IDLE SPEED (a) Race the engine at 2.500 rpm for a few seconds. (b} Check the idle speed, Idle speed: 800 rpm (w/ Cooling fan OFF) (c) Adjust the idle speed by turning the IDLE SPEED ADJUSTING SCREW,EM-40 ENGINE MECHANICAL — Engine Tune-up (4A-GE) IDLE HC/CO CONCENTRATION CHECK METHOD (w/ TWC} NOTE: This check is used only to determine whether oF not the idle HC/CO complies with regulations, 1, INITIAL CONDITIONS (@) Engine at reach normal operating temperature (0) Ai closner installed ‘el All pipes and hoses of sir induction system con- rected All eccessories switched OFF {e) Ait vacuum lines property connected NOTE: All vacuum hoses for EGR systems, ete, should be properly connected Uf) EFt system wiring connectors fully plugged (@) Ignition timing set correctly (hn) Transmission in N range (Tachometer and HC/CO meter calibrated and et hand. 2. CHECK OXYGEN SENSOR (See page FI-101) 3. CHECK VF VOLTAGE {a} Connect the positive (2) probe of a voltmeter to ter- minal VF of the check connector, and negative (-) probe to terminal E1 1b) Hold the engine speed at 2,500 rpm for approx. 90 ‘seconds te warm up the oxygen sensor. {@)_ With engine idling, measure the VF vottage. Vouuneier It the VF voltage is not as specified, check the tion systom, If necessary, see EF! SYSTEM. induc 4. RACE ENGINE AT 2,500 RPM FOR APPROX. 90 SECONDS 6, INSERT CO METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm (1.3 ft) 6. CHECK CO CONCENTRATION AT IDLE Wait at least one minute before measuring to allow the concentration to stabilize. Complete the measuring within three minutes. {dle CO concen 0-05 % (w/ Cooling tan OFF) If the CO concentration does not conform to regulations, see the toble below for possible causesENGINE MECHANICAL — Engine tune-up (44-GE} EM-41 Troubleshooting ‘SYMPTOMS j ‘CAUSES: ough ile 1. Faulty ignition: © Incorrect timing ‘© Fouled, shorted or improperly gapped plugs © Open or crossed ignition wires © Cracked distributer cap © Intake air control vatve Incorrect valve clearance Leaky EGR valve (w! EGR system) Leaky intake and exhaust valves Leaky cylind High Low Rough idle 1. Vacuum leak © Vacuum hose EGR valve lw! EGR system) Intake manifold (Air intake chambeo) Intake control valve Throttle body Cylinder head gasket Brake booster line 2. Lean misture causing misfire (Fluctuating HC reading) High igh Rough idle 1. Restricted ar titer 2. Faulty EFI system Faulty pressure regulator Clogged fuel return ine Faulty air flow meter Defective water temp. sensor Detective air emp. sensor Feulty ECU Foulty injector Faulty cold start injector Faulty throtte position sensor (Black smoke from exhaust)EM-42 ENGINE MECHANICAL — Engine Tune-up (4A-GE) ADJUSTMENT OF IDLE SPEED AND IDLE MIXTURE (w/o TWC) 1. INITIAL CONDITIONS (@) Engine at reach normal operating temperature (0) Air cleaner installed (c) All pipes and hoses of air induction system con nected (4) All vacuum lines properly connected (e) EFI system wiring connectors fully plugged (Ignition timing set correctly (All accessories switched OFF (h) Transmission in “N" range 2. START ENGINE @. CONNECT TACHOMETER (See page EM-37) 4. CHECK AIR VALVE OPERATION (Soe page FI-87) 5. ADJUST IDLE SPEED (a) Race the engine at 2,600 rpm for a few seconds. <> yo (b) Check the icle speed. ldle speed: 800 rpm I tae (w/ Cooling fan OFF) 3 Rating (6) Adjust the idle speed by turning the IDLE SPEED Screw ‘ADJUSTING SCREW. 6, ADJUST IDLE MIXTURE CAUTION: Always use a CO meter when adjusting the idle mixture. It is not necessary to adjust with the Idle mixture adjusting screw in most vehicle if they ar {In good condition. H@ CO motor is not available, DO NOT ATTEMPT TO ADJUST IDLE MIXTURE. {@) Race the engine at 2,500 rpm for approx. 90 ‘seconds. Tachometer aoe 90 SecondENGINE MECHANICAL — Engine Tune-up (4A-GE) M43 cometer Ido Mixture Adjusting Screw 260 degress (0) Insert a tosting probe at least 40 em (1.3 #1 into the tailpipe. (c}_ Measure the concentration with 1 ~ 3 minutes after racing the engine to allow the concentration to stabil- Idle CO concentration: 1.5 + 0.5 % (w/ Cooling tan OFF) If the CO concentration is not as specified, adjust the idle jxture_by turning the IDLE MIXTURE ADJUSTING ‘SCREW in the variable resister. © If the concentration is within specification, this adjust- ‘mont is complete, lf the CO concentration cannot be corrected by idle mixture adjustment, seo the table on page EM-41 for other possible causes, NOTE: Always check the idle speed after turning the idle mixture adjusting screw. If it is incorrect, repeat steps 5 ‘and 6.EM-44 ENGINE MECHANICAL — Engine Turn-up (4A-GE) ADJUSTMENT OF DASH POT (DP) SETTING SPEED (w/ Air Flow Meter) 1. WARM UP AND STOP ENGINE Allow the engine to reach normal operating temperature. 2. CHECK IDLE SPEED (See page EM-39) 3, REMOVE CAP, FILTER AND SEPARATER FROM DP 4, ADJUST DP SETTING SPEED {8) Race the engine at 2,500 rpm for a few seconds, (0) Plug the VTV hole. Tachometer 1800 pm] (c)_ Rolease the throttle valve. (@) Check the OP setting speed. DP setting speed: 1.800 rpm NA (w! Cooling fan OFF) RPM Tachometer sous {e) Adjust the DP setting speed by tuming the OP ‘ADJUSTING SCREW. (#) Repeat steps from (a) to (c), and recheck the DP set- ting speed 6. REINSTALL DP SEPARATER, FILTER AND CAP 6. CHECK VTV OPERATION ‘AFew Seconds, Race the engine at 2,500 rpm for a few seconds, release 2.80010 2 tho vote valve and check tha the engine return le . ine fow seconde beg ise RPM TochometerENGINE MECHANICAL — Engine Tune-up (6A-GE) EM 45 INSPECTION OF TOYOTA-VARIABLE INDUCTION SYSTEM (T-ViS) 1. WARM UP AND STOP ENGINE Allow the engine to reach normal operating temperature, 2 CONNECT TACHOMETER (See page EM-37) 3. CONNECT VACUUM GAUGE Using a 3-way connector, connect a vacuum gauge to the hhose between the VSV and actuator 4. INSPECT T-vIs (a) Check that the vacuum gauge indicates vacuum at low speed. (b) Check that the vacuum gauge indicates zero at high speed (w/ TWC approx. 4,350 «pm or wio TWC approx. 5,000 rpm.ENGINE MECHANICAL — Cylinder Block EM-125 CYLINDER BLOCK COMPONENTS S| Piston Ring Pat Breer ae © ——tomering Rt sing os cain Rs fe OF Sn esi _-Connecting Red Cop © Gosker nee sr End Plate [axe M/T 800 69,70] nr eto [aoe M7 750 (56. 74) Flyemnee! ‘Drive Pltol Grankshatt Hearing AQ Hemmant ttnst esr % Dy crea tein cp t {ero a. G0 | [kg.em tie, Nem] = Specified torque # Non-reusoble port usa]EM-126 ENGINE MECHANICAL — Cylinder Block PREPARATION FOR DISASSEMBLY 1, REMOVE CLUTCH COVER AND DISC (M/T only) 2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T) 3. REMOVE REAR END PLATE a INSTALL ENGINE ASSEMBLY TO ENGINE STAND FOR DISASSEMBLY REMOVE A/C COMPRESSOR MOUNT (A/C only) REMOVE ALTERNATOR AND BRACKET REMOVE RH MOUNTING BRACKET exuoe REMOVE TIMING BELT AND TIMING PULLEYS 40-F (See pages EM-48 to 50) 4A-GE (See pages EM-87 to 69) 9, REMOVE EXHAUST AND INTAKE MANIFOLD STAYS 10. DISCONNECT WATER INLET HOUSING HOSES. 11, REMOVE CYLINDER HEAD ASSEMBLY 4A-F_— (See pages EM-71 to 74) 4A-GE (See pages EM-100 to 104) 12, REMOVE WATER PUMP ASSEMBLY (See pages CO-11 and 12) 13, REMOVE OIL PAN, OIL STRAINER AND OIL PUMP ASSEMBLY (See pages LU-8 and 9) 14, REMOVE OIL FILTER BRACKET (See page LU-20 or 21)ENGINE MECHANICAL — Cylinder Block EM -127 DISASSEMBLY OF CYLINDER BLOCK (See page EM-125) 1, REMOVE REAR OIL SEAL RETAINER Remove the six bolts, rear oil seal retainer and gasket, MEASURE CONNECTING ROD THRUST CLEARANCE Using 2 dial indicator, measure the thrust clearance while moving the rod back and forth. ‘Standard thrust olearanes 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in.) ince: 0.30 mm (0.0118 in] nce is greater than maximum, replace the connect ing rod assembly. If necessary, replace the crankshaft 3. REMOVE CONNECTING ROD CAPS AND MEASURE ‘ONL CLEARANCE If replacing the bearing, replace with one having the same hhumber as marked on the bearing cap. There are three sizes of standard bearings supplied, marked 1, 2 or 3 respectively. Boaring thickness (Center wall: sto No.1 1.486 — 1.490 mm (0.0585 — 0.0587 in) No.2 1.490 ~ 1.494 mm (0.0687 ~ 0.0588 in} No.3 1.494 — 1.498 mm (0.0888 ~ 0.0590 in} ws. 0.26 1.607 ~ 1.613 mm (0.0633 ~ 0.0636 in} la) Using 2 punch or numbering stamp, place the matchmarks on the rod and cap to ensure correct reassembly. (b) Remove the connecting rod cap nuts.EM-128 ENGINE MECHANICAL — Cylinder Block, (ec) Using @ plestic-faced hammer, lightly tap the con necting rod bolts and liftoff the connecting rod cap. NOTE: Keep the lower bearing inserted with the con- necting rod cap. (@) Cover the connecting rod bolts with a short piece oF hose to protect the crankshaft from damage. (6) Clean the crank pin and bearing (9) Check the cronk pin and bearing for pitting and scratches, Wf the crank pin or bearing are damaged, replace the bea ings. If necessary, replace the crankshaft {g) Lay 2 strip of Plastigage across the crank pin. (h) Align the ounched marks on the rod and cap. Install ‘and torque the cop nuts alternately, in two or three passes, (See page EM-146) Torque: 500 kg-cm (36 ft-lb, 49. N-m) NOTE: | © Do not turn the crankshaft © Apply a light coating of engine oil on the nut threads | ‘and under the nut before installation,ENGINE MECHANICAL — Cylinder Block EM-129 Remove the connecting rod cap. (See procedure ) and {c} above G) Measure the Plostigage ot its widest point. 0.020 ~ 0.051 mm (0.0008 — 0.0020 in 0.018 ~ 0.073 mi (0.0007 — 0.002: Maximum oil clearance: 0,08 mm (0.0031 in) If the oil clearance is greater than maximum, replac ‘bearings. i necessary, replace the crenkshat (Completely remove the Plastigage. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (a) Remove all the corbon from the top of the cylinder (b) Cover the rod bolts with a short piece of hose to pro- tect the crankshaft from damage. (2) Push out the piston, connecting rod assembly and the upper bearing through the top of the cylinder block. NOTE: ‘© Keep the bearing insert with the connecting rod and cap. ‘© Arrange the piston and connecting rod assembli order.Block Vg SYR 3.4004 ;. CHECK CRANKSHAFT THRUST CLEARANCE Using 9 dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. ‘Standard thrust clearance: 0.02 ~ 0.22 mm (0.0008 ~ 0.0087 in} Maximum thrust clearance: 0.30 mm (0.0118 in.) I the clearance is greater than maximum, replace the thrust washers a8 a set 6 REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE NOTE: replacing a bearing, replace with one having the same number. if the number of the bearing cannot be etermined, select a bearing from the table below accord ing to the numbers imprinted on the eylinder block and crankshaft, Giese Ts > ]s]1 [els] [2/3 GronkshaftNo 0) ofo;+|a{i)2[2 2 Beating No 11 2)3)2/]3) 4/3 )4i5 Example: Cylinder Block No.2, Crankshaft No.1 =Bearing Nos ‘fetorenced vm tn ‘Cylinder block Crankahatt * Bearng "No. inain journal Dora|"®| diameter No.) * riers 1 |§2.026-52.031 | 0 | 47994-48000/ 1 | 2.002-2.005 (2.0482-20aam)| © |(1-8a96.1.8898)| | |(0.0788-0.0788] 2 |°20008-2.008 (06788-00791) 2 |92031-82037| 1, 4798847 99¢/ 3 | 2008-2011 (2.0885.20887| |(1.9883-1.8895)| | |(0.0791-00792) 4 |"2ors-2ora 3 |52.097-52049 | 2 | 47.982-47.988 | |(0.0702.00783) (2.0487-2.0489)| ~ |(1.6821-1 8893) 5 | 2014-2017 (0.0793-0.0734)) “+ Bearing thickness = Center wal thickness Bearing thickness (center wall U/S 0.25 2.121 — 2.127 mm (0.0835 ~ 0.0837 in} (al Remove the bearing caps with the lower bearing ond lower thrust washers.INGINE MECHANICAL — Cylinder Block EM-131 $$ SSE MECHANICAL — Cylinder Block M131 NOTE: Gradually loosen and remove the bearing cap. bolts in three passes and in the numerical order shown () Using the removed bearing cap bolts, wiggle the bearing cap back and forth, and remove it with the ower bearings and thrust washers (No.3 cap only), NoTE: © Keep the lower bearing inserted with the cap. ‘© Arrange the caps and lower thrust washers in correct order. (2) Lift out the crankshaft NOTE: Keep the upper bearings and upper thrust washers (No.3 cap only) inserted in the cylinder block. |) Clean each journal and bearing, (e) Check each jours! and bearing for pitting and seratches, 41 the journal or bearing is demaged, replace the bearings. If necessary, grind or replace crankshaft, (f) Place the crankshaft on the cylinder block. (6) Lay a strip of Plestigage across each journal (h) Install the bearing caps with the lower bearing and thrust washers (No. 3 cap only) (See step 4 on page EM-145) Torque: 610 kg-cm (44 ft-lb, 60 Nem) NOTE: Do not tum the crankshaft.EM-132 ENGINE MECHANICAL — Cylinder Block 10 Remove the bearing caps with the lower bearing and thrust washers (No.3 cap only]. (See procedure (a) and (b} above) Measure the Plastigage at its widest point. Standard oil clearance: st 0.018 ~ 0.033 mm (0.0006 ~ 0.0013 in} u/s 0.28 0.013 — 0.083 mm {0.0008 = 0.9021 int ‘Moximum oil clearance: 0.10 mm (0.0038 Undersized: U/S 0.25 NOTE: If replacing the eylinder block subassembly, the bearing standard clearance will be: 0.015 ~ 0.048 mm (0.0008 ~ 0.0018 in} If the oll clearance is greater than maximum, replace the ‘baarings. If necessary, grind o replace the crankshaft. (kK) Completely remove the Piastigage REMOVE CRANKSHAFT (a) Lift out the crankshaft (b) Remove the upper bearings and upper thrust washers NOTE: © Arrange the cops, bearings and thrust washers in cor- rect order. ‘© The pilot bearing in the crankshaft rear end is perma: ently lubricated and requires no cleaning or lubricationENGINE MECHANICAL — Cylinder Block EM-133 7 INSPECTION OF CYLINDER BLOCK 1. REMOVE GASKET MATERIAL Using a gosket scraper, rem from the cylinder block surface. all the gasket material 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, clean the block. 3. INSPECT TOP OF CYLINDER BLOCK FOR FLATNESS: Using 2 precision straight edge and fesler gauge, measure the surfaces contacting the cylinder head gasket for war- poge, Maximum warpage: 0,05 mm (0.0020 in) If warpage is greater than maximum, replace the cylinder block 4, INSPECT CYLINDERS FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all four cylinders or replace the cylinder block 5. INSPECT CYLINDER BORE DIAMETER © Tat Using a cylinder gauge, measure the cylinder bore «Direction diameter at positions A, 8 and C in the thrust and axial axial directions. ronmcten Standard diameter: som 81.00 ~ 81.03 mm (039 in} (3.1890 — 3.1902 in} \ Midate O/S 0.50 81.50 ~ 81.53 mm 10 mm (3.2087 ~ 3.2098 ind S (0:38 ind Maximum diameter: us STD 81.23 mm (3.1980 in} 0/S 0.60 81.73 mm (3.2177 in) If the diameter is greater than maximum, rebore all four 6. REMOVE CYLINDER RIDGES If the woar is less than 0.2 mm (0,008 in), use a ridge reamer to machine the top of the cylinder.ENGINE MECHANICAL DISASSEMBLY OF PISTON AND. CONNECTING ROD ASSEMBLIES {See page EM-128) 1. CHECK FIT BETWEEN PISTON AND PIN ‘Try to move the piston back and forth on the piston pin, If any movernent is felt, replace the piston and pin as @ set. 2. REMOVE PISTON RINGS (a) Using 2 piston ring expander, remove the compres: sion rings. (0) Remove the two side rai hand. NOTE: Arrange the rings in correct order. and oil ring expander by (4a-FI Using SST, press out the pin from the piston. SST 09221-25022 (09221-00080, 09221-00130, 09221-00140) 3. DISCONNECT CONNECTING ROD FROM PISTON | i | Sst | NOTE '¢ The piston and pin are a matched set '@ Arrange the pistons, pins, rings, connecting rods ono e Reo O8 bearings in cartes! orderENGINE MECHANICAL — Cylinder Block EM-135 (4a-ce) (a) Using needle-nose pliers, remove the snap rings, (b) Gradually heat the piston to 70 - 80°C (158 ~ 176°F) (c) Using 2 plastic-foced hammer and brass bar, ightly tap out the piston pin and remove the connecting rod. NOTE: © The piston and pin are a matched set. © Arrange the pistons, pins, rings, connecting rods and bearings in correct order,ENGINE MECHANICAL — Cylinder Block ARF 38.5 mm 4a.GE 420 mm INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES: 1. CLEAN PISTONS {e) Using a gasket scraper, remove the carbon from the piston top. {b) Using » groove cleaning too! or broken ring, clean the ring grooves. {ec} Using 2 soft brush and solvent, thoroughly clean the piston. CAUTION: Do not damage the piston. 2. INSPECT PISTON DIAMETER AND Olt CLEARANCE (a) Using 6 micrometer and with the piston upside down, ‘measure the piston diameter at & right angles to the piston pin hole center line, the indicated cistance from the skirt bottom edge. 4A-F 38.5 mm (1.576 in) 4A-GE 42.0 mm (1.654 in) Piston diameter: 4AF STD 80.93 ~ 80.96 mm (3.1862 ~ 3.1874 in) 0/S 0.50 81.43 ~ 81.46 mm (3.2089 — 3.2071 in} 4n-GE ‘STD 80.89 ~ 80.92 mm (3.1046 - 3.1868 in) 0/S 0,50 81.39 ~ 81.42 mm (3.2043 — 3.2065 in)ENGINE MECHANICAL — Cylinder Block eM-137 Thrust Direction ® anal Direction 10 mm (033%) Made 10 mm (038m) 4 Cylinder Block Surface 87 mm (b) Measure the cylinder bore diometer in thrust direc- tions (See page EM-133) and subtract the piston diameter measurement from the cylinder bore diameter measurement, Piston oil clearance: 4A-F 0.06 — 0.08 mm (0.0024 ~ 0.0031 in.) 4A-GE 0.10 — 0.12 mm (0.0039 — 0.0047 in.) not within specification, replace the pistons, If necessary, rebore or replace the cylinder block. INSPECT PISTON RING GROOVE CLEARANCE Using a feeter gaugo, measure the clearance between 3 now piston ring and the wall of the piston ring groove Piston ring groove clearance: No.1 0.04 — 0.08 mm (0.0016 — 0.0031 in} No.2 0.03 ~ 0.07 mm (0.0012 — 0.0028 in) If the clearance is not within specification, replace the piston, INSPECT PISTON RING END GAP. (a) insert the piston ring into the cylinder bore. (6) Using @ piston, push the piston ring a little beyond the bottom of the ring travel to 87 mm (0.43 in) from the top surface of the cylinder block. fc} Using 2 feeler gauge, measure the end gap. ‘Standard piston ring end gap: 4A-F No.1 0.26 ~ 0.35 mm (0.0098 ~ 0.0138 i No.2 0.16 — 0.30 mm (0.0089 — 0.011: Oi 0.10 0.60 mm {0.0039 ~ 0.0236 in.) 4R-GE No.1 0.25 — 0.47 mm (0.0098 — 0.0186 in) No.2 0.20 = 0.42 mm (0.0079 — 0.016 Oil 0.18 0.62 mm (0.0059 — 0.0208 in) ‘Maximum piston ring end gap: 4A-F No.1 1.07 mm (0.0421 in} No.2 1.02 mm (0.0402 in.) Oil 1.62 mm (0.0638 in} AA.GE No.1 1.07 mm (0.0421 in} No. 2 1.02 mm (0.0402 in} Oil 1.12 mm (0.0441 in) If the gap is greater than maximum, replace the piston ting, If the gap is greater than maximum, even with 3 new piston ring, rebore the cylinder and use an O/' piston ring, )ENGINE MECHANICAL — Cylinder Block aaGE (4A-GE) INSPECT PISTON PIN FIT ‘As 80°C (176°F) you should be to push the piston pin into fhe plston pin hole with your thumb. | | | | INSPECT CONNECTING RODS Using a rod sligner, check the connecting rod alignment {@) Check for bend. ‘Maximum bend: 4A-F 0.05 mm (0.0020 in) per 100 mm (3.94 in} 4A-GE 0.03 mm (0.0012 in] per 100 mm (3.94 in} Hf bend is greater than maximum, repiace the connecting rod assembly. tb) Check For twist Maximum twist: ‘0.05 mm (0.0020 in.) per 100 mm (3.94 in) IF twist is greater than maximum, replace the connecting rod assembly. NOTE: If replacing the connecting rod, replace the same number of connecting rod bearings as that of new cor. | necting rod caps. (See page EM-127) (4a-ce) ; INSPECT PISTON PIN OIL CLEARANCE (@) Using 2 caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 20.012 — 20.022 mm (0.7879 - 0.7883 in) ) Using a micrometer, measure the piston pin diameter Piston pin diameter: 20.006 ~ 20.016 mm (0.7876 ~ 0.7880 in}ENGINE MECHANICAL — Cylinder Block EM-138 (€)_ Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oll clearance: 0.004 — 0.008 mm (0.0002 — 0.0003 in) Maximum oil clearance: 0,08 mm (0.0020 in) If clearance is greater than maximum, replace the bushing. IH necessary, replace the piston and piston pin assembly. 8. (4A-GE) IF NECESSARY, REPLACE CONNECTING ROD BUSHINGS. (2) Using SST and 2 press, push out the bushing, SST 09222-30010 RCE (b) Align the oil holes of the bushing and connecting rod. (2) Using SST and a press, press in the bushing. SST 09222-30010 1d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See step 7) be- tween the bushing and piston pin. Roe (@) Check the piston pin fit at normal room temperature. Coat the piston pin with engine cil and push it into, the connecting rod with your thumb,EM-140, ENGINE MECHANICAL — Cylinder Block BORING OF CYLINDERS NOTE: # Bore all four cylinders for the oversized piston outside diameter © Replace the piston rings with ones to match the over sized pistons. 1. KEEP OVERSIZED PISTON Oversized piston diameter 4A-F 0/8060 81.43 ~ 81.46 mm (3.2059 ~ 3.2071 in} AA-GE 0/$ 0.50 81.39 - 81.42 mm (3.2043 — 3.2085 in) 2. CALCULATE AMOUNT TO BORE CYLINDER (@)_ Using a micrometer and with the piston upside down, ‘measure the piston diameter at a right angles to the piston pin hole center line, the indicated distance {from skirt bottom edge. 4A-F 38.5 mm (1.576 in) 4A-GE 42.0 mm (1.654 in} 4a 285mm aaceaz0mm = (b) Calculate the amount each cylinder is to be rebored as follows: Size to be rebored = P + C = P = Piston diameter Piston clearance 4A-F 0.06 ~ 0.08 mm {0.0024 ~ 0.0031 in} 4A-GE 0.10 = 0.12 mm (0.0039 ~ 0.0047 in) H = allowance for honing Less than 0.02 mm (0.0008 in.) 3. BORE AND HONE CYLINDERS TO CALCULATED DIMENSIONS Amount of honing: 0.02 mm (0.0008 in.) maximum CAUTION: Excess honing will destroy the finished roundness.ENGINE MECHANICAL — Cylinder Block 1 INSPECTION OF CRANKSHAFT INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V-blocks. (b} Using @ dial indicator, measure the circle runout at the center journal fe runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft Maximum ci INSPECT MAIN JOURNALS AND CRANK PINS fa) Using @ micrometer, measure the diame ‘main journal and crank pin, Main journal diameter: 47.982 — 48.000 mm (1.8891 - 1.8898 in) 4A-F 39.085 — 40,000 mm (1.5742 ~ 1.6748 in) 4A-GE 41.989 ~ 42.000 mm (1.6529 — 1.6538 in} If the diameter is not within specification, check the oi clearance. of each Crank pin diamet {B) Check each main journal and crank pin for taper and out-of-round as shown, Maximum taper and out-of-round: 0.02 mm {0.0008 in) If taper or out-of-round are greater than maximum, grind or replace the crankshaft, GRIND CRANK PIN AND/OR MAIN JOURNAL (F NECESSARY Grind the crank pins and/or main journals to the under- sized finished diameter, Install 2 new pin and/or main undersized bearings. Bearing size (U/S 0.25) ‘Main journal finished diameter: U/S 0.25 47.745 ~ 47.755 mm (1.8797 ~ 1.8801 in) Crank pin finished diameter; U/S 0.25 an 39.745 — 39.755 mm (1.5648 — 1.5652 in) 4A-GE 41.745 — 41.765 mm (1.6435 ~ 1.6439 in} Taper and out-of-round limit: 0.02 mm (0.0008 in}ENGINE MECHANICAL — Cyii cut Position r Block REPLACEMENT OF CRANKSHAFT OIL SEAL NOTE: Thore are two methods replace the oil sea! depending on whether the rear oll seal retainer is assembled (0 the engine or not 1, REPLACE CRANKSHAFT REAR OIL SEAL @) Using a screwdriver and hammer, tap out the ol see, (0) Using SST and @ hammer, tap in a new oil its surface is flush with the rear oll seal retainer edge. SST 09223-41020 NOTE: Be careful nat to install the oll seal stantwise. (ch Apply MP grease to the oil seal lip. | | 2 IF REAR Ol SEAL RETAINER IS INSTALLED ON CYLINDER BLOCK (a) Using a knife, cut off the lip of the oil seal as shown (b) Using a screwdriver of taping tip, pry out the oil seal CAUTION: Be careful not to damage the crankshaft. fo) Check the oll seal lip contact surface of the | crankshaft for cracks or damage. (d) Apply MP grease to 2 new oll seal lip. (@) Using SST and a hammer, tap in the oil seal until its | ‘surface is flush with the rear oil seal retainer edge. SST 09223-41020ENGINE MECHANICAL — Cylinder Block Front Mark (Camy) Front Mark (Proton! EM-143 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES 1. ASSEMBLE PISTON AND CONNECTING ROD (ar @) Align the front marks of the rod. iston and connecting {b) Coat the piston pin with engine oi, (ch Using SST. press in the piston pin. SST 09221-25022 (09221-00080, 08221-00130, 09221-00140) (d) Check that the piston moves smoothly back and forth on the piston pin, (aa-ce) @)_intall a new snap ring one side of the piston pin hole. (b) Gradually heat the piston to 70 — 80°C (158 — 176"F)(EM-144 ENGINE MECHANICAL — Cylinder Block (c) Coat the piston pin with engine oil fa) Align the front marks of the piston and connecting ‘od, and push in the piston pin with your thumb. {e} Install 9 naw snop ring on the other side of the piston hole, (a) Install the oll ring expander and two side rails by | | | 1 | i 2. INSTALL PISTON RINGS hand | {b) Using a piston ring expander, install the two com. Not Code Merk pression rings with the code mark facing upward. (c)__ Position the piston rings so that the ring ends are as Side Ral (Upper) No.2 shown, Front Mark. CAUTION: Do not align the end gaps. (Caviyh Front ZB Side Rat ower No. 1 and Expander 3, INSTALL BEARINGS {) Align the bearing claw with the claw groove of the connecting rod or connecting rod cap. {b} Install the bearing in the connecting rod and rod cap. {e) Lubricate the face of the bearings with clean engine oil NOTE: If raplacing the bearings, replace with one having the same number as marked on the bearing cap. CAUTION: Install the bearing with the oil hole in the connecting rod.ENGINE MECHANICAL — Cylinder Block ASSEMBLY OF CYLINDER BLOCK (Gee page EM-125) NOTE © Thoroughly clean all parts to be assembled, © Bofore installing the parts, apply new engine oil to all sliding and rotating surfaces, © Replace all gaskets, O-rings and cil seals with now parts, <= 1. INSTALL MAIN BEARINGS (a) Align the bearing claw with the claw groove of the f ‘main bearing cap or cylinder block. {b) Install the bearing in the cylinder block and bearing caps. 7 (Lubricate the faces of the bearings with clean engine oil f CAUTION: Install the bearing with the oll hole in the f block. 2. INSTALL UPPER THRUST WASHERS Install the thrust washers on the center main beating with the oil grooves facing outward. 3. PLACE CRANKSHAFT ON CYLINDER BLOCK 4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS NOTE: Each bearing cap has a number and front mark. {a} Install the thrust washers on the center bearing cap with the oil grooves facing outward, (b) install the bearing caps in numerical order with the arrows facing forward.Front Mork iProwusion ENGINE MECHANICAL — Cylinder Block fc) Apply a light coat of engine oil on the threads an Under the heads of the cap bolts, 4d) Install and uniformly tighten the ten cap bolts in several passes, in the sequence shown Torque: 610 kg-cm (44 ft-lb, 60 N-m) (e) Check that the crankshaft turns smoothly. #) Check the crankshaft thrust clearance. (See page EM-130) INSTALL PISTON AND CONNECTING ROD ASSE! BLIES (a) Lubricate the cylinder bores and crank pins with clean engine oil (b) Cover the connecting rod bolts with a short piece of hose to protect the crankshatt from damage {e) Using 2 piston ring compressor, push the correctly numbered piston and connecting rod assembly into teach cylinder with the front mark of the piston Facing forward INSTALL CONNECTING ROD CAPS fa) Match the numbered cap with the qumbered con: necting rod. lb) Install the cap with the front mark facing forward, NOTE: Align the marks punched on the rod and cap. {c) Apply light cost of the engine oll on the threads and Under the nuts of the connecting rod cap. {d)_ \nstall and slternatety tighten the cap nuts in several passes, Torque: 500 kg-cm (36 ft-lb, 49 Nem) (e) Check that the crankshett turns smoothly @) Check the connecting rod thrust clearance, (See page EM-127),ENGINE MECHANICAL — Cylindor Block EM-147 INSTALL REAR OIL SEAL RETAINER 4 Install a new gasket and the rear oil seal retainer with the six bolts, Torque: 96 kg-cm (82 in-tb, 9.3 Nem) ASSEMBLY OF ENGINE 1. INSTALL OIL FILTER BRACKET (See page LU-22 or 23) 2. INSTALL OIL PUMP ASSEMBLY, OIL STRAINER AND O1L PAN (See pages LU-14 to 16) 3. INSTALL WATER PUMP ASSEMBLY (See pages CO-16 and 17) 4. INSTALL CYLINDER HEAD ASSEMBLY 4A-F _— (See pages EM-88 to 92) 4A-GE (See pages EM-117 to 124) 5. CONNECT INLET WATER HOUSING HOSES. 6. INSTALL INTAKE AND EXHAUST MANIFOLD STAYS 7. INSTALL TIMING PULLEYS AND TIMING BELT 4A-F_— (See pages EM-53 to 56) 4A-GE (See pages EM-62 to 65) INSTALL RH MOUNTING BRACKET Torque: 500 kg-cm (36 ft-lb, 49 Nem) INSTALL BRACKET AND ALTERNATOR Torque(Bracket): 500 kg-om (36 ft-lb, 49 Nem) |. INSTALL A/C COMPRESSOR MOUNT (A/C only) |. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND . INSTALL REAR END PLATE . INSTALL FLYWHEEL (M/T) OR DRIVE PLATE (A/T) Install the flywheel or drive plate on the crankshaft Tighten the bolts to the specified torque in two or three passes in the sequence shown. Torque: Flywheel 4A-F 800 kg-om (58 ft-lb, 78 Nem) 4A-GE 750 kg-cm (64 ft-Ib, 74 N-m) Drive plate (4A-F) 650 kg-om (47 ft-lb, 64 N-m) 14, INSTALL CLUTCH DISC AND COVER (M/T only) NOTE: If necessary, inspect the clutch unit before installation,ENGINE MECHANICAL — Cylinder Head (4A-GE) EM-99 CYLINDER HEAD COMPONENTS Scone Cynder Heed Cover EGR Valve eGasket Camshaft Boar Cop "8 adjusting Shim es Maie tor Valve Spring Retoiner ene Sire ‘a Manito oper Isulator al Menifold Stay (AE'ond ATH BH Manifold Stay Exhaust Manifold Exhaust Manifold Lowor Hest Insulator I: Specitiod torave 4 Non-reusable partEM-100, Head (4A-GED REMOVAL OF CYLINDER HEAD (See page EM-99) 1. DRAIN ENGINE COOLANT (See page CO-6 or 7) 2, REMOVE DISTRIBUTOR 3. REMOVE EXHAUST MANIFOLD (2) Remove the four bolts, two nuts and upper heat Insulator (©) (AE and AT) Remove the three bolts, nut, RH and LH manifold stays fe) (aw) Remove the bolt, nut and RH manifold stay. p\ CW Manifold Stay Y tat'and At on (@) Remove the three bolts, two nuts, manifold and gesket (e) Remove the three bolts and lower heat insulator.ENGINE MECHANICAL — Cylinder Head (4A-GE) EM-101 4. (w/ EGR SYSTEM) REMOVE EGR VALVE AND MODULATOR {a) Disconnect the vacuum hoses from the vacuum pipe. (0) Remove the bolt and EGR vacuum modulator fc) Remove the union bolt, four bolts, the EGR valve, ipes assembly and gaskets. REMOVE COLD START INJECTOR PIPE (See steps 2 and 3 on page FI-72) 6. REMOVE DELIVERY PIPE AND INJECTORS. (See stops 3 to 7 on page FI-78) REMOVE VACUUM PIPE ( w/ EGR SYSTEM) AND CYLINDER HEAD REAR COVER (2) (w/ EGR System) Disconnect the vacuum hoses from the throttle body (©) (w/o EGR System) Femove the two bolts, rear cover and gasket (c)(w/ EGR System) Remove the four bolts, vacuum pipe, rear cover and, ‘gaskot REMOVE THROTTLE BODY (See steps 5 and 6 on page FI-85) REMOVE T-VIS VSV AND VACUUM TANK (a) Disconnect the vacuum hoses from the air control valve and actuator. (b) Remove the two bolts, the VSV and vacuum tank assembiy, REMOVE INTAKE MANIFOLD / (a) Remove the two bolts and manifold stay.AE and AT es ENGINE MECHANICAL, " 12, 13, 4 15. 16. Cylinder Head (44-GE) te @ Remove the PCV hose. Remove the seven bolts, two nuts, intake manifold, air control valve and gaskets. REMOVE WATER OUTLET AND BY-PASS PIPE la} Remove the three bolts and elternator drive belt adjusting be (6) Remove the three bolts, the water outlet, by-pass pipe assembly and gasket. REMOVE WATER PUMP PULLEY AND DRIVE BELT REMOVE NO.3 AND NO.2 TIMING BELT COVERS Remove the seven bolts, No.3, No.2 belt covers and ‘gaskets REMOVE CYLINDER HEAD COVER (@) Remove the four bolts, center cover and gasket (0) Remove the eight cap nuts, seal washers, two head covers and gaskets. REMOVE SPARK PLUGS (See page IG: SET NO.1 CYLINDER TO TDC/COMPRESSION (@) Turn the crankshaft pulley and align its groove with the timing mark "0" of the No. timing belt cover (AE ‘and AT) or timing pointer (AW) (b) Check that the valve lifters on the No.1 cylinder ar loose and valve lifters on the No.4 cylinder are tight, {f not, tum the crankshaft one revolution (360°)ENGINE MECHANICAL — Cylinder Head (4A-GE) EM-103 17. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS (a) Place matchmarks on the camshaft timing pulleys and timing belt. (©) Loosen the idler pulley bolt and shift the pulley toward the left as far as it will go, temporarily tighten if (ec) Remove the timing belt from the camshaft timing pulleys. NOTE © Support the belt so the meshing of the crankshaft tim- ing pulley and timing belt does not shift. © Be careful not to drop anything inside the timing belt cover. ® Do not allow the belt to come into contact with oil, water or dust REMOVE CAMSHAFT TIMING PULLEYS (See step 11 on page EM-59) REMOVE RH MOUNTING BRACKET Remove the three bolts and bracket. REMOVE NO.4 TIMING BELT COVER Remove the seven bolts and belt cover,ENGINE MECHA! a. 22. :AL — Cylinder Head (4A-GE) REMOVE CAMSHAFTS (@) Uniformly loosen and remove the bearing cap bolts in ‘several passes, in the sequence shown. {&} Remove the bearing caps, cil seal and camshaft. NOTE: Arrange the intake and exhaust camshafts. REMOVE CYLINDER HEAD (a) Using SST. uniformly loosen and remove the ten cylinder head bolts in Several passes. in the sequence shown. ‘SST 09205-16010 CAUTION: Head warpage or cracl from removing bolts in incorrect order. (b) Lift the cylinder head from the dowols on the cylinder block and place the head on wooden blocks on & bench. NOTE: If the cylinder hoad is difficult to lift off, pry with a screwdriver betwoen the cylinder head and block saliences. CAUTION: Be careful not to damage the cylinder head and cylinder block surfaces of cylinder head gasket sicENGINE MECHANICAL — Cylinder Head (¢A-GE) EM-105 DISASSEMBLY OF CYLINDER HEAD (See page EM. 1. REMOVE VALVE LIFTERS AND SHIMS. NOTE: Arrange the valve lifters and shims in correct order. 2. REMOVE VALVES (2) Using SST, compress the valve spring and remove the two keepers, SST 09202-70010 (b] Remove the spring retainer, valve spring. valve and spring seat NOTE: Arrange the valves, valve springs, spring seats ‘and spring retainers in correct order. (c) Using needie-nose pliers, remove the oil seal.ENGINE MECHANICAL — Cylinder Head (44-GE) INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS 1. CLEAN TOP OF PISTONS AND TOP OF BLOCK (a) Turn the crankshaft and bring each piston to top dead center (TDC). Using o gasket scraper, remove al ‘the cerbon from the piston top. (b} Remove all the gasket material from the top of the cylinder block (ec) Using compressed air, blow carbon and oil from the bolt holes. WARNING: Protect your eyes when using prossure air 2. REMOVE GASKET MATERIAL Using 2 gasket scraper, remove all the gasket materia from the manifold ond cylinder head surtace. CAUTION: Be careful not scratch the surfaces. h 3. CLEAN COMBUSTION CHAMBERS Using a wite brush, remove all the carbon fram tho com: bustion chambers, CAUTION: contact surfac aretul not to scratch the head gasket 4. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushi 6. CLEAN CYLINDER HEAD. Using a soft brush and solvent, thoroughly clean cylinder hood.ENGINE MECHANICAL — Cylinder Head (4A-GE) EM-107 6 a INSPECT CYLINDER HEAD FOR FLATNESS. Using a precision straight edge and fester gauge, measure the surfaces contacting the cylinder block manifolds for warpage. Maximum wi Grlinder block side 0.05 mm (0.0020 in) Intake manifold side 0.05 mm (0.0020 in.) Exhaust manifold side 0.10 mm (0.0039 in) If warpage is greater than maximum, replace the cylinder head, INSPECT CYLINDER HEAD FOR CRACKS. Using a dye penetrant, check the combustion chamber, intake and exhaust ports, head surface and the top of the head for cracks, If cracked, replace the eylinder heed. CLEAN VALVES (2) Using 8 gasket scraper, chip any carbon from the valve head. (0) Using a wire brush, thoroughly clean the valve, INSPECT VALVE STEMS AND GUIDE BUSHINGS (2) Using a caliper gauge, measure the inside diameter of the guide bushing, Bushing inside diameter: 6.010 ~ 6.030 mm (0.2366 — 0.2374 in)€M-108 ENGINE MECHANICAL — Cylinder Head |4A-GE) (©) Using 2 micrometer, mi valve stem, Valve stem diameter sure the diameter of the 2366 in.) Exhaust 6.965 — 6.980 mm (0.2348 ~ 0.2364 in) (c) Subtract the valve stem diameter measurement from ‘he guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 ~ 0.060 mm (0.0010 ~ 0.0024 in} Exhaust 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in} Maximum oil clearance: Intake 0.08 mm (0.0031 Exhaust 0.10 mm {0.0038 in) If the clearance is o and guide bushing, fe than maximum, replace the valve 10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS Ora valve (a) Insert an old valve wrapped with tape into the vaive = guide bushing, and break off the valve quide bushing by hitting & with @ hammer. CAUTION: careful not to damage th ter hole. Tape. (©) Gradually heat the cylinder head to 80 ~ 100°C (176 = 212°F, (©) Using SST and a hammer, tap out the guide bushing 4 SST 09201-70010ENGINE MECHANICAL ~ Cylinder Head (GA-GE) EM-109 Both intake ond exhaust Bushing bore mm (in) Bushing 11,000 - 11,027 (0.4331 - 0.4341) Over 11.027 (o.43a1) Use S7D Use 0/6 0.05 {d) Using s caliper gauge, measure the bushing bore diameter of the cylinder head. le) Select « new guide bushing (STD size or O/S 0.08). HH the bushing bore diameter of the cylinder head is greater than 11.027 mm (0.4341 in., machine the bushing bore ‘0 the following dimension: Rebored cylinder head bushing bore dimension: 11.080 — 11.077 mm (0.4350 — 0.4361 in) If the bushing bore diameter of the cylinder head is greater, than 11.077 mm (0.4361 in), replace the cylinder head, {f) Gradually heat the cylinder head to 80 ~ 100°C (176 = 212°F, (g)_ Using SST and a hammer, tap in @ new guide bushing until the snap ring makes contact with the cylinder head SST 09201-70010 4h) Using a sharp 6 mm reamer, ream the guide bushing, to obtain the standard specified clearance (See page EN-108) between the guide bushing and valve stem. INSPECT AND GRIND VALVES {a} Grind the valve enough to remove pits and carbon, (©) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5°M110 Morgin Thickness ‘Overall length 2 ENGINE MECHANICAL — Cylinder Head (4A-GE) (0) Check the valve head margin thicknes ‘Stondard margin thickness: 0.8 ~ 1.2 mm (0.031 ~ 0.047 in) Minimum margin thickness: 0.6 mm (0.020 in.) If the morgin thickness is less than mini valve. um, replace the () Check the valve overall length Exhaust 99.26 mm (3.9078 in) 1 the overall length is less than minimum, replace the valve, (el Check the surface of the valve stem tip for wear, If the valve stem tip is wom, resurtace the tip with & grinder oF replace the valve, CAUTION: Do not grind off more than the overall length. INSPECT AND CLEAN VALVE SEATS. (a) Using a 45° carbide cutter, resurface the valve seats Remove only enough metal to clean the seats. (©) Cheek the valve seating position. Apply @ thin coat of prussian biue (or white lead) to the valve face. Lightly pross the valve against the seat. Do not rotate the valve. Check the valve face and seat for the following: © If blue appears 360° around the face, the valve is concentric. if not, replace the valve. © If blue appears 360° around tho valve seat, the ‘guide and face are concentric. H not, resurface th ‘oat ‘© Chock thet the seat contact is on the middle of the valve face with the following width 1.0 = 1.4 mm (0.039 ~ 0.085 in)ENGINE MECHANICAL — Cylinder Head (4A-GE) EM-111 If not. correct the valve seats as follows: (1) Af the seating is too high on the valve face, use 90° and 45° cutters to correct the seat. (2). If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat {d)Hand-lap the vaive and valve seat with an abrasive ‘compound, (e) After hand-lapping, clean the valve and valve seat. 13. INSPECT VALVE SPRINGS. (a) Using a stee! square, measure the squareness of the valve spring, ‘Maximum squareness: 1.8 mm (0.071 ind If squareness is greater than maximum, replace the valve spring (0) Using calipers, measure the free length of the valve spring Free length: 41.09 mm (1.6177 in} If the free length is not as specified, replace the valve springENGINE MECHANICAL — Cylinder Heed (4A-GE) os {c) Using a spring tester, measure the tension of the ‘valve spring at the specified installed length. Installed tension: 14.6 — 17.0 kg (32.2 ~ 37.5 th, 143 - 167 N) at 34.7 mm (1.366 in) If the installed tension isnot as specified, rep spring. the valve INSPECT CAMSHAFTS AND BEARINGS Inspect camshaft for runout (@l_ Place the camshaft on V-blocks () Using 2 dial indicator, messure the citcle runout et ‘the center journal Maximum circle runout: 0.04 mm (0.0016 in} IW the circle runout is greater than maximum, replace the camshaft Inspect cam tobi Using a micrometer, measure the cam lobe height. Standard cam lobe height: 36.410 ~ 35.510 mm {1,3041 ~ 1.3980 in) 36.11 mm (1.3823 in) 28 than minimum, replace the Minimum cam lobe height: IF the cam lobe height camshaft Inspect camshaft journal Using @ micrometer, measure the journal diameter. Journal diameter: 26.949 ~ 26.965 mm {1.0610 — 1.0616 in} the joumel diameter is not as specified, check the oil clearance. Inspect camshatt bearings Chock the bearings for flaking and scoring. the bearings are damaged, replace the bearing caps and cylinder head as a set.ENGINE MECHANICAL — Cylinder Head (4A-GE) eB 15. Inspect camshaft journal oil clearance (2) Clean the bearing caps and camshatt journals, {b) Place the camshafts on the cylinder head. (cl Laya strip of Plastigage across each of the camshaft journal (a) Install the bearing caps. (Gee step 2 on pages EM-118 end 119) Torque: 130 kg-em (9 ft-lb, 13. Nm) NOTE: Do not turn the camshaft. {e) Remove the bearing caps. (| Measure the Plastigage at its widest point. ‘Standard oll clearance: 0.035 ~ 0.072 mm (0.0014 - 0.0028 in. Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and ‘oylinder head as a set G@) Completely remove the Plastigage. Inspect camshaft thrust clearance (a) Install the camshafts. (See step 2 on pages EN-118 end 119) (b} Using @ dial indicator, measure the thrust clearance while moving the camshaft back and forth ‘Standard thrust clearance: 0.080 - 0.190 mm {0.0031 ~ 0.0075 in) fance: 0.30 mm (0.0118 in) If the thrust clearance is greater than maximum, replace the camshatt. If necessary, replace the bearing caps and. cylinder head as a set. Maximum thrust el INSPECT VALVE LIFTERS AND LIFTER BORES {a} Using 2 micrometer, measure the lifter diameter. Lifter diameter: 27.975 — 27.986 mm (1.1014 = 1.1018 in) (b) Using caliper gauge, measure the lifter bore diameter of the cylinder head Lifter bore diameter: 28.000 - 28.021 mm (1.1024 ~ 1.1032 in} (e) Subtract the lifter diameter measurement from the lifter bore diameter measurement. ‘Standard oll clearance: 0.015 ~ 0.046 mm (0.0006 0.0018 in) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.EM114 ENGINE MECHANICAL — Cylinder Head (GA-GE) 16, INSPECT INTAKE, EXHAUST MANIFOLDS AND AIR CONTROL VALVE. Using a precision straight edge and feeler gauge, measure ‘the surface contacting the cylinder head or air controt valve for warpage, ‘Maximum warpage: Intake manifold 0.05 mm (0.0020 in) Exhaust manifold 0.30 mm (0.0118 in) Air control valve 0.05 mm (0.0020 in) H warpage is greater than maximum, replace the manifold. INSPECTION OF TOYOTA — VARIABLE INDUCTION SYSTEM (T-VIS) 1. INSPECT AIR CONTROL VALVE ng (a) With 300 mm (11.81 inHg, 40.0 kpa) of vacuum ‘applied to the actuator, check that the control valve moves smoothly to the fully closed position. (b} With the vacuum released, check that the valve Vacuum Quickly fully opens, cuss] Hf abnormal, replace the valve. 2. INSPECT VACUUM TANK Air (@) Check that air flows from pipes A to B. a (b) Check that air does not flow from pipes B to A. (c) Apply 800 mmbig (12.69 inHg, 66.7 kPa) of vacuum to pipe A and check that there is no change in vacuum after one minute jeplace the vacuum tank It there is changeENGINE MECHANICAL — Cylinder Head (4A-GE) EM-115 INSPECT VACUUM SWITCHING VALVE (VSV) ‘A. Inspect VSV for open circuit Contiovity Using an chmmeter, check thet there is continuity bet= ween the terminals. Resistance (Cold): 33-39 0 IF there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity bet- ween each terminal and the VSV body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from pipe E to the filter. {o) Apply battery voltage across the terminals. fc} Check that air flows from pipes E to F. If operation is not es specified, replace the VSV.M116 ENGINE MECHANICAL — Cylinder Head (4A-GE) ASSEMBLY OF CYLINDER HEAD +—@ 01 Dipstek Guide Driven Rotor (4A-F) # Driven Gear l@a-GP) mS cost sy orn at az PORiIng—e #01 Seal Drive Rotor (48.7) Drive Gear (4A-GE} elo! Vale} Se Spring # Gasket Less Retainer ————e 1 Pan Battie Ploe (4A.Ce) Snap ring——~ 01 Strainer K . il Pan © Gasket ———“e Drain Phag #Noo-reusable portLUBRICATION SYSTEM — Oil Pump REMOVAL OF OIL PUMP NOTE: When repairing the oll pump, the oil pan and strainer should be removed and cleanod. DRAIN ENGINE OIL (2) Remove the cil filler cap, (0) Remove the oil drain plug and drain the ol into a con- tainer. REMOVE OIL PAN (a) Remove the two nuts and nineteen bolts (wo) a-F) Insort the blade of SST between the oil pan and cylinder block, cut off applied sealer and then remove the oil pan: SST 08032-00100 (0) (40-Ge) Insert the blade of SST between the oil pan and bat fle plate, cut off applied sealer and then remove the oil pan. ‘8ST 09032-00100 ‘CAUTION: ‘* Do not use SST for the oil pump body si ary, use a serewdriver. © When removing the oil pan, be careful not to damage the oi pan flangé H necess- REMOVE OIL STRAINER Remove the two bolts, nuts, oil strainer and gasket (aa-Gep REMOVE OIL PAN BAFFLE PLATE Insert the blade of SST between the cylinder block ané baffle plate, cut off applied sealer and remove the battle plete SST 09032-00100 CAUTION: # Do not use SST for the oil pump body side. If necess- ary, use a screwdriver. ‘* When removing the haffle plate, be careful not te damage the baffle plate flangtLUBRICATION SYSTEM — Oil Pump Lu-8 5. 2 REMOVE TIMING BELT, IDLER PULLEY AND ‘CRANKSHAFT TIMING PULLEY 4A.F (See pages EM-48 to 5 4A.GE (See pages EM-57 to 5: REMOVE OIL DIPSTICK GUIDE AND DIPSTICK REMOVE OIL PUMP (a) Remove the seven bolts. (0) Using a plastic-faced hammer, caretully tap the oil pump body,u-10 LUBRICATION SYSTEM — Oil Pump Drive Rotor (i Driven Roter (Gear, Qo Joos Retainer DISASSEMBLY OF OIL PUMP (See page Lu-7) 1. REMOVE DRIVE AND DRIVEN ROTORS (GEARS) {a} Remove the five bolts and oil purnp body cover. (b) Remove the drive and driven rotors (g 2 REMOVE RELIEF VALVE {a} Using snap ring pliers, remove the snap ring, (©) Remove the retainer, spring and relief valve,LUBRICATION SYSTEM — Oil Pump Lu-11 INSPECTION OF RELIEF VALVE INSPECT RELIEF VALVE Coat the relief valve with engine oil and check that it falls, smoothly into the vaive hole by its own weight Hit does not, replace the relief valve. If necessary. replace the oil pump assembly. INSPECTION OF OIL PUMP (4a-F) 1. MEASURE BODY CLEARANCE Using a fecter gauge, measure the clearanca between the driven rotor and pump body Standard clearance: 0.080 ~ 0.135 mm {0.0031 — 0.0083 int 0.20 mm (0.0079 tf the clearance is greater than maximum, valve the rotor sat and/or body. 2. MEASURE TIP CLEARANCE Using @ feeler gauge, measure the clearance between both rotor tips, Standard olearance: 0.116 ~ 0.186 mm (0.0046 ~ 0.0081 in) Maximum clearance: 0.35 mm (0.0138 in] If the clearance is greater than maximum, replace the rotor set 3. MEASURE SIDE CLEARANCE Using feeler gauge and flat block, measure the side clearance as shown. Standard clearance: 0,25 ~ 0.085 mm (0.0010 — 0.0026 in) 0.10 mm (0.0038 in.) If the clearance is greater than maximum, replace the rotor set and/or body, (4A-GE) 1. MEASURE BODY CLEARANCE Using a feelor gauge, measure the clearance between the ‘driven gear and pump body Standard ol 0.100 = 0.191 mm (0.0038 ~ 0.0075 in) 0.20 mm (0.0079 in If the clearance is greater than maximum, replace the gear ‘sot and/or body. Maximum clearance:Luiz LUBRICATION SYSTEM — Oil Fump 2 MEASURE TIP CLEARANCE Using a feeter gauge. measure the clearance between both (gear tips and crescent. Standard clearance: Drive gear to crescent 0.107 — 0.248 mm (0.0042 ~ 0.0098 in Driven gear to crescent 0.058 — 0.310 mm (0.0023 ~ 0.0122 in} Maximum clearance: 0.35 mm (0.0138 in} If the clearance is greater than maximum, replace the gest set and/or body. MEASURE SIDE CLEARANCE Using a feeler gauge and fiat block, measure the side clearance as shown, Standard clearance: 0.025 ~ 0.075 mm {0.0010 = 0.0030 in.) 0.10 men (0.0038 in} feater than maximum, replace the gear Iv the clearance is: set and/or body, REPLACEMENT OF OIL SEAL 1 REMOVE OIL SEAL Using @ screwdriver, pry out the oil seal INSTALL OIL SEAL (a) Using SST and a hammer, drive in a new oil seal SST 09517-30010 NOTE: Be careful not to install a new oil seal slantwise (bo) Apply MP groase to the oi seal lip.LUBRICATION SYSTEM — Oil Pump Fp Rotor vate Prove S—Rersiner Drive Rotor (Gear) bien Rotor h 4 ASSEMBLY OF OIL PUMP (See page LU-7) 1, INSTALL RELIEF VALVE (@]_ Insert the relief valve, spring and retainer into the ‘ump body. (©) Using snap ring pliers, install the snap ting 2. INSTALL DRIVE AND DRIVEN ROTORS (GEARS) (a) Insert the drive and driven rotors (gears) into the pump body. (b} Install the oil pump body cover with the five screws, Torque the screws. Torque: 105 kg-em (8 in-tb, 10 N-m)Lu-14 LUBRICATION SYSTEM — Oil Pump INSTALLATION OF OIL PUMP (See page LU-7) 1. INSTALL Ol PUMP ASSEMBLY (a) Place a new gasket on the block. (6) Install the oil pump to the crankshaft with the spline teeth of the drive gear engaged with the large teeth of the crankshaft, {c) install and torque the seven bolts, Torque: 218 kg-cm (16 ft-1b, 21 Nm) 2. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK {a) Push in the oil dipstick guide with the O-ring coated with a small amount of engine oil (b) Install a new O-ring to the oil dipstick guide (c) Install the mounting bolt. {4} lnsert the oi dipstick 3, INSTALL CRANKSHAFT TIMING PULLEY, IDLER PULLEY AND TIMING BELT 4A-F_ (See pages EM-63 to 56) 4A-GE (See pages EM-62 to 65) 4. (4A-GE} INSTALL OIL PAN BAFFLE PLATE (2) Remove any old packing (FIPG) material and be care- ful not to drop any oil on the contacting surfaces of the baffle plate and cylinder block. © Using @ razor blade and gasket scraper, remove at ‘the packing (FIPG) material from the gasket sur- feces. ‘© Thoroughly clean all components to remove all the loose material.uu LUBRICATION SYSTEM ‘um Lu-1s pa ‘Seal Diameter 3-5 mm, (12 "O20 in '* Clean both sealing surfaces with a non-residue solvent. CAUTION: Do not use a solvent which will affect the painted surfaces. (b} Apply seal packing to the bottle plate as shown in the figure. Seal packing: Part No. 08826-00080 or equivalent © Install a nozzle that hes been cut to a 3 = § mm 0.12 = 0.20 in) opening, NOTE: Avoid applying an excess amount to the surface. Be particularly careful near oil passages © Ports must be assembled within 3 minutes of application. Otherwise, the material must. be removed and reapplied © Immediately remove nozzle from tube and reinstall cap. (6) Install the baffle piste, INSTALL OIL STRAINER Place 2 new oil strainer gasket and install the oil strainer With two bolts and two nuts. Torque the bolts and nuts. Torque: 95 kg-cm (82 in-Ib, 9.3 Nm) INSTALL OIL PAN (a) Remove any old packing (FIPG) material and be car {ul not t0 drop eny cil on the contacting surfeces of the oil pan and cylinder block (4A-F) or baffle plate (4A-GE) © Using a razor blade and gasket soraper, remove all the packing (FIPG) materia! from the gasket sur- faces. © Thoroughly clean all components to remove sll the loose materia Cleon both sealing surfaces with @ non-residue solvent CAUTION: Do not use a solvent which will affect the painted surtaces, (©) Apply seal packing to the oil pan as shown in the figure, Seat packing: Part No. 08826-00080 or equivalent © Install a nozzle that has been cut to a3 - 5 mm (0.12 = 0.20 in} opening.Lute LUBRICATION SYSTEM — Oil Pump. NOTE: Avoid applying an excess emount to the surface. Be particularly careful near oll passages, © Parts must be assembled within 3 minutes of ‘application. Otherwise, the material must. be removed and reapplied. © Immediately remove nozzle from tube and reinstall cap. , (ch Install the oil pan over the studs on the block with the ninetoen bolts and two nuts, Torque the bolts and nuts Torque: 50 kg-cm (43 in.-b, 4.9 Nem) REFILL WITH ENGINE OIL (See step 3 on page LU-6) START ENGINE AND CHECK FOR LEAKS RECHECK OIL LEVEL, Recheck the engine oil level and refill if necessaryLUBRICATION SYSTEM — Oil Cooler and Pressure Regulator, OIL COOLER AND PRESSURE REGULATOR COMPONENTS wuz AE Union Bott © Gacket Union Pipe a Rete Valve Gasket Bs pring E———4 Gasket &—nalot valve Plug off Union Pipe = sab On Cooler # tion-rousable partLuts LUBRICATION SYSTEM — Oil Cooler and Pressure Regulator COMPONENTS (Cont'd) aT sn os ter edu) f Qos Use Poe oi Fi Basi il Cooler Hose- e 8 reliet valve Roliet Voive Pig # Gasket it Cooler Hose it Cooler Pipe 4 Non-reusable part owlLUBRICATION SYSTEM — Oil Cooler and Pressure Regulator 1-19 COMPONENTS (Cont'd) AW No.1 OU Filter Bracket No. 2. Ol Fiter Bracket #o-8Ing ! O-Ring Union Bost Union ott @ionFiter Relet Va Soring— © Geske__e Flot Voive Pug Union Oit Cooler Pipe it Cooier Hose. Ot Cooter 4 Non-reusable part |Lu-20 LUBRICATION SYSTEM — Oi Zooler and Pressure Regulator REMOVAL AND DISASSEMBLY OF OIL COOLER AND PRESSURE REGULATOR (AE and AT) (See page LU-17 or 18) REMOVE UNION PIPE Remove the union bolt, two gaskets and union pipe. 2. REMOVE OIL FILTER Using SST, remove the oil filter SST 09228-08500 3, REMOVE OIL FILTER BRACKET (OIL PRESSURE REGULATOR) Remove the union bolt, oil filter bracket and O-ring, 4, DISASSEMBLE OIL FILTER BRACKET (OIL PRESSURE REGULATOR) Remove the plug, gasket, spring and relief valve.LUBRICATION SYSTEM — Oil Cooler and Pressure Regulator Lu-21 \e A REMOVAL AND DISASSEMBLY OF OIL COOLER AND PRESSURE REGULATOR (AW) (See page LU-19) 1, DISCONNECT OIL COOLER PIPE Remove the bolt, union bolt, cooler pipe and two gasket 2, REMOVE OIL FILTER (See page LU-20) 3. REMOVE NO.2 OIL FILTER BRACKET Remove the two bolts, two nuts, filter bracket and O-ring 4, REMOVE NO.1 OIL FILTER BRACKET (OIL PRESSURE REGULATOR) Remove the union bolt, gasket, filter bracket and O-ring 5. DISASSEMBLE NO.1 OIL FILTER BRACKET (OIL PRESSURE REGULATOR) (See step 4 on page LU-20) INSPECTION OIL PRESSURE REGULATOR INSPECT RELIEF VALVE Cost the relief vaive with engine oil, and check thet it fas, Smoothly into the valve hole by its own weight Wit does not, replace the relief valve. It necessary, the oil filter bracket (No. 1) and relief valve as 2LU-22 LUBRICATION SYSTEM — Oil Cooler and Pressure Regulator ASSEMBLY AND INSTALLATION OF OIL COOLER AND PRESSURE REGULATOR (AE and AT} (See page LU-17 or 18) 1. ASSEMBLE OIL FILTER BRACKET (OIL PRESSURE REGULATOR) Insert the relief valve, spring, © new gasket ond screw on the relief valve plug. Torque the plug. Torque: 375 kg-cm (27 ft-lb, 37 N-m) 2. INSTALL OIL FILTER BRACKET Insert a new O-ring and the filter bracket with the union bbolt. Torque the union bolt. Torque: 450 kg-om (33 ft-tb, 44 Nem) 3. INSTALL OIL FILTER (See page LU-6) 4, INSTALL UNION PIPE Install the union pipe with two new gaskets and union bolt as shown. Torque the union bolt Torque: 300 kg-em (22 ft-lb, 29 N-m) 5. REFILL WITH ENGINE OIL (See page LU-6) 6. START ENGINE AND CHECK FOR LEAKSLUBRICATION SYSTEM — Oil Cooler ond sure Regulator u ASSEMBLY AND INSTALLATION OF OIL COOLER AND PRESSURE REGULATOR (AW) (See page LU-19) 1. ASSEMBLE NO.1 OIL FILTER BRACKET (OIL PRESSURE REGULATOR) (See page LU-22) Torque: 375 kg-om (27 ft-lb, 37 N-m) 2. INSTALL NO.1 OIL FILTER BRACKET (OIL PRESSURE REGULATOR) Install a new O-ring and the filter bracket with 3 new ‘gasket and the union bolt. Torque the union bolt Torque: 450 kg-om (33 ft-lb, 44 Nm) 3. INSTALL NO.2 OIL FILTER BRACKET Install @ new O-ring and the filter bracket with the two bolts and two nuts. Torque: 200 kg-cm (14 ft-lb, 20 N-ml 4. INSTALL OIL FILTER (See page LU-6) 5. CONNECT OfL COOLER PIPE Install the cooler pipe with the bolt, new two gaskets and the union bolt Torque the union bolt Torque (Union bolt): 300 kg-em (22 ft-Ib, 29 Nem) 6. REFILL WITH ENGINE OIL {See page LU-6) 7. START ENGINE AND CHECK FOR LEAKSAS SEAVICE SPECIFICATIONS — Engine Mechanical (44-GE) ENGINE MECHANICAL (4A-GE) Specifications (Cont'd) Difference of pressure between each cylinder Engine Drive belt (Alternator) tune-up Detection New bet | 4-5 mm 018 - 020m. Used bett | 6 — 7 mm 0.24 ~ 028 in Tension (Reference) New bet | 70-80 kg Used belt | 30 45 kg Engine coolant capacity (w/ Hester) ‘AE ond AT 60liters «BUS ats Simp. gis AW 124 Stes 13.1 US Gts 10.9 Imp. ats Engine oll capacity ‘w/o Oilcooler Drain and refi ‘w/o Oi fiter change | 30 liters «32S gts 2.6 Imp. ats wi Oillfter change | 33 ters — 35.USqte 29 Imp. ats Dry fit 27 ites 3BUSats 3.3 mp ats W/ Oil cooler Drain and roti w/o Ollfiter chonge | 34iters «3.6. US ats 3.0 Imp. ats w/ Oilfiter change | 37 ters 3.9.US ats 3.3 imp. ats Dry fl 41 liters 43. US ats 3.6 Imp. ate Battery specific gravity 1.25 ~ 1.27 when fully charged at 20°C (68°F) High-tension cord resistance Limit 25 k2 per cord ‘Spark plug Conventional tipped type Type No. a20R-U11 Nick BCPREEYI1 Air gap 1.1 omen 0,083 in Platinum tipped type Type ND Pater NK BCPRSEPIY Air 980 TD 11 ram 0.043 in. Lit 13mm 0.051 in, Ignition ting 10° BTDC @ iate (u/ Terminals T and E1 short-circuited) Fring order 1-3-4-2 Valve clearance inske | 0.15-0.25mm 0.008 - 0.010 in, Exhaust | 020-0.30mm 0.008 ~ 0.012 in, Idle speed 800 rpm (w/ Cooling fan OFF VF vottage 25=06V ldle CO concentration wiTwe | 0-08% wotwe) 18-05% Dash pot setting speed {w/ Airflow meter) | 1,800 rpm (w/ Cooling fan OFF) Intake at ldle speed 400 mmnkig (15.75 ing, 63.3 kPa) ‘ranks Compression | at 250-rpm st 126 kg/em? (178 pes 1,236 KPa) pressure Limit 1000 kglem? (142 psi, 981 KPa or more 1.0 ka/em® (14 psi, 98 KPa) oF lossSERVICE SPECIFICATIONS — Engine Mechanical (4A-GE) Specifications (Cont'd) AT ‘ater pulley | Free lenath 43.5 mm 1.713 in tension Installed toad 1.80.2. mm (1.976 in) | 9.97 kg (22.0 hb, 98 NI Cylinder Warpage Cylinder block side Umit 0.05 mm 0.0020 in ead tntoke manifold side Limit 0.05 mm 0.0020 in Exhaust manifold side Lirnt 0.10 mm 0.0039 in, Valve sest Refacing angle 30", 45", 80° Contacting angle 45° ‘Contacting width 1.0 ~ 1.4mm 0.039 ~ 0058 in. Valve guide | Inside diameter 6.010 ~ 6030 mm 0.2366 - 0.2374 in. busing Outside diameter sto 11.033 ~ 11.044 mm 0.4344 - 0.4348 in, OVS 0.05 | 11.089 ~ 11.094 mm 0.4363 - 0.4368 in, Valve Valve overall length STD. Intake | 98.60 mm 3.9213 in Exhaust | 99.75 mm 3.9272 in Limit Intake 88.10 mm 3.8016 in, Exhaust | 98.25 mm 3.9075 in, Volve face angle 4a" tem diameter Intake | 6.970 6.985 mm 0.2350 - 0.2386 in. Exhaust | 5.965 - 5.980mm 0.2348 - 0.2366 in. Stem oil clearance STD Intake | 0.025 -0.060mm — 0.0010 ~ 0.0024 in Exhaust, | 0030 - 0.085 mm 0.0012 - 0.0026 in Limit intake | 0.08 mm 0.0081 in, Exhaust | 0.10 mm 2.0039 in. Margin thickness, sto 08 - 1.2mm 0.031 ~ 0.047 in, Limit 0.6 mm 0.020 in. Valve spring | Free length 41.08 mm 1.6177 in Installed tension at 24,7 mm (7.966 in) | 146 - 17.0 kg (82.2 - 975 be 143 - 167 N) ‘Squareness, Limit 1.8mm 0.071 in Valve litter | Lifter giometer 27.975 ~ 27.985 mm 1.1014 ~ 1.1018 in Cylinder head lifter bore giame 26.000 - 28.021 mm 1.1024 ~ 1.1032 in it clearance sTo 0018 ~ 0.046 mm 0.0005 - 0.0018 in Ll Limit 2.07 mm, 0.0028 in. ‘aritolt — | Warpage intake manifold Limit 0.05 mm 00020 in. \ Exhaust manifold Limit 0.30 mm 0.0118 in, Ait contol | Warpage Limit 0.08 mim. 0.0020 in. T-VIS VSV | Resistance 33-390 Camshaft | Thrust clearance so 0.08 -0.190mm 0.0031 - 00075 in Git 0.30 mm 0.0118 in Journal oil clearance sto 0035-0072 mm 0.0014 - 0.0028 in, Limit 0.10 mm 0.0039 in.AS SERVICE SPECIFICATIONS — Engine Mechanical (4A-GE) Specifications (Cont'd) uss 0.25 Gamsnatt | Journal ameter 26.949 — 26.965 mm 1.0610 ~ 1.0616 in, (one Circle runout Limit 0.08 mm 0.0016 in, Cam lobe height sto 36.410 35.510 mm 1.3823 - 1.3980 in Umit 35.11 mm 1.3823 ia Cyinder Cylindor head surface warpage Limit 0.08 mm 0.0020 in, tock Cylinder bore diameter STD 81.00 - 81.03mm 3.1890 ~ 31902 in 0/8050| 8150-8153mm 32087 - 32098, Umit STD 81.23 mm 3.1980 in 0/8080] 81.73 mm 3.2177 in Piston and | Piston diameter sto 80.89 - 60.92 mm 3.1848 ~ 3.1858 in. Piston ring 0/S050| 8139-8142 mm $2043 ~ 3.2085 in Piston oil clearance 0.10 012mm 0.0039 - 0.0047 in Piston ring groove cloarance No.1 0.04 0.08mm 0.0016 - 0.0031 in No.2 | 003-007 mm 0.0012 - 0.0028 in Piston ring end gap STD. No.1 025-047 mm 0.0088 - 0.0185 in No. 2 020-042mm 0.0079 ~ 0.0165 in ol 0.15- 052mm 0.0058 ~ 0.0208 in. Limit No 1 1.07 mm 0.0421 in, No. 2 41,02 men 0.0402 in o# 112 mm 0.0441 in Connecting | Thrust clearance STD 015 -025mm 0.0059 — 0.0098 in rod Limit 0.30 mm 0.0118 i Connecting rod oil clearance STD STD 0.020 - 0.081 mm 0.0008 - 0.0020 in S026 | 0019-0073 mm 0.0007 - 0.0029 in, Limit 0.08 mm 0.0031 in Connecting rod bearing center wall thickness STO Not 1.486 - 1.490 mm 0.0585 ~ 0.0587 in. No.2 1.480 ~ 1.494 mm 0.0587 ~ 0.0588 in No.3 1.494 ~ 1.438 mm 0.0588 ~ 0.0590 in Bent Limit per 100 mm (3.94 in} | 0.03 mm 0.0012 in Twist Litt per 100mm (3.94 in} | 0.05 rm (0.0020 in. Bushing inside dameter —/ 20.012 = 20.022 mm 0.7879 - 0.7883 in Piston pin diameter 20,008 - 20.016 men 0.7876 ~ 0.7880 in Piston pin ol clearance sto (0.004 ~ 0.008 mm 0.0092 ~ 0.0008 in Limit 2.05 mm 0.0020 in, Crankshatt | Thrust clearance ‘STD (002 - 022mm 0.0008 - 0.0087 in Lint 0.30 mm 0.0118 in, ‘Thrust washer thickness sto 2.440 ~ 2.430 mm 0.0861 - 0.0980 in ‘Main journal ol lesrance sto sto 0.015 ~ 0.033 mm 0.0006 ~ 0.0013 in U/S.0.28 | 0.013 0.053 mm 0.0005 - 0.0021 in Limit 0.10 mm (0.0038 in, ' main jours! diameter st 47.982 ~ 48.000 mm 1.8891 - 1.8898 in 47.748 - 7.785 mm 1.8797 ~ 1.8801 inSpecifications (Cont'd) Torque SpecificationsA10 SERVICE SPECIFICATIONS — Ef! System (4A-GE) EFI SYSTEM (4A-GE) Specifications Toa pea] Fo panne Ra aS Tea reas b= 20 62 Tae — s00 ven Tas gan] Rearncs aaa Seon" | fonts de top oft per mite Wecior | Resklnce wa Kitow mee 1 appro 23-0 Nianieemee, | Aspen taan Icon voume —wioaittowmene | 48°C ta'o 12 ~ 20 cu par ¥6 ae Wiantowmer | S07 s3ce01~ 32cam}per see Dittanca between ach nce BectO3t ori) ors Pantatove Ge cop on priate oe = Throttle Clearance between T os Tria aor bese, Bewoon rina Fositonce a Omm = Oin, ‘VTA — £2 200 = 800, O38 mm Oot4in oe 2300.0 ori faba gorse ale ney Thesis ve ty Ta ra000 0 ni ie vase 3.200 7 voe — e2 3.000 - 7.000 1 Saad —| Roamans a8 na t6 7-30 ‘eae ine go3a (flow meter } Cou sad | fabian SiA~STitaow SC Tn | 20-70 Seo toow aoe oer) | 40-60 a ‘time ewiton ‘STA - Ground. 20-800 Ti tow | Resi VEE 2 #000 " mote Fst re ay ra so] Sees a — (Measunng plate fully closed-open) ve-e2 eon sun were 200 2400 Tha #2 at=20-c an | Io000's 26.000 a nocuzn” | donou 7oco'n soocwsry | 200023000 8 mane oa | 8002 13000 aore torn) | deo 700.0 rents wr Petting te fy lead : | (Others) Tay wn] Wenetenee a BET 10 = 20 a Nocamn are wie Air at 20°C (68°F) 2-3ko [ow mer nascaoen | do ctaan on Néocaeon | aecosen wa secenree | oan oaun, Srypen | ea a nas eo Sa - Fel preswre|Rnance so 39n a igen VV | Pesca waaE SPECIFICATIONS Specifications (Cont'd) EFI Syst ecu NOTE: «© Porrorm ail volage and resistance messuremants with the computer connected © Verity that the battery voltage fz 11 V or above with the ignition switch is ON Voltage (TCS ECU wio Air flow meter) Terminals Condition STD voltage (1 +8 hee Iss) won 10-14 BATT eI = 10-14 ToL - €2 Throttle valve open 45-55 Throttle valve fully closed 05 oF is via -e2 | IGswoN “Throttie valve fully open 35-85 vee - &2 = 45-55 ict - €1 Cranking oF ing o7-10 STA EI Cranking ota No. 10 node - Et 1g swoon ona woe 'No trouble (check engine warming tight off! ooaa ‘and engine running _ Pim — €2 33-39 6 Siw ON vec ~ &2 45-95 THA — 2 Intake air tomperature 20°C (68°F) 20-28 THW ~ £2 ‘Coolant tomperature 80°C (178°F) 04-08 ac et | is won ‘Ae conditioning ON 5-14 Check engine connector T — Ft not short | 5 - 55 1-8 N (Check engine connector T — €1 short 05 oriess ‘i 0-3 STH Et fp ——_Sia_} ‘Approx. 6,000 rpm or more 10-14 Resistonce (TCCS ECU wio Air flow meted Torminals Condition Resistance (22) Throttle valve fully open Infinity or -€2 Theotle valve fully closed 2,800 or less Throttle valve futy open 3,300 -10,000 via ~e2 Theottie valve fully closed 200 ~ 800 vec ~€2 = 3,000 ~ 7,000 THA —€2 Intoke air temperature 20°C (68°F) 2,000 ~ 3,000 THW -€2 Coolant temperature 80°C (176°F) ~__ 200 = 400 6-68 = 340 ~ 180 NE -66 = 140 - 180ANZ SERVICE SPECIFICATIONS — EFI System (4A-GE) Specifications (Cont'd) eu Watage 1008 FOU WA Tow meio leona | Fermi Condin STO vie 8 oe 16 sow on 1-14 BATT =e — ii ou | Tote vo pon 10-4 Tivoto vale fly lsed 05 aries VTA ~ ER IG Siw ON ‘Throttle valve fully open 35-55 vee —_ ae-ss Te Canny oF tng 07-10 “wane Crating fe No 10 ey 16 Siw ON oo woe To vous Ghost engine Waring Ha of a . | Malepine Tuning vere | . ea i08 | eswon ‘Messing late fy cosa rere wee ‘esr lta uly open o2-ea Ialing - 39-58 THA = E2 ~ intake air temperature 20°C (68°F) 2-28 moe Cootnt onperotung0°E 76-41 Oa- 07 | Ne =e | 1 condoning OW 5-1 yey | 6SWON | Chas ogi comet, T= El notator | 10-14 ‘Check engine connector T- El short (05 or Wess Fuel onl S/W NORMAL 10-14 np el Fuel control S/W SUPER 05 or less, tas 3 bddidintias ‘Approx. 4,350 rpm or more 10-14 Fsistnoe TGCS ECU w/ Ar Yow mete Terminal Cenden Fesitanee @) T Tht vole ful 0580 vey ro = Theotth ye tully closed 2,300 or less “Tivtte wae fay open 3.300 - 10.000 | VTA = BR ‘Throttle valve fully closed 200 - 800 [wee -e2 = 3,000 - 7,000 vs -e2 Measuring plate fully closed [20 - 400 Neosuig site fly pen ——_+[_20 = 8,000 ve =e = 700 = 300 Wa 82 Tate si tpeate 20° 15571 7000 = 3.000 Taw =e Coolntempeature 80°C 07677 200 800 o=65 = 140 180 NE -G2] = __ 140 - 180SERVICE SPECIFICATIONS — Efi System (4A-GE) An3 fy re a ceed 0 knvh any, FUCUEHBM wo Ait matr | 1,800 rpm 7 pod ieas Suh ad) wir flow meter | 1.400 rom MIT (cootert temperature 80°C 1176°F) wecen 1.800 rpm MT (VIS ON) 1,800 rpm AT Fuel retuin rpm w/o Air flow meter | 1,400 rpm. w/ Air flow meter | 1,200 rom Torque Specifications Part tightened kg-om feo Nm Fuel tine Union belt type 300 2 29 Flare nut type 310 22 30 Fuel pump x Fuel tank 35, 30 int 34 Cold start injector » intake manifold 5 65 into 74 Cold start injector pipe x Cold start injector 150 " 1 Cd start injector pipe x Delivery pipe 150 " 15 Fuol pressure rogulator x Delivery pipe 75 65 int 74 Fue! pressure rogulator x fuel return pipe (AW! 300 22 29 Bevery pipe x Cylinder head 175 13 ” Fuol niet pipe x Delivery pipe 300 22 28 ‘Throttle body x Air intake chambor lntake manifold) 220 16 2SERVICE SPECIFICATIONS — Cooling System, Lubrication System peu COOLING SYSTEM Coolant capacity w heater or sie conditioner ane wt Europe | S.2iites — SSUSqts 4.6 Ima. ate Generat | 5.8iters — 5.9.US q's 4.9 Imp. gts aT 5S iiters SUS gts 4.8 Imp. ats 4AGE AE and AT 6Oiiters 63 US gts 5.3 Imp. ats aw 124 liters 13.1 US ats 10.9 Imp. ats Raastor | Rel vale opening pressure STD 0175 = 1.08 k/em* (10.7 ~ 14.9 psi, 74 - 103 «Pad Limit 26 kgiem® — BE psi 59 kPe Woter pump | Bearing instaling temperature 85°C 185°F Therinostat | Vsive opening temperature 4 Starts to open at 80 - 84° 176 ~ 183°F Fully opens at 95°C 203F Valve opening travel B mm oF more 0.31 in or more LUBRICATION SYSTEM Oil pressure (normal operating temperature) at Idle speed More than 0.3 kgiemé (4.3 psi 29 kPa) {at 3,000 rom 25 ~ 5.0 kglem* (95.6 ~ 71.1 pei, 245 ~ 480 KPa) Oil pump | aar Body clearance st 0080-0135 mm 0.0031 - 00053 in. Limit 0.20 em 0.0079 in Tip ek stb 0.116 = 0.156 mm 0.0046 ~ 0.0061 in. Limit 0.35 mm 0.0138 in Side clearance sto 0.025 = 0065 mm 0.0010 - 0.0028 in. Limi 0.10 men 0.0039 in, 4a.ce Body clearance sto 0.100 ~ 0.191 mm 0.0039 - 0.0075 in, Limit 0.20 mm 0.0079 in, Tip clearance Drive gear to crescent S10 0107-0248 mm 0.0042 - 0.0088 in, Limit 035 mm 00128 in Driven gear to crescent STD. 0058-0310 mm 0.0023 - 0.0122 mn. iit 035 mm 0.0138 in, Sida clearance STD 0025 - 0075 mm 0.0010 ~ 0.0030 in Lit 0.10 mm 0.0039 inSERVICE SPECIFICATIONS — Starting System, Charging System STARTING SYSTEM Se = Conan = | Ree votape nd int pes | 12 OB bw vio "om | More an 000m | Mone hn 3.00 rm Armane tat came S10. | 008-080 ° (80020 - 00235 in) gon enn top cet sto | 01 04 mm - cienronce (0.004 ~ 0.016 in) usm tang SD | 16mm Em 18mm Omatin time | 10mm 0am | Bsmm gabe Sermo atte esd 81D | ta hbhg 705g ~ 2415 49 G1-35m18-18M | Go- eam 828M Umit | 1049228100 | Dig @emt2w comma Gute donee st | 28mm 140m | dom 118 Lint | 27mm 100m | 28mm ein Undecutsern SID |B mm Dozk m - me | 02mm coca. L | ccwnino ut | 4mm 0016m_| 05mm 00020 CHARGING SYSTEM Battery specitic gravity When fully chorged at 20°C (68°F) [128-127 Alternetor | Rated output 12V BOA 12V708 Rotor col resistance 28-300 Slip ring ciame stp 142-144mm 0889 - 0587 in, Li 140 mm 0551 in Brush exposed length sto 105 mm 0413 in Limi 45min 0.177 in Alternator, | Regulating voltage at 26°C (77°F) 139-151 seudees? Hel at 118°C (238°F1 135-143 IGNITION SYSTEM (4A-GE) tanition timing, See page A-6 ‘Spark plug See page A-6 Firing order 1-3-4-2 High-tension | Resistance 25 kA per cord cord _ Ignition cot | Primary coil resistance AE 041 - 0508 AT and AW o2- 0.94 0 Secondary coil resistance AE 102 - 13.8ka AT and AW 115 - 155k Distibutor | Air g 02 - 04mm (0.008 - 001 L__Siansl generator (pickup eal) resistance 140 - 180.8cz SST AND SSM ~ SST (Special Servic SST (SPECIAL SERVICE TOOLS) NOTE: Classitication A™= SST required for vehicle inspections and minor repairs and multipurpose SST. SST required for maior repairs involving disassembly of com- onents, C= SST required for rather special, less frequent work not Classifiable as either A or B FI (4A-GE) Section Classification Note J 2 \ \ toner.rzran | (foows vente) e 4A-GE eure) | e 9032-00100 || 08155-16100 | (Soak Pg wencrd | AL® le aap nz-ro |("250~"2) Lag csnasason | (Grins) a gy osars-t4aro | (Crmictettruter) | alg oar sna 31021 09213-70010 ae 4A-GESST AND SSM — SST (Special Service Tools! SST (SPECIAL SERVICE TOOLS) (Cont'd) 13] gl iz 2/8/23 25/8) Note e216. | mesrensorcaien |Al@ ie exai6-c0n0 | ser rewoncsti Al@, e st 20122 |(poros atce) |) | B —onzrans| omer | le ane <—» (09221-00130) | Guise "a" e a tosz2-00140)] tease We) eo | EO ene ERE) oe an | Sheauce ee | | (cesstnecoe? (8) | fo cr | fc (oiSeimecwee) (2) @ ccomahaft ol saat {Coto ont 4A.GE for (Gicetneance) | 8] @ amsnatt oi sea (onrite wien | e (eesa"") 8 i*ca SST AND SSM — SST (Special Servi SST (SPECIAL SERVICE TOOLS) (Cont'd) ‘Section Classitication _ | Part Name rt No. \ \ Mustration \ Note —M FI (4A-G6)| FU (4A-F) co iw 1s st cH Co _ | ama scar0| vin son e | mmm (serge e Corer ame) canvas el neste) omens le <=> ganas] wnomen lal | lol = exocona (2asm) [ale sas {Yare Ounce) “Aghust Toot se | ozop-sioes |(inectonvemwinn) a) lq) einarsie, |) |, - njecton Pump '*) Starter front bearing Eck) ors rn | Cartage er oun ame atc e2oarbeanng [- Z nocton Ps “+ Starter font bearing a) nzos-agons [neste Pame | | for 1-0 kw type “ez Recttier end frameSST AND SSM — SST (Special Service Tools) oe SST (SPECIAL SERVICE TOOLS) (Cont'd) zl g\e| ?| g| z= N lore \ =|2]8/3/2)5)3 essaconsas | (canmeron=ee) | | @| (Crankshaft pulley avsrzsoo | (Soeesaomt) |e e Cuankahatt onto seat cosso-10t2 | caraesscrsey | 8 (0052.1010)| au 2 epecarionte) | @ | | \ 48. tor spark pig tbe gesket oosen-10010| (Sorramouce) | [| Fon exave.20012 {Sree tering || 8 (00608-00020 | sce © Rotor rontbesrng 2 Powe Sting — CS | oness.z2029 || rovenn srt?) |A) | @l Fuel line flare nut ex veren) tart Re) (8420-00021 | \sescing Pubes! 8 e eaz-soro | (Stowe Fer) | ° eseaameso (Since) (8) || cssczsonee | ("09°56") |e] | W/o ie tow meter ! asoazsoore | (nee) fa! Jl w/ Airflow meter ‘panso-riars |(arburtor Drive) | eAND SSM — SSM (Special Service Mater SSM (SPECIAL SERVICE MATERIALS) Part Nome Cylinder haad cover rw | Camshatt bearing cap Not Half cecio pig For 4A-F) ‘Seal packing or equivalent 28825-00009 oy pn Oil pan battle plate (For 4A-GE) 16 | Ignition coi seal packing No. 1282-8 em | Water inlet housing Sst mtng - 08826-00100 Water out pipe co | Water pump seal ‘Spark plug tube (For 48.F) Adhesive 1224, 09839-00070 park plug Three bond 1324 or oquivatent 16 | Pickup set screw For 48-F1STARTING SYSTEM TROUBLESHOOTING ......... STARTING SYSTEM CIRCUIT . CONVENTIONAL TYPE STARTER . REDUCTION TYPE STARTER STARTER RELAY (AW) sT-1 Page st2 st-3 sta st14 st-23STARTING SYSTEM — Troubleshooting ‘wil not rank Flywee! teeth broken Replace fiywheel TROUBLESHOOTING Problem Possible cause Remedy Page Engine wil not crank | Battery charge low Check battery specitic gravity [CH Charge or replace battery Battery cables loose, corroded or worn Repsir or replace cables Novtral start switch faulty (A/T oni) Adjust or replace switch Fusible link blown Replace fusible tne Starter faulty pair starier ST-t o 14 Ignition switen faulty Replace ignition switch Engine cranks slowly | Bottery charge low Check battery specific gravity | CH-& Charge or replace battery Battery cables loose, corroded or wom | Repatr or replace cables Starter tautty Repair starter ST-4 or 14 Starter keepe running] Starter feuty Repair startor /ST-4 oF 14 Ignition switeh faulty Ropiace ignition switeh Short ia witing Repair wiring Starter spins-ongine | Pinion gear teoth broken or faulty starter | Repair starter ST or 14]STARTING SYSTEM — Starting System Circuit 81-3 STARTING SYSTEM CIRCUIT rr pore seta § | eas y Puincor [Hei Coil i {tite se Ene ey ats aon J, lon Seich 1 (ae AD $ AM2 7.58 Seusibie Link AW) Fuse 1.288 ALT 80a, ean) ree Link vw Starter Relay| aw [Feminal 80 ‘StorterSTARTING SYSTEM — Conventional Type Starter CONVENTIONAL TYPE STARTER COMPONENTS Drive Housing Drive Lever Magnetic Switch | e stones Starter Catch Armature Field Frame Commutator End Frame Through Bolt .# Non-reusable part sr c DISASSEMBLY OF CONVENTIONAL TYPE STARTER 1, REMOVE MAGNETIC SWITCH lo) Remove the nut, and disconnect the lead wire from the magnetic switch terminal (b) Loosen the two nuts holding the magnetic switch to the drive housing. Lift the magnetic switch up and ‘ut to unhook the plunger from the drive lever. 2. REMOVE END FRAME lo) Remove the screws and beating cover. (b) Using a thickness gauge, check the armature shaft thrust clearance between the lock plate and end frame. Thrust clearance: 0.05 ~ 0.60 mm (0.0020 ~ 0.0236 in}STARTING SYSTEM — Cor tional Type Starter st. {fc} Remove the lock plate. spring and rubber. {d) Remove the two through bolts and pull out the com- mutator end frame. 3, REMOVE BRUSHES AND BRUSH HOLDER lal Using @ piece of stee! wire, the brush springs, and remove the brushes from the brush holder. (b) Pull the brush holder off the armature. 4. REMOVE FIELD FRAME FROM DRIVE HOUSING Pull apart by hand 5. REMOVE ARMATURE (a) Remove the drive lever from the drive housing, (b] Pull the armature from the drive housing. 6 REMOVE STARTER CLUTCH (a) Using a scremdriver, top in the stop collar. a (el Using a screwdriver. pry off the snap ring a . (cl) Remove the stop collar from the shaft. ()_ If the pinion wos difficult to pull out, smooth the shaft with an cil stone. (e) Remove the starter clutch.sT-6 Continuity STARTING SYSTEM — Conventional Type Starter INSPECTION OF CONVENTIONAL TYPE STARTER Armature Coil 1. CHECK THAT COMMUTATOR IS NOT GROUNDED Using an ohmmeter, chack that there is no continuity bet- ween the commutator and armature coil core. If there is continuity, replace the armature, 2. CHECK COMMUTATOR FOR OPEN CIRCUIT Using an ohmmetar, check for continuity between the segments of the commutator. It there is no continuity between any segment, replace the armature, Commutator 1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES, Wf surface is dirty or bumt, correct with sandpaper (No.400) or a lathe. 2. CHECK COMMUTATOR RUNOUT Maximum circle runout: 0.4 mm (0.016 in.) Hf runout is greater than maximum, correct with a lathe. 3. MEASURE DIAMETER OF COMMUTATOR: Standard diameter: 28 mm (1.10 in) Minimum diameter; 27 mm (1.06 in.) IH the diameter of the commutator is less then minimum, replace the armature.STARTING SYSTEM — Conventional Type Starter ST-7 4. CHECK SEGMENT Check thet the segment is clean and free of foreign parti- cles. 0.6 mm (0.024 in.) Minimum undercut 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct with & hacksaw blade and smooth out the edge. Field Coil 1. CHECK FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check for continuity betwe field coil brush leads. Hf there is no continuity, replace the field frame. the 2. CHECK THAT FIELD COIL 1S NOT GROUNDED Using an ohmmeter, check for no continuity between the field coil end and field frame, If there is continuity, replace the field frame. Magnetic Switch 1. CHECK PLUNGER Push in the plunger and release it. Check that it returns Quickly to its original position 2. PERFORM PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check for continuity between terminal 50 and terminal C. If there is no continuity, replace the magnetic switch.STARTING SYSTEM — Conventional Type Starter 3. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check for continuity between termina! 50 and the switch body. If there is no continuity, replace the magnetic switch. Starter Clutch 1. INSPECT PINION GEAR AND SPRINE TEETH Inspect the pinion gear and spline teeth for wear or damage. f damaged, replece and also inspect the flywheel ring gear for wear or damage. 2 CHECK CLUTCH Rotate the pinion clockwise and check that it tums freely ‘Try to rotate the pinion counterclockwise and check that it locks. Brushes MEASURE BRUSH LENGTH Standard length: 16 mm (0.63 Minimum length: 10 mm (0.39 in) If the length is less than minimum, replace the brush and dress with an emery cloth Brush Springs MEASURE BRUSH SPRING LOAD WITH A PULL SCALE Take the pull scale reading the instant the brush spring soparates from the brush. ‘Standard installed load: = 1.6 kg (3.1 - 3.5 ib, 14-16 NI ‘Minimum installed load: 1.0 kg (2.2 1b, 10 NI If the installed load is less than minimum, replace the brush springs.STARTING SYSTEM — Conventional Type Starter sto [No continuity Brush Holder CHECK INSULATION OF BRUSH HOLDER Using an ohmmeter, check for no continuity between the Positive and negative brush holders. If there is continuity, repair or replace the brush holder.$110 STARTING SYSTEM — Conventional Type Starter ASSEMBLY OF CONVENTIONAL TYPE STARTER (Seo page ST-4) NOTE: Use high-temperature grease to lubricate the bearings and sliding parts when ossemblying the starter 1, ASSEMBLE STARTER CLUTCH TO ARMATURE (@) Place a new stop collar on the armature. (b) Drive in the snap ring with a 14 mm (0.5 in} socket ‘wrench, then fit it into the shaft groove. {c) Using a vise, compress the snap ring. ‘Make sure that the snap ring fits correctly (©) Using a screwdriver, tap the pinion to slide the stop collar onto the snap ring. 2. ASSEMBLE DRIVE LEVER TO DRIVE HOUSING AND FIELD FRAME TO ARMATURE la) Apply grease to the drive lever and drive housing bushing ~ (b) Install the drive lever to the drive housing, (c) Install the field frame on the armatureSTARTING SYSTEM — Conventional Type Starter sT-11 3 INSTALL BRUSH HOLDER AND BRUSHES (2) Place the brush holder, over the armature shaft. (b} Using a piece of steel wire, hold the brush spring back and install the brush in the brush holder. Install ‘the four the brushes. INSTALL END FRAME (2) Apply grease to the end frame bushing. (b) Install the end frame on the armature shaft. INSTALL FIELD FRAME WITH ARMATURE AND END FRAME IN DRIVE HOUSING (2) Match the protrusion of the drive lever with field frame lb) Install and tighten the two through bolts. INSTALL BEARING COVER (a) Install the rubber, spring and lock plate. (b) Using 2 thickness gauge, measure the armature thrust clearance between the lock plate and end frame. ‘Thrust clearane 0.05 ~ 0.60 mm (0.0020 = 0.0236 in.) (c) Install the bearing cover with the two screws. INSTALL MAGNETIC SWITCH Hook the magnetic switch stud underneath the drive lever spring. install the two nuts,sTiz STARTING SYSTEM — Conventional Type Starter PERFORMANCE TEST OF CONVENTIONAL TYPE STARTER CAUTION: These tests must be performed within 3 ‘to 5 seconds to avoid burning out the coil. Tommaso 1. PERFORM PULL-IN TEST Terminal (a) Disconnect the field coil lead from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the pinion moves outward. If the pinion does not move, replace the magnetic switch, PERFORM HOLD-IN TEST With the battery connected as above end with the pinion ‘out, disconnect the negative lead from terminal C. Check that the pinion remains out If the pinion returns inward, replace the magnetic switch. 3. CHECK PINION RETURN Disconnect the negative lead from the switch body. Check that the pinion retums inward. Hf the pinion does not retumn, replace the magnetic switch 4. CHECK PINION CLEARANCE (2) Connect the bettery to the magnetic switch os shown.STARTING SYSTEM — Conventional Type Sterter 87-13 {b) Move the pinion gear toward the armature to remove slack and measure the clearance between the pinion fend and stop collar. Standard clearance: 0.1 — 0.4 mm (0.004 ~ 0.016 in) PERFORM NO-LOAD PERFORMANCE TEST la) Connect the field coil lead to terminat C. Mal the lead is not grounded, (6) Connect the battery and ammeter to the starter a shown, () Check that the starter ratates smoothly and steadily with the pinion moving out (@) Chock that the ammeter reads the specified current. Specified current: Less than 60 A at 11VsT14 STARTING SYSTEM — Reduction Type Starter REDUCTION TYPE STARTER COMPONENTS Bearing lee Gear Clutch Assembly ‘Stool Ball Spring Starter Housing DISASSEMBLY OF REDUCTION TYPE STARTER 1. REMOVE FIELD FRAME WITH ARMATURE FROM. MAGNETIC SWITCH (@) Remove the nut. Disconnect the lead wire from the ‘magnetic switch terminal lb) Remove the two through bolts. Pull out the field frame with the armature from the magnetic switchSTARTING SYSTEM — Reduction Type Starter STS 2 REMOVE STARTER HOUSING FROM MAGNETIC ‘SWITCH ASSEMBLY Remove the two screws and remove the starter housing ‘with the idler geor ond clutch assembly REMOVE CLUTCH ASSEMBLY AND IDLER GEAR FROM STARTER HOUSING REMOVE STEEL BALL AND SPRING Using @ magnetic finger, remove the spring and stee! ball from the clutch shaft hole. REMOVE BRUSHES AND BRUSH HOLDER {a} Remove the two screws and end cover from the field frame. (0) Using » screwdriver or steel wire separate the brush ‘springs, and remove the brushes from the brush holder. (o) Pull the brush holder off the armature. REMOVE ARMATURE FROM FIELD FRAMESTARTING SYSTEM — Reduction Type Starter INSPECTION OF STARTER Armature Coil 1. INSPECT THAT COMMUTATOR IS NOT GROUNDED Using an ohmmeter, check that there is no continuity bet ween the commutator and armature coil core, Hf there is continuity, replace the armature. 2. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check for continuity between the segments of the commutator. If there is no continuity betwee armature, ny Segment, replace the Commutator 1. INSPECT COMMUTATOR FOR DIRTY AND BURNT ‘SURFACES. If the surface is dirty or burt, correct with sandpaper (No.400) or a lathe 2. INSPECT COMMUTATOR RUNOUT Maximum circle runout: 0.08 mm (0.0020 in) If the circle runout is greater than maximum, correctit with a lathe. MEASURE DIAMETER OF COMMUTATOR Standard diameter; 30 mm (1.18 in) Minimum diameter: 29 mm (1.14 in) If the diameter of the commutator is less than minimum, replace the armature.STARTING SYSTEM — Reduction Type Starter Continuity eR Nocontinuity STAT 4, CHECK SEGMENT ‘Check that the segment is clean and free of foreign parti- cles ‘Standard undercut depth: 0.6 mm (0.24 ind Minimum undercut depth: 0.2 mm (0.008 in.) I the undercut depth is less then minimum, correct it with ‘a hacksaw blade and smooth out the edge. Field Coil 1, INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, chack for continuity betwoon th wire and field coil brush lead, Hf there is no continuity, replace the field frame. 2. INSPECT THAT FIELD COIL IS NOT GROUNDED Using an ohmmeter, check for no continuity between the field coll end and field frame. It there ity, repair or replace the field frame. Brushes MEASURE BRUSH LENGTH Standard length: 13.6 mm (0.531 In) Minimum length: 8.6 mm (0.335 in) If the length is less than minimum, replace the brush end dress with an emery cloth. Brush Spring MEASURE BRUSH SPRING LOAD WITH PULL SCALE Take the pull scale reading the instant the brush spring separates from the brush, ‘Standard Installed load: 1.785 — 2.415 kg (3.9 - 5.3, 18-24) Minimum Installed load: 1.2 kg (2.6 Ib, 12 N) Hf the installed load is tess than minimum, replace the brush springs.ST.18 STARTING SYSTEM — Reduction Type Starter Brush Holder INSPECT INSULATION OF BRUSH HOLDER Using an ohmmeter, check for continuity between the positive and negative brush holders. If there is continuity, repair or replace the brush holder Clutch and Gears 1 INSPECT GEAR TEETH (Check the gear teeth on the pinion gear. idler gear and clutch assembly for wear or damage. IM damaged, replace, and also check the flywheo! ring gear for wear or damage INSPECT CLUTCH Rotate the pinion clockwise and check that it tums freely Try to rotate the pinion counterclockwise and check thatit locks. ings INSPECT BEARINGS ‘Turn each bearing by hand while applying inward force. f resistance is felt or f the bearing sticks, replace the bear- ing IF NECESSARY, REPLACE BEARINGS (2) Using $ST, remove the bearing from the armature shaft (b) Using SST, remove the other bearing from the opposite side. SST 09286-46011STARTING SYSTEM — Reduction Type Starter st SST tone 50.5) hor Terminal ‘Switch Body reesi20 (D\) Continuity (©) Using SST and a press, install @ now front bearing conto the shaft. SST 09285-76010 (d) Using @ press, install » new reer bearing onto the shaft Magnetic Switch 1 PERFORM PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check for continuity between terminal 0 and terminal C If there is no continuity. replece the magnetic switch. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check for continuity between ter 50 and the switch body. Hf there is no continuity, replace the magnetic switch,STARTING SYSTEM — Reduction Tys ASSEMBLY OF REDUCTION TYPE STARTER (See page ST-14) NOTE: Use high-temperature grease to lubricate the bearings and gears when assembling the starter PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings and insert the armature into the field frame. INSTALL BRUSH HOLDER AND BRUSHES (2) Using a screwdriver, hold the brush spring back, and install the brush into the brush holder. Install the four brushes. NOTE: Make sure that the positive lead wires are not ‘grounded. (o) Install the end cover to the field frame. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE Apply grease to the ball and spring and insert them into the clutch shaft hole,STARTING SYSTEM — Reduc 4 ‘Type Starter St INSTALL GEAR AND CLUTCH ASSEMBLY {a) Apply grease to the gear and clutch assembly. (b} Place the clutch assembly, idler gear and bearing in ‘the starter housing, INSTALL STARTER HOUSING Place the starter housing on the magnetic switch and install the two screws. INSTALL FIELD FRAME WITH ARMATURE IN MAGNETIC SWITCH (a) Match the protrusion of the field frame with the mag- netic switch, (| Install the two through bolts. (c)_ Connect the coil lead to the terminal on the magnetic switch,st-22 STARTING SYSTEM — Reduction Type Starter PERFORMANCE TEST OF STARTER CAUTION: These tosts must be performed within 3 to § seconds to avold burning aut the coi 1. PERFORM PULL-IN TEST {fa} Disconnect the field coil lead from terminal C. 0} Connect the battery to the magnetic switch os shown, (c) Check that the plunger moves outward, If the plunger does not move, replace the magnetic switch 2. PERFORM HOLD-IN TEST (2) While connected as above with the plunger out, dis- connect the negative fead from terminal C. (0) Check that the plunger remsi out. 'W the plunger returns inward, replace the magnetic switch. 3. INSPECT PLUNGER RETURN (2) Disconnect the negative lead from the switch body. (b) Check that the plunger returns inward. Hf the plunger does not return, replace the magnetic switch, 4. PERFORM NO-LOAD PERFORMANCE TEST (2) Connect the battery and ammeter to the starter as shown, (} Check that the starter rotates smoothly and steadily with the pinion moving out fc) Check that the ammeter reads the specified current Specified current: Less than 80 A at 11.8 VSTARTING SYSTEM — Storter Relay (AW) s1-23 [No continuity Continuity Continuity STARTER RELAY (AW) INSPECTION OF STARTER RELAY LOCATION: In the No. 2 junction black of the engine compartment. 1. INSPECT RELAY CONTINUITY 8) Using an ohmmeter, check that there is continuity between terminals 1 and 3 (b} Check that there is no continuity between terminals 2 ‘and 4, HH continuity is not as specified, replace the relay. INSPECT RELAY OPERATION (2) Apply battery voltage across terminals 1 and 3 {bi Using an ohmmeter, check that there is continuity betwoen terminals 2'ond 4. It operation is not as specified, replace the relay.