Toyota 4A-F Repair Manual
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Toyota 4A-F Repair Manual

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4A-F,4A-GE
ENGINE
REPAIR MANUAL
May, 1987

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Summary of Contents for Toyota 4A-F

  • Page 1 4A-F,4A-GE ENGINE REPAIR MANUAL May, 1987...

  • Page 2: How To Use This Manual

    HOW TO USE THIS MANUAL To assist vou in finding vou, wav thl"Ough this manual, the Sec· tion Tille end majo, heading lite given at the top of every page. INDEX 1 II i. provided on the "ege of each .ection to guide vou to tM item t o be ,epaired.
  • Page 3 IN·3 prOCedurllS are presllnted e stllp·by·IIIP format: • what when • Ihowl do it ll inu$lration do lind task huding tells wh.t The detailed tel1$ • text to perform the tnk and give, othe, infolmalion such as spee;ific;ations and warnings. Example: /T8Sk hr8di ng : wIuIt to d...
  • Page 4 IN·8 ABBREVIATIONS USED IN THIS MANUAL "'u.oIill<Y Acceler.tioo Pump "'i, Conditioner "' i, S "'utomatic Tr.n'mISlIon 8TDC 8.lo.e Top Dead Center Chok. 8reake. Dnh Pot Electronic Controlled Unit '" EIKlroni(: Fuel lOjeclion bhlWlt Gn Reci,cul.tion Elec:lron;c Spark Advance lmanifold..I EKn.usl �'I E_c:ept...
  • Page 5 EM-'" DESCRIPTION The 4A·Ge engine � .n in-line 4-cv�nder 1.6 �Ier .A-GE ENGINE OOHC val". engine.
  • Page 6 ENGINE MECHANICAL Description {4A·GEI TIM! cylinder block is made of CltSt iron. has 4 The 4A-GE engi('lfl is en in-�ne 4-cylinder engine cylinder, which are approJO.imalely 2 times the with the cylinders numbeTed '.2·3-4 from the length of the piston stroke.
  • Page 7 STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETEAMINE BOLT STRENGTH M�' M�' Clall bolt � head bolt hl&dNo 5- " "\ . . . Stud " " " " No maf� bolt " No mark Ho.U'ilOO lI.n(18 "...
  • Page 8 STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS CI ... Specili.d tOfqll. DI,..,., •• Pltcll • kg-em " 48 in._lb 52 in·1t> " 1.25 "0 " '" " 1.25 " " " " 1.25 " " " 0 " "...
  • Page 9 FUEL SYSTEM • INJECTOR • COLO START INJECTOR INJECTOR COLD START INJECTOR SQL£�O'C(O'L SOLE�UIU r:t>" "' ..l T ... cold stan injector, m.I�II",lln theCcnler sreH Thll injcclOl j)!'flo''''' The Injection of fu.1 in is provIded to accord3n�e wllh ,,()mJluterclllcul�tlKl ;",\OI:,;on the �j, ciinributlon...
  • Page 10 AIR INDUCTION SYSTEM • AIR VALVE AIR VALVE CA'. \/A' \/F "",-vt CA\O FRU .. ""01 C'-U."�H O, .. ""Al OPERATION The ai. �ilvc " '"st odie ""t'f�ted by <Mv;"� When y a cold eng""'. �te v81"" is ope" • "...
  • Page 11 CHARGING SYSTEM P.ge PRECAUTIONS CH-2 TROUBLESHOOTING CH·2 CH·3 CHARGING CIRCUIT ON-VEHICLE INSPECTION eH·4 ALTERNATOR CH·7 ENGINE MAIN RELAY CH·15...
  • Page 12 SYSTEM CH-2 CHARGING Precautions. Troubleshooting PRECAUTIONS Check that the battery cabl .. are connected correct terminala. DI.connect the battery cable. when the battery is given a quick ch.rge. •. Do not perlOt'm .. ts with . high voltage insulation ,.alu.nce teUer. Never disconnect the b.ttery whil.

  • Page 13: Charging Circuit

    CHARGING CIRCUIT 1(;2 Fuse Fusib le ' N GN' Li n k - � . AM ' Swi t ch F usi ble lO A <OA ru.. IA n fusib le �, ?O N A 4A_FI 30 A �2 �!.!� Ch, rge �.;;'"' , <i>(�...
  • Page 14 CH." ON-VEHICLE INSPECTION INSPECT BATIERY SPECIFIC QRAVITY AND ELECTROLYTE LEVEL cell. Check the specific grevity of Standard apeclflc grevity charged at 20'C 1.2fi - 1.27 when fully 188�F): If not with;" charge The banery. specifications. cell. Check each electrolyte quantity of insufficient., refill with distilled lor purified) weter.
  • Page 15 !Reference' Using SST, check the drive belt tension. SST B 09218-00020 SST A 09215-00030 Drive belt '1I",loO'i: •• 4A-F New be" 60 - 70kg d belt 40-55k 9 eA-GE 70 - 80k9 New belt ,<000> « _ Used belt 30-lI li kg...
  • Page 16 CH-6 CHECK CHARGING CIRCUIT WITHOUT LOAD NOTE' a battery/alternalor leSler is available. coonecl Ihe tHtar to the charging circuit according to mlll n ufacturer', instructions. f . tetter i, I'IOt av8�8b1e, connect a voltmeter and Immeler Ihe charging cirt:uit as follows: 8 Disconnect the wire from terminal of the III l teml­...
  • Page 17 ALTERNATOR COMPONENTS DISASSEMBLY OF ALTERNATOR REMOVE RE AR END COVER Remo va Ihe nul and tsr mlnal Insulator · ree nuts end cover emove the...
  • Page 18 · •. REMOVE BRUSH HOLDER AND IC REOULATOR Remove the five lerew bnlsh holder end IC regulator. REMOVE RECTIFIER HOLDER Remove the lour lerews lind rKtili e < holder. Remove the lour rubber insulators. REMOVE PULLEY S ST Hold SST A with torque wrench.
  • Page 19 CHARGING SYSTEM INSPECTION AND REPAIR OF ALTERNATOR Rotor INSPECT ROTOR FOR OPEN CIRCUIT ohmmeter, check that there continuity be- ng an tween the s p rings. Standard r •• i.tanc. (c If there is no the lotor. replace m.>i INSPECT ROTOR FOR GROUND �...
  • Page 20 CH·l0 Brushes MEASURE EXPOSED BRUSH LENGTH Minimum .xpos.d I'nslth: 10.177 If the bruUl length is len th.n minimum. replace the bnJshes. IF NECESSARY, REPLACE BRUSHES Unsolder lind remove the bruSh and spring. (II ) the wire of brush through the hole brush holder, the spring'nd brush into the lind in54lrt...
  • Page 21 CH-ll INSPECT NEGATIVE SIDE RECTIFIER Connect o teslet probe to each rectifier terminal eech the oth rectifier negative lerminal. Reverse the polarity the tester probes. Check that one sho continuity a"'" the other ..shOWS no continuity. If not. replace the rectifier holder. Bearings INSPECT FRONT BEARING the bearing...
  • Page 22 CH.12 Using SST sod a press, press in a new Iro bearillQ into Ihe drive end frame. 09608·20012 109606.00(30) claws of the bearing reUilner the slotl the drive end frame. Install the bearing retain8f" with th four screws not rough or worn. INSPECT REAR BEARING Chllck that the bearing...
  • Page 23 CH·U ASSEMBLY OF ALTERNATOR CH· 71 ISe. Pig. ROTOR TO DRIVE END FRAME INSTALL 1.. ) INSTALL RE C TIFIER END FRAME Using e plo.lle·f8Ced hemmer. lightly tep in the end freme. Install the lour nuts. INSTALL PULLEY In.!tll Ihe puley IhI rotor shefl by lightening pu.ey hend.
  • Page 24 CH-14 COlllf 10 hold ... INSTAll BRUSH HOLDER AND IC RfOUlATOR Place the brush hoidel' the bru,h hoktI(, wlllf In.tllI IC regulator .nd bf\I,h hoklltf to tilt ,..� freme horizon tilly ahOl/Wn In figure. NOTE: M�e ,ure bruah doe",·t sli p during in,I.II.tion.
  • Page 25 CH-1S ENGINE MAIN RELAY INSPECTION OF ENGINE MAIN RELAY LOCATON: In the engine comp.rtment r.lav boll. .nd AT In the No.5 junction block of the f,ont lug. gage compartm.nt. INSPECT RELAY CONTINUITY Using .n ohmmeter. check that the,e is continallv between terminals an.d Check that there is continultv between terminals...
  • Page 26 CO-l COOLING SYSTEM Pig' DESCRIPTION • . CO-2 TROUBLESHOOTING COot; CHECK AND REPLACEMENT OF ENGINE COOLANT coos Check of IInglne cool.nt • • . • • • , •• • • COoS Replacement of Engine Cool.,1l • • • jAE end AT) coos ReplllCllment of Engine Coolent (AW) CO-7...
  • Page 27 ••• DESCRIPTION •. pr."urizeG WII.r lon::ed c i r cullliion cooling system which include, I thermostat equip . This engine uli�z ped with. byp.lu . 1 ..mounted on the inlet sid 4A-Of...
  • Page 28 CO·3 T ile cooling sYSI(�m is composed of Ihe w,uer lank. The core conlie , ins msny tubes through which lICk't Gnside the cylinder block and cylinder head), coolant flows from the left ,ide tank to th-e righl· radi3tor, waler pump, thermostat, elllCtric fan, side tank 8S well es cooling fins whiCh rlldlll!S heat hoses and other components, away from the coolent in th-e tubes.
  • Page 29 CO-4 type el ... THERMOSTAT The Ihe.mostat hts a walt bypass ... e loo is mounted in the water inlet housing. The ther­ mostat includes a tyPtl of automltic e oper­ ated by fluctUltions in the coolant temperature This ... alvl closes when the cool ..t t.mp.rature ...
  • Page 30 CO-6 TROUBLESHOOTING .. . P.obl.m POlSlbl. c.u •• PIO' Remedy Din. inHCts Engi<M o ..heats AdjuSI or repiKI bell W.ler pump dr . b.1t 100$11 or mts!l.ing CH_4 Hose5. leave. or .eliIIOt Cleln .,di.lo< CO-19 • waler pump, lhermoslll housing. Repair n&Ce-ssary r;ldiIlOf.
  • Page 31 CO-6 COOLING SYSTEM Check .nd Rept.cement of Engine Cootlnl CHECK AND REPLACEMENT OF ENGINE COOLANT TANK Check of Engine Coolant CHECK ENGINE COOLANT LEVEL AT RESERVE "FUll" FULL 1m. Th. coolant level should be between the "lOW" linn. low, check for I.ek, and edd coolant up to the I"V Stilet CHECK ENGINE COOLANT QUALITV...

  • Page 32: Coolant Circuit

    COOUNQ SYSTEM Ctteck and Rej)lacemcml of Engine Coolant CO°' Replacement of Engine Coolant (AW) COOLANT CIRCUIT DRAINAGE OF ENGINE COOLANT 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 ORAIN ENGINE COOLANT Connect...
  • Page 33 CO-8 COOLING SYSTEM Check �nd Replacement of Engine Coolent Drain the coollnl from the two redia tor pipe drell 'l cocks. REFILL OF ENGINE COOLANT CLOSE DRAIN COCKS Tight the rediatOf pipe, radilltor end engine dr"n co<:h. Torque: 170 kg-em 112 ft-Ib. 1 7 N'm) Redietor pip.
  • Page 34 COOLING SYSTEM and Replacement of Engine Coolant CO-9 Check heater air drsin lIallle Close the radiator and service hoses. Disconnect th filler Clip) to NOTE: remOlling the service hoses. place a ritg When any dripping coolant. beneath the lIallle 10 asten the radialor cap (water the firsl stop point.

  • Page 35: Water Pump

    CO·10 WATER PUMP COMPONENTS • Sepl Pulley Seat • Body Geske! Wiler Pump • NGn-reusable parI REMOVAL OF WATER PUMP ORAIN COOLANT CO-6 or 71 (See plge (4A-GEI REMOVE ANOIOR Ale DRIVE BELT LOOSEN WATER PUMP PULLEY AND REMOVE ALTERNATOR DRIVE SELT Loosen the four water pump pulley bolts.
  • Page 36 CO·l1 loosen the lOCk boll end piyot Moye the alternator fullv right. and remove the driye belt. 14A-FI REMOVE PS DRIVE BelT REMOVf. WATER PUMP PUllEY Remoye the fou. bolts and pump puUeV. REMOVE WATER INLET PIPE Di.connect the inlet and watt. bv-pass hO$es waler the inlet pipe.
  • Page 37 CO-12 REMOVE OIL DIPSTICK GUICE AND OIPSTICK Remove the mounting bolt and pull put the dipstid! guidl 0\1\ and gauge . �Ia. NOTE: After pulling the o� dipstick guide. be sure plug oil pump body REMOVE NO.3 AND NO.2 TIMING BELT COVERS pliO_ "A-F [See pege EM-59}...
  • Page 38 CO·t3 (See p DISASSEMBLY OF WATER PUMP ge CO-l0) Ihe three bolts. REMOVE WATER PUMP SUCTION COVER Remove Using screwdriver. pry off Ihe waler pump suction cover. REMOVE PUllEY SEAT ,S> Using SST end press, remove the pulley seal from the Wllter pump bearing shaft SST 09236·001 0 1 {09237·00010.
  • Page 39 co·,. ASSEMBLY OF WATER PUMP ISee pege CO·l0) set. NOTE: Alw,ys assemble Ihe w pomp with a new sui a new rOlor and iI new bearing. INSTAll WATER PUMP BEARING GradlJ.ll l ly hcat the water pomp body to appro�. 85'C 11 85GFI.
  • Page 41 Torque: 150 kg·em ( 1 1 ft-Ib, N·m] •• INSTALL NO.2 AND NO.3 TIMING BelT COVERS •• P-sli 4A-F p�1 EM-94) 4A-GE EM-12l) INSTALL OIL DIPSTICK GUIDE AND DIPSTICK InslaM new O-ring on oil dipstick guide.
  • Page 42 co·n Connect the waler inlet .nd Wit ... by.pa$$ hot" to tM Inlel pipe. TfMPORARILY INSTALL WATER PUMP PULLEY In"all tn. wlte, pump pulley end temporarily tighten the four bolts. I.A·F} INSTALL PS DRIVE 8ELT INSTALL ALTERNATOR DRIVE BELT belL Pleee the drive belt on the Nch pulley and set up the drive Tighten the four bolts of the water pump...
  • Page 43 THERMOSTAT REMOVAL OF THERMOSTAT DRAIN COOLANT COoS ISee p-.ge REMOVE WATER INLET HOUSINQ COVER AND THERMOSTAT Remove the two nutS. Ihe housing cover end Ihermostal from Ihe waler inlet hOU$ing. • • INSPECTION OF THERMOSTAT NOTE: The thermosle $ numbered according to thl! vllve opening temperature.
  • Page 44 RADIATOR CLEANING OF RADIATOR • Using water or steam cleaner, remove any dirt from the radiatOf' core. CAUTION: high pr ur. type 1;:1,,0Ilr. be not to deform the of the r •. If elt.ful fin..4() the c kg/em" pr ...
  • Page 45 00-20 COMPONENTS PIlle -,.& • D_Ring DISASSEMBLY OF RADIATOR (AE and AT) REMOVE TANK PLATE with SST in !hi Raise the clews of the plates numerical order shown in the figur 09230-00010 core p lele. NOTE: Be clreful not damllge the •...
  • Page 46 COOt.INO CO-21 SYSTEM Radiator Pull the tank p4ates o utward. REMOVE TANK AND O-RING Pull the tank upward. Remove the D-ring. (AfT) REMOVE OIL COOLER FROM LOWIER TANK Remove nuts. sp,ing washers, plate washers cooler. D-ring Remove tile eoole,. from...
  • Page 47 COOLING SYSTEM d· a lator O� Cool.,.. ASSEMBLY OF RADIATOR (AE CO-20) (See page INSTALL OIL COOLER TO LOWER TANK Clean the O-ring ..er l&11k contact surface of the lo Install ne ..O_ring to l cooler . Install the oil cooler ..ith the a-rings to the tank.
  • Page 48 COOLING SYST CO-23 STAKE CLA.W OF TANK PLA.TE 09230 punch SST to Setlhe "LOW". .()()()10 numerical ord ar te . with SST Stake the claw of the t a nk 09230 -00010 ,� tgU Il'!. shown in the PlHlf. It pl�l.
  • Page 49 CO-24 points shown in tha illustration cannot ba slaked • with the Use a pliers or like object and be carelU SST. not to damage the core plates. INSPECT FOR WATfR LEAKS Tighten the drein plug. Plug the Inlet and outlel pipes of the radiator with SST.
  • Page 50 G SYS Radiator COOLIN CO-25 INSTAllATION OF RADIATOR " ,,'AT INSTAll RADIATOR PlaC4!l the radiator in installed position and install the two supporb with the two bolts. NOTE: After in.,allation. confirm that the rubber cuahiorl !A) of the support is not depressed.
  • Page 51 CO·26 ELECTRIC COOLING FAN Radiator Coolin g Fan (Ex. AW Europe) SYSTEM CIRCUIT RADIATOR Fusible Lin" FAN 30A RAD FAN lOA IA£) AN lOA !All (AW) 10A IAEl (AE.AT! !AWl Fus.ibla FUM IGN AM2 30A IAE. !AWl Fuse AM2 5A Cooling ""...
  • Page 52 . shon c t betwllen the Ian relay and switCh. AI! (4A-F) CONNECT TEMPERATURE SWITCH CONNECTOR High Coolant Temperature (above 90°C (1 94°F)) START ENGINE to above 9O"C It 94"FI. se engine eoolant Check thai the fan rotates.
  • Page 53 CO-28 COOLING SYSTEM - Electric Cooling INSPECTION OF ELECTRIC COOLING FAN INSPECT TEMPERATURE SWITCH LOCATION: AE and AT t housi On the water i On t ft s rlldi ide. Using an ohmmeter. check Ihat thetl is no c nti,.,.,., 9J"C when coolanl temperllurl...
  • Page 54 COol' Radiator Cooling Fan (AW Europe) SYSTEM CIRCUIT COO�I'I\I �In CDS FAN Compute, Fuse RAD rAN Ignition SwitCh Fusible Fute No ' link AM27.5A Coolin\l Coolin\! HEAD ,� ,� """ Reillv No. 3 Fusible Cooiinll link .2.58 Relav Wit .. Temp.
  • Page 55 CO-30 ON-VEHICLE INSPECTION Low Coolant Temperature {below 85°C (1 85°F)) TURN IGNITION SWITCH ON btl· Check thet the fan does not rotate. ''''-'' t rotate. the Ian relay and temperature chick switch. Check for a separaled connecto, or ""e,ed wire ween the relay and temperature switch.
  • Page 56 COOLING SYSTEM CO-31 INSPECTION OF ELECTRIC COOLING FAN COMPONENTS INSPECT WATER TEMPERATURE SENSOR LOCATION: On the rsd,stOt' l Using an ohmmeter, measure the resistance between the terminals. Re,I,lance: ApprOll. 1.36 kll B6-C !1B6'F) Approx. 1.19 kO OO'C !lS4"F) Appro". 1.06 kll at S6'C !203·F) If res sten is not as specified, replece the sensor.
  • Page 57 00-32 NO.3 COOLING SYSTEM Electric Cooling Fan INSPECT COOLING FAN RELAY LOCATION; In the No.5 junction block of the frorl! kI9- gage compartment. 'n'p.et relay continuity U,ing an Ohmmeter, check that there i, continuity between terminals 1 and Check that thlrl Is no continuity between terminais 2 ;md 4.
  • Page 58 CO·33 Engine Compartment Cooling Fan (A W l SYSTEM CIRCUIT fusible Link AMI SOA Co ol in g "n Fusible """ U" 1 .258 'EurOPe COMPONENTS...
  • Page 59 CO·34 ON·VEHICLE INSPECTION Low Temperature (Below 64"C (1 47"FII TURN IONITION SWITCH " ON" dQe'S Check that Ion SIOP$. COlI­ If il not. check the cooling Ian relay and comPIfI' menl temperilture 5en$Or. and chKk for a seporated I'le(;tor or severed wire batwaen tha cooliog fan relay " com�rtment temperatura sensor.
  • Page 60 COOLING SYSTEM flee INSPECTION OF ELECTRIC COOLING FAN COMPONENTS r."" INSPECT COMPARTMENT TEMPERATURE SENSOR LOCATION; On the head plilte. Using ohmmeter, re the resistence between terminals. Rut,lInee: Approll. 627.0 scoC (U9"F) 2(16.5 SO'C (1 7S"F) Approx. 'ttrslonce is not specified. r place sensor.

  • Page 61: Table Of Contents

    Ft-' EFI SYSTEM Page SYSTEM DESCRIPTION FI·2 PRECAUTIONS FI-6 INSPECTION PRECAUTIONS FI·6 FI-10 TROUBL.ESHOOTING • • • . DIAGNOSIS SYSTEM . . . FI-22 TROUBL.ESHOOTING WITH VOLT/OHMMETER FI-29 FI·66 FUEL SYSTEM FI-66 Fuel Pump ..FI·72 Cold Start Injector FI·76...

  • Page 62: System Description

    SYSTEM DESCRIPTION Ftow Meter AIC ComP"iuor CO ... Iwnition Switch COI1nectOl' '"" '""'" <Cu Int.�. Cion,.., r.mp. SWItch Cold Start 1n,ec:1Or SWllch W,I_T.mp.Swt!Ch...
  • Page 63 SYSTEM DESCRIPTION (Cont'd) wf Air Flow Meter Ignilion AlC ComPfeuor Switch Check Check fogone ConnllCtor We.niog Light (T -E Inluke Temp, Sensor Fuel Pressure Regut.ltor SUlrt SwilCh Inj&clor Cold Time Waler Temp. Sensor...

  • Page 64: Electronic Control System

    System Description EFI SYSTEM Diagl)Qsls EFI _v.tem i. compoNd of thr •• b •• lc sub· .ystem: Induction, Air Induction and FUI' The fCU delects any malfunctions or abnor­ Electronic Control System. maltias in the sensOf network and �ghls check engine weming light the instrument FUEL SYSTEM panel.

  • Page 65: Maintenance Precautions

    FI-6 PRECAUTIONS Before wOIking the fuel Iyltem. dl.conneet the cab" from negative terminal the be«ery. NOTE: Al'ly diagnostic code retained by the computer will be eraK'(! when the battery termillal is removed. Thefefore. necessary. read the diagnosis belore remov­ ing the battery lermil'lll L not Imoke or work on open fllme when working on the fuel Iyltem.

  • Page 66: Precautions

    IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM. CB. ETC.) willl The fCU hilS been designed so Ihal il wi. not be affected by outside inteftMence. However. if your vehicle is equipped a C8 radio er. etc. \&�en one wilh about l O W oulpu1!. espedal'f it may.
  • Page 67 FI·7 Care is raquired when pulling and inset1ing wiring con· necto". Release the lock and pull out the connector, pulling on the connectolS. Fully Insert the connector and check that it Is locked. When inspecting connector with a volt/Ohmmeter. Carefully take out the water-ploofing rubber if it is water-ploof type connector.
  • Page 69 FI-9 Che(:k that there are no fuel leaks after performing any maintenance on the luel system. Wah engine stopp$'CI. tum the ignition switch ON. Using a service wire, short te'mlnals and FP of the check connector. See page FI·S9 LOCATION: When the fuel ,etum hose is pinched.

  • Page 70: Troubl.eshooting • • •

    TROUBLESHOOTING TROUBLESHOOTING HINTS flrsl Engine trouble Irt uSUII H y not caused by the EFI Iyltent When troubleshooting. alWIIY, check lhe cooditkm the other systems. Electronic source • htlery • Fusible link. • Fuses Body ground Fuel .uPOly • Fuel leakage F...eI •...
  • Page 71 Troubleshooting EFI SYSTEM Use a volt/ohmmeter with high impedance [);g'lalTVpe minimum) for troubleshooting the electrical circuit. Analog Type (See page FI.29J TROUBLESHOOTING PROCEDURES SYMPTOM - DIFFICULT TO START OR NO START (ENGINE WILL NOT CRANK OR CRANKS SLQWl VI ELECTRIC SOURCE CHECK Battery ( 1 ) Connection...
  • Page 72 FROM FI·12 CONTINUED E FI· I I prenure CHECK FUEl SUPPLY TO INJECTOA 1. fuel in tank FuslI fuel in fuel line Circuit opening .elIlV (See page FI-91] (1) Short tcrminals +B lind FP of Ihe pump (See �e FI-55] Fuel (See l f�tfll' "...
  • Page 73 SYMPTOM - ENGINE OFTEN STALLS !See CHECK DIAGNOSIS SYSTEM Diagnostic eodelsl (See page fl-25 or Check for output of diagoollic code. Malfunction FI_221 !HIge cadetsl code NorTnII CHECK fOR VACUUM LEAKS IN AIR Oil filler cap INTAKE LINE 2. Oil dipstick Hose connections PCV hosels) 2.
  • Page 74 bit! h Efl SYSTEM $ OOI ::!i eONmUEO FROM PAGE FI-13 A u.i!iary ai, "aI", ISee page FI-a7) Wiler hose Air hOI" PII98 CHECK fUEL PRESSURE FI-55) fuel pump lSI, !See FI-571 P&gI Foel fil ..Fuel pressure reg ..alo' fl-75) ISH page CHECK INJECTORS...
  • Page 75 SYMPTOM - ROUGH IDLING AND/OR MISSING CHECK DIAGNOSIS SYSTEM Diagnosti<: coc/e\sJ diagnoslic code. Check OUtpYl Malluncllon (See page FI-25 FI-2SJ !Sae page FI-22) code\s) Normal cOde CHECk FOR VACUUM LEAKS IN AIR Oil filler cap INTAKE LINE Oil dips l ick COl"lntlClions Hose hose lsi...
  • Page 76 II I h o tin EFI SYSTEM CONTINUED FROM PAGE FI-1S 1. Fuel pump (See page FI-65) CHECK fUEL PRESSURE (See page Fl-67) 2. Fuel filter 3. Fuel preS5ure regulator (See page FI-75) paoe Inj8(;liOn condition CHECK INJECTORS (See FI-77) W iring connections CHECK EFI ELECTRONIC CIRCUIT 2.
  • Page 77 EFI SYSTEM Troubleshooting E FI.16 CONTINUED FROM PAG CHECK FUEL PRESSURE Fuel prllssure regulator High pressure pagll FI·67f !See CHECK COLD START INJECTOR Cold start Injector - FI·72f lSee page Fl." , pltgll Lealage, Injection quantity CHECK EFI ELECTRONIC CIRCUIT Wiring connection USING VOLT/OHMMETER 2.
  • Page 78 FROM CONTINUED PAGE fl- 1 7 CHECK COLD START INJECTOR Cold start injection (See page fl-72) Cold start in�tor l ime switch. pege Fl-95) pump CHECK FUEL PRESSURE Fuel page FI-65) p.ge Fuel f�ter ISee FI_67) Fuel pl"lIssure reguletor ISee FI-7SI pege Injectors...
  • Page 79 EFt S S " e.hooting CONTINUED FROM PAGE FI·18 CHECK IDLE SPEED lAND IDLE CO Idle speed - Adjust CONCENTRATION] 2. Idle CO concentration Adjust (See page EM-39 or CHECK COLD START INJECTOR Cold start injector (Sf!e page Fl· 72) Cold start injector rime switch.
  • Page 80 EFI SYSTEM Trooble$OOoling 11'1·20 CONTINUED FROM PAGE FI· 1 9 AIR FILTER ELEMENT CHECK DIAQNOSIS SYSTEM ISee CHECK Diagl1O$tic cadets) FI·25 or 26) page Check for outpul of OilIgnollic code. tion lSee codelsl FI-22) Normal code CHECK IONITION SPARK High·ten$ion corels IS"...
  • Page 81 Fl· .. FROM PAGE FI.20 CHECK EFI ElECTRONIC CIRCUIT Wiring connections tlSlNG Power to ECU VOLT/OHMMETER (1 I fusible �nks page FI-2S1 (2 ) Fuses Efl main relay Air flow meter (wI Air flow meterl Vacuum seosor (w/o Air flow meter) Water temp.

  • Page 82: Diagnosis System

    R-22 DIAGNOSIS SYSTEM DESCRIPTION contaif'ls buill_if'l self-dia9f'lOsi. aYltem b y 81" which troubles with the ef'lgiM .igmill f'letwonr. detected 8f'ld a che<:k engif'le wemif'l9 light Of'l the if'lltlU­ maf'l! pef'lel flashes. By af'lalyzing various sigmll. as show" if'l the Ister table (See page fl-26 or 261 the ECU detects syltem mlllt.,lIlt·...
  • Page 83 SYSTEM fl 23 '8gnoS" 0. 5 DiagnOStic Codes (See p ge FI·25 or 26) {TeeS ECU w/o Air Flow Meted Normal System Operation (codl! No.1) (normal tunc- seconds. The lighl will blink every 4.5 • (Seconds) 01 ti �I Malfunction Code Indicat ion The lighl blink number mes equal to the mal-...
  • Page 84 Dillgnosis System EFI SYSTEM CANCELLING DIAGNOSTIC CODE 1.SA Alter repair trouble area. the diagnostiC code retained in STOP memory by the ECU must be cancelled by removing the luse STOP !SA !AEI. EFI !SA tATI or AM2 !AWl. located In the eflgine compartment.elay bo�. lo. seconds or more, depending o n ambient tempe'etu,e !the lower the temperllture, the longer the fuse must be leh out) with the ignition switch OFF.
  • Page 85 EFI SYSTEM DiagnoSis System FI-25 DIAGNOSTIC CODES (TCCS ECU w/o Air Flow Meter) " CHECK ENGINE Di8gooli. Troubl • •• • • blink. appeal'S wh.n non" 01 This NOnTIal codes Ihru 1 1 ) other Vacuum SenSOr circuit Open shon circuit i Vacuum SenSOr FI_44 sensor signal...
  • Page 86 1'1·26 Diagnosis System DIAGNOSTIC CODES (TCCS ECU wI Air Flow Meter) •.. • •••• CHECK ENGINE Syll.m DiIIgno.ia Troubl - . . olher code. 112 IIwu !ill ia Cf G sigNl EeU wilhin o;.uibulo< " ---.l lJ\JL RPM�I several seconds Iller engine Slart ..
  • Page 87 INSPECTION OF DIAGNOSIS CIRCUIT 81n.., '" ru .. FUI lbie 8A TT �5R Un� linl< ALl AMI 80A 40A 8111..-y "" f�-..bIo o "", ", ..
  • Page 88 FI-28 Syllem Normsl when ignition switch is rmin light Does check engine warning come when grounded to the body luse aod wiring between ignition switch. Repair or replace. engine werning light go off Does check when the engine is stGrled? Is there diagnostic code output when check connector...

  • Page 89: Troubl.eshooting With Volt/Ohmmeter

    FI·29 TROUBLESHOOTING WITH VOLT/OHMM ETER following troubleshooting procedures are NOTE: following troubleShooting pro­ cedures designed for inspection of II&ch sepa­ blSed on the supposition that the tr o oble �e5 in either II short or open circuit in a component out­ rile system.
  • Page 90 LOCATION OF FUSES AND FUSIBLE LINKS (Cont'dl '". GAUGE (Europel TURN-GAG 10111_1 ���k 1 258...
  • Page 91 fFI SYSTEM Troublt.hooti!' l g with Volt/Ohmmeter FI-31 EFI SYSTEM CHECK PROCEDURE NOTE' thll' the bettery V 01' voltage measurements with lhe cOnneclof$ • connecled Is I I voltage mote when the • ignition switch is at " ON" , Using e voltmeter with high impedence (10 kilN minimum), measure...
  • Page 92 Voltage at ECU Wiring Connectors (TeeS ECU wlo Air Flow Meter! TermiNlI, voltage (VI Condition - E> 10 - 1 4 Ignition SIW ON FI-33 BATT - '" fl_34 0.5 Of lou IDl - Thro t tle ..!ve open open Throttle valv.
  • Page 93 FI -3 3 '0 - vol�lIe Condition ' 4 V ReillY EFI Maon fUlible Link Igt>ilion Swileh O.85R :i �':. ' k ibte Fuso IGN Fusible lOA IAEI 1.5A IAT) '''' AM2 30A 1.258 lAt:. AT) ..;> F�. AM2 1.5A lAW) Ballery replllce.
  • Page 94 FI-34 Condition No \lol�t' 10 - 1. V IIATT SlOP 'SA l A D 80A (AE) EFt 'SA (AT) \AWl 7.SA \ A Wl 2 SB...
  • Page 95 EFI SYSTEM Troubleshooting with Volt/Ohmmeter F'-35 Condition vol1_fe 4.5 - 1i.6 Ie .. TlwoWe v_lv_ fully cloud V or 10 S!W ON Throttle v_lve fully open 3.15 6.6 V lhfotlle Po,illon SenJ(lr ��� e 1Dl - E2 Repair or replace. iSee page FI-84l Try another feU...
  • Page 96 FI·36 • VTA wi r iog 1,.m",,1 E' Ind body betw""" ECU Check t !Se,�. R""" to No FI·33) .eplace R&IM" Ct>o<;k !HIli" $Ifl$O'. PO&lloon lSee fl.84) lind ehKk wring betwe"n EeU Repai, or rep Ihrottle posilion sensor. Try .nother Eeu.
  • Page 97 Volt/Ohmmeter EFI SYSTEM Troobleshootmg with FI-37 Termlna'i TroLibl. Condition STO voltae- voltage Idlil'lQ AE and />ehOmete. fusible link Ignkion Coil fusible 1 258...
  • Page 98 FI-38 roubleshooling with Volt/Ohmmeler "OIt. bet""."n ECU lerminals IGT .OO EI. Udlll.·;d lhere I. BnCI voltage ECU terrninBl IGT body ground, !Idllng) ... Hfl Check wiring bet ... un Repair or r.pI�ce. ",ound. IInOlh"r ECU. Check luSB. fu,ibte tonk. ignition (AW).
  • Page 99 FI·39 • - • Trouble C.eMl", 14 1/ No volU,. AE MtI SwilCh ignition U", F" ..A M , 40A ,­ All 8 0A Link aenary ITerm;I\lII A M 2 Ignltoo n Switch , 26 8 O�ning Ci r c"it...
  • Page 100 ignition Iwft," ' ..1 Che,k wirin g be t ween ECU le r monel ST. Ind STl tAE IKld AT) 0< ST2 tAWl S>A...
  • Page 101 \/Olt�. Condition tG SIW ON , - 14 V Ignition SWItch fulllblfl "'" AM2 30A Injector No 20 Switch !glll tion '"� Fusi� 7.5A Un k Injec 1.25B...
  • Page 102 10 ...,;J/ O f"" 20 .., Replace IIIje.:IOf Try .nothfl<...
  • Page 103 FI -43 • STO \/oltaV"' .nd 'II9m. rUN'll n.g . No Iroubl_ (�he<:: k _119'''' w.rnlng Ught - ,. V offl ..UGE 7 5A IA EI GAUGE 15A. GAUGE 7.5A lAW LI-1D EUJopoI) TURN·G ..G 7 5A lAW Olhe,,)
  • Page 104 FO ... STD volt_we - 5.5 No yoltage 10 S/W ON R"poir or .eplllCe. ECU. aoothe.
  • Page 105 Terml ..STO volt"ll e Trouble 2 .0 20"(: (6'"F1 No vol t age Intake Ii, limP. SfW ON Ai. Temp. Sensor (+Bl)
  • Page 106 FI ... Troubl. Condit ion 10 S{W ON volta",. THW - U No vo/tlllle Wa!", Sansor Temp. 1+811 "" " Re�ir ,eplDce.
  • Page 107 EFI SYSTEM roubleshooting with Volt/Ohmmeter "" No volteg. condllionlnU ON - 14 S10 "oIU� Am p lifier Ale Compreswr ClMK:k wiring btllween ECU ,.rminal AlC and ... p litier f�. Repaor or Repair or repl,,,,,...
  • Page 108 FI · 48 Terminals of Eeu (TeeS Eeu wI Air Flow Meter) Symbol Symbol Terminal Name ENGINE GROUND SENSOR GROUND ENGINE GROUND DISTRIBUTOR No.l0 INJECTOR OXYGEN SENSOR INJECTOR DISTRIBUTOR NO.20 STARTER SWITCH VACUUM SENSOR IGNITER THROTTLE PosmON SENSOR " CHECK CONNECTOR DISTRIBUTOR TH W ENGINE GROUND...
  • Page 109 Vott/Ohmmeter EFI SYSTEM Troubleshootil'lg with Vottage at ECU Wiring Connectors (TCCS ECU wI Air Flow Meterl volUo", T.,mhyll Condition - EO 1 0 - Ignition SIW ON fl-50 BATT - EI 10 - I . fl-51 IDL - E2 10 - 1 4 Thfottle vltve open Throll»...
  • Page 110 FI·50 IG SfW ON !Qno1io<1 Switch � Link O.8SA F" s;bIe link (AE. AT) lItTJ 3010. Fuse Fusible "l IAEJ 7.510. 1.510. .,; AM2 1 258 (AWl litE. Bon", .A.M2...
  • Page 111 FI-51 BATT - rOllbl. Termin.l, Condition volt.ge No vo lt' IiI' Fusible UnIr. STOP ISA tAfJ BA TT ALT 80A tAEI EFI ISA tAli O SSR (All AM2 1.5A tAWI USB tAWI B�IIMV R.pe i r Of replace Rep/l«.
  • Page 112 A·52 T r 04lbl<t - 14 V Condldon IDl - E2 Throttl. v.lv. open No vol� III SIW ON - &.5 VCC - T"'ollie Sensor Pos.ilion...
  • Page 113 FI·53 - E2 e VTA replace Repai, or 10 No ISee PIIi}e Fl-501 Refer repiac4l. Repw ®Check Ih,ol1le position sensor. p8ge fl-841 fSefI ECU. Try another e VCC - E2 R�I 01" ,eplece -'""...
  • Page 114 Condition STD voll.,. " No volt.g. Idling 0.7 - 1.0 '11 To TachOlTlflt.r Fusible "'" Ignition Coi! Bentry Fusible 7.SA L..1.258...
  • Page 116 FI-56 ' .. mlnal. TrOUble CondItion yolt.� STA - El - 1 4 " AE and Ignition Switch fusible AMI 40A StattM link Fusible S ,. ALT 80 Link ITermin",1 501 To Ci�u-it Opuninll RellV 8attery Stlluer Relay fuse Starter IgllltOoo Switch "A Fusible...
  • Page 117 EFI SYSTEM FI-57 TIDublelhooting with VOlt/Ohmmeter Repe;, ,,>0 repl.ce. ® ..Chll c k iring be, ,,,n ECU '.rmlr\ll ! E 1 bodv ground Try another ECU.
  • Page 118 FI-58 EFI SYSTEM Troubleshooting with VOlt/Ohmmeter Terminals Trouble Condition STD voltllge No. 10 No voltlOge 10 SfW ON 8 - 14 V No. 20 ." AEandAT Switch Injeetor Fusible Link fusible Link InjKtor .258 No. 1 0 Battery...
  • Page 119 FI-59 20 and and/or No. Check wi'ing between fCU terminel EOI andla< E02 IItId body ground. Try .nothflr ECU. R.paoIr or "pIKa. lonk. Check fusible fuse. betwHn Check wiring terminal <lind battery. NO. 1 and/or No.
  • Page 120 FI·SO .. min.l, oubl Condition No trouble ,ogine we,nlng IIghl off! No volWgoo STO v Icheck - 14 V e ngine '" CAUGE 7.SA Warning lig'" tAEI GAUGE 1SA "WI GAUGE 7.SA T,V a.nothe, ECU fuse .nd Check chee. engine wa.,n,ng �ght.
  • Page 121 FI-61 STD volt.� 1:.2 10.B SfW DN ..I"III plete lly cloMd No voltage M_u.i"lll plate lully open Id lin g 3.8 - 6.8 V...
  • Page 122 FI-62 STD voltll o - 2 - Z. B V •• n<A It" lAir MeIer) @ ChCk termmal + 8 or +81 that I�we;$ vQII&ge batween body ground. /SIo , P" 9' FI -a 2l...
  • Page 123 FI·&3 0.4 - 0.7 '1 +B(+81) W,te< Temp. SenIOr...
  • Page 124 TrOl,ll;>Ie Terminel. Condition voltage No voltage A/C - El Air conditioning 14 V �p lili&f AlC Compressor ECU wminal$ Ale and EI (Air concUtioning ONI lIol"'lIe b,"w89n is ,,01l811e Mlween ECU terminal AlC aoo Ir.al lh bodV lI'Ol,lnd wiring belween and body le."';nal Cr.ock...
  • Page 125 EF) SYSTEM Fuel System F)·56 FUEL SYSTEM Fuel Pump OUTLET Reliet fM.ET EFI Main RelaY f,� '" ��� :: 10A IAEI 1.�A �: :' 3 0 .0. . b Ie ", 0.8�R FlOw MII t e.) (w/o To Eeu Ai< Flow Meter)

  • Page 126: Fuel System

    SYSTEM Fuel System MDIn ReI.y ,," 1 '" Fusible "". 1.25B (wI Air Flow Meterl Battery (w/o Ail Flow Meled To ECU...

  • Page 127: Fuel Pump

    ON·VEHICLE INSPECTION INSPECT FUEL PUMP FP O O+B Turn the Ignition switch nOI start the s,"_. Using service wire, short ls +8 and FP 01 the check connector. FI·B9 LOCATION: See page thll Check Ihal hose from fuel re i. pressure In time, you will heir fuel relum noise.
  • Page 128 fl·sa stall th.e d SST Ipressure gaugel to pipe willi new two gask!ts and union boll. SST 09268-4501 1 kg·cm 1 1 1 ft·lb. 1 Torque: N·ml Wipe off any spLattered gasoline !h I Recoonect the �lIery negatille ( S-) cable.
  • Page 129 Reconnecl the vacuum sensing hose to the fuel pressure regulator. kg/cmt Measure the fuel pressure at idling. Fuel pressure: 2.1 - 2.3 pressure i5 psi, kPe) Jut!! Specified, check the V3Cuum sensing hose and pressure regulator. 011, Stop the engine, Check th't the fvel pressure remains 121 psi, kPa)
  • Page 130 REMOVAL OF FUEL PUMP G"�ft FUfL Pump Br8ck/1t <S�--- R Ubbef Cushion DRAIN FUEL TANK WARNING: AvoLd smoking and open flame wh.� on the fuel pump. working REMOVE FUEL TANK REMOVE FUEL PUMP BRACKET FROM FUEL TANK " I Remove Ihe five boilS. Ib) Pull out the pump bfacket.
  • Page 131 CuShion. REMOVE FUel PUMP FILTER FROM FUEL PUMP MOIl the lubber Remove Remove the clip. pump Illtel. pullout the INSTAllATION OF FUEL PUMP ISee pegl FI-70) INSTALL FUEL PUMP FilTER TO FUEL PUMP INSTALL FUEl PUMP TO FUEL PUMP BRACKET Insen the outlet port of the fuel pump into the fuel hose.

  • Page 132: Cold Start Injector

    FI-72 Cold Start Injector rmln ignition t Inj&etOl' Col d Injector rime SWItch SUM't To Stlll1 e r 5W1tch Relay (AW) Solenoid Coil Polot ..,,,, ON-VEHICLE INSPECTION Disconnect the INSPECT AESISTANCE OF COLD START INJECTOR COld start injector connector, Resistance: Using an ohmm the re,lstance...
  • Page 133 INSPECTION OF COLD START INJECTOR INSPECT INJECTION OF COLO START INJECTOR WARNING: Keep cIa" the te.t. of .park. during Instllil !two unions) to Ihe injector and delivery pipe with Ilew gilskets IIf1d tha union bolls. 09268·41045 Connect the unions with SST (hose). 09268-41045 Connect SST (wife) to the injector.
  • Page 134 INSTALLATION OF COLD START INJECTOR INSTALL COLD START INJECTOR Inltlll the two bolls. I new gaskl1 end the injector with Torqu.: 75 kg·em 1.4 N·ml in..lb, INSTALL COLD START INJECTOR PIPE Inlilll four the injector pipe with new gnkets Ind 'he boilS.
  • Page 135 Fuel Pressure Regulator Fuel Pressu,. Regulator FROM DELIVERY TO RETURN HOSE (PIPEI ON·VEHICLE INSPECTION INSPECT FUEL PRESSURE (See pege FI-67) REMOVAL OF FUEL PRESSURE REGULATOR DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DISCONNECT VACUUM SENSING HOSE DISCONNECT FUEL RETURN HOSE (AE AND AT) OR PIPE (AW) suitablo conlainer or shop towel under pressure...

  • Page 136: Fuel Pressure Regulator

    FI-76 REMOVE FUEL PRESSURE REQULATOR Remove the two boltS. a",d pull out li1e pressure regulalGr. INSTALLATION OF FUEL PRESSURE REGULATOR 1/1) COll i 10 I INSTALL FUn PRESSURE REGULATOR Apply light ot gasoline new O-ring. install it to the pressure regulator. 0:1) Ill$lall thl! pressure regulator with the two bolts.

  • Page 137: Injectors

    Injectors ON·VEHICLE INSPECTION INSPECT INJECTOR OPERATION sound Check from ellch Injector. III ) With the engine running or cranking. a sound scope to check Ihat Ihefll is normsl Operllting noise in proportion to engine rpm. you hllve no sound scope. you can check the injec­ tor lrensminion operallon wilh your flogel'".
  • Page 138 REMOVAL OF INJECTORS DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY RfMOVE COLO START INJECTOR PIPE step. and 3 page FI-72) •• DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR DISCONNECT INJECTOR CONNECTORS DISCONNECT HOSE FROM FUEL RETURN PIPE REMOVE FUEL INLET PIPE pip.
  • Page 139 FI·7t instill 1 new O·ring to the pressur1I '8O ... IIIO Removi the p&gll fl-151 and hoMl to the prassure regulator. ptllSsure !union 1111 COflnKt SST regulator with two bolts. SST 09268·" 1045 Connect the fuel teturn hose \AE Ind AT! or pipe IAWI.
  • Page 140 FI·80 INSPECT LEAKAGE (w;,.e) luel In the condition above. dis.conl'l8Ct the test Pl'obM from the battery and check the leakage from the injector. !w/o Air flow mater) 09842·30060 flow metar) 09842_30070 Fuel drop: One drop or Ie .. per minute. Disconnect ma battery ne9ative IF.t cable.
  • Page 141 FI-81 I",tall and torque the three 00111. Torqu.: 175 kll-em (13 II-lb. 17 N'm) INSTALL FUEL INLET PIPE Install new gasket. the inlet pipe end , new gasket with the union end mount bolts. TOfque: 300 kll-em (22 't-Ib. N·m) CONNECT FUEL RETURN HOSE CONNECT INJECTOR CONNECTORS CONNECT VACUUM SENSING HOSE...

  • Page 142: Air Induction System

    FI-82 AIR INDUCTION SYSTEM Air Flow Meter (wi Air Flow Meter) CLE A NER SIDE VBvevs ON-VEHICLE INSPECTION INSPECT RESISTANCE OF AIR FLOW METER EHCE2 Disconnect the .ir flow meter ConnectOl. !bl Using an ohmmeter, measure the resistance betwnn Resiltll'lU 0 Temp.

  • Page 144: Throttle Body

    FI-a4 Throttle Body ON-VEHICLE INSPECTION INSPECT THROTTLE BODY Check throttle that the linkage moves smoothly. Check the vacuum lit port • Start the engine • Check the vacuum with your finger. INSPECT THROTTLE POSITION SENSOR screw Disconnect the sensor connector. Insett a feeler gaUQe between the throttle stop and stop lever.
  • Page 145 EFI SYST FI 815 Icrew ,nc. between 8elw •• n lev.r and alOP Ruilline. �" 1.---:1 Terminel i rTll i mm Gr..1 0 (0) - E2 L... _ 0.35 10.0141 0 59 10.0231 - E2 Infinity I tully Tivoli" 3.300 - 10.000 pOSition �ned - E2...
  • Page 146 FI-86 INSPECT THROTTLE POSITION SENSOR (S ..• tep 2 on plge FI-84, IF NECESSARY, ADJUST THROTTLE POSmON SENSOR Loosen the mount screw. of the sensor. Insert a 0.47 mm 10.0 1 9 gauge. be,WfII! the throttle stop screw and stop lever. £2 Connect the test probe of an ohmmeter the ...
  • Page 147 EFI SYSTEM Air Indvction System Auxiliary Air Valve Screw "��NfOLO Audiaty An VlIlve ON· VEHICLE INSPECTION INSPECT AIR VALVE OPERATION (w/o Air Flow Meter) Remove Ihe ai, cleaner hose. Check the engir)9 rpm by closing the a port on the throUle body.
  • Page 148 FI·BB INSTALLATION OF AIR VALVE INSTALL AIR VALVE TO THROTTLE BOOY PllICe gasket end O·ring on the throttle body. Instell the eir velve with the five screws. •• It.pS 2 10 INSTALL THROTTLE BODV 8 on �g. FI·861...

  • Page 149: Electronic Control System

    FI-alil ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts Solenoid Resillor Mete,) ILHO ,..10 Ait F l ow Idle-up VSV Solenoid A.if Cireuit Openiflg Relay Res;,tOf Metet') �HO wlo Flow ConnectOf Verillblt Re.ittOf Mewl {wlo Air Flow $efl10f Ai" Temp. !w/o Air Flow Meted EFI Main Relay Vacuum s.n.or...
  • Page 150 FI·1I0 EFI Main Relay Efl Mlin Relay Fusible Ignition Switch O.B5R Fuse Fusible FUSible lOA !AE) U,,. Lill k 7.5A !AT) AM2 30A 1.25B "'E. ,�. AM2 7.5A IAWl BiI"ery INSPECTION OF EFI MAIN RELAY (A E) INSPECT RELAY CONTiNUITY ohmmeter.
  • Page 151 EFI SYSTEM Eleclroni4; Control System FI·1iI1 Circuit Opening Relay To Stoll n ., Retty IAWl Igf>ition S�ch (ST11 10Iherl) ISTA) Circuit Opening R,IIV /0 Att Flow Fl o w Fuel Pump Switch Meter) '0" , tAir Meter) ,.,. To fCU IFC) INS PECTION OF CIRCUIT OPENING RElAY (AE wlo Air Flow Meter, AT and AWl...
  • Page 152 FHll INSPECTION OF CIRCUIT OPENING RELAY (AE wI Air Flow Meter) INSPfCT RELAY CONTINUITY thai Using an ohmmetflt'. check thlll Ih,r, fs tor1lin� between tennine l s STA 8M Check there is continuity between terminels and FC. Check that there i, no continUity betweeo t,","lWIlt 8 If COntinuity i, not as specified.

  • Page 153: Solenoid Resistor And Injector Relay

    FI·93 Solenoid Resistor and Injector Relay (wlo Flow Mlterl (w/o Flow Meted Switch Ignition FUlibie linl\ AM2 JOA 8al1etV AW (w/o Flow Meterl Fusible U," Injoelor 1 .258 A W (wI Flow Meterl f" " AM ' 1 258 7.SA Fusib�...
  • Page 154 INSPECTION OF SOLENOID RESISTOR (w/o Air Flow Meter) Using an ohmmeter, measure the resistance between !tIt­ INSPECT SOLENOID RESISTOR RESISTANCE - 3 n each minel B end other terminals (No. 10, No.20). No. to +8 NO. 20 Resistance: If th" resistance is not liS specllied. rep'"ce the resistor ..

  • Page 155: Cold Start Injector Time Switch

    EFI SYSTEM Electronic Control System FI-i5 !At" IIIld Cold Start Injector Time Switch To Ignition Switch ISTl) A TI Starter Fle!IIY lAW} ISTAI r-- --- 'IITIII I Switch _ _ _ _ _ _ SbJrt Injec; Cold INSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT COLD START INJECTOR TIME SWITCH Using lin ohmmeter, measure the resistance between each...
  • Page 156 Water Temperature Sensor WATER TEMP. SENSOR " . * O.� � 80 100 120 {_4) {321 (68){1 04)1140)(1 761121 2112481 TEMPERATURE °C (or) INSPECTION OF WATER TEMPERATURE SENSOR IIle INSPECT WATER TEMPERATURE SENSOR Using an ohmmeter, measure the rllsistlmce between ter m inals.
  • Page 157 Vacuum Sensor {w/o Air Flow Meter' {Manifold Absolute Pressure Sensor' Vpcuum Sensor Vacu"", m.,O"'"'' fROM INT AI(£ MANifOLD INSPECTION OF VACUUM SENSOR INspeCT POWER SOURCE VOLTAGE OF VACUUM Discon SENSOR the vacuum sensor connector. Tum t e ignition switch II I minals vee and E2 of the vacuum sensor lhin9 a voltmeter.
  • Page 158 fl-e8 Variable Resistor (w/o Air Flow Meter) <Cu •• 1+81) VA> INSPECTION OF VARIABLE RESISTOR INSPECT VOLTAGE Of VARIA8LE RESISTOR s vee Using voltmeter. measure the voltage between Ectl .nd E2. ermina Voltag_; voltage between ECU tenninals Measo e the E2 whilll slowly turning idle mixttlfe adjusting screw fully couniorclockwise.
  • Page 159 FI-89 INSPECT RESISTANCE OF VARIABLE RESISTOR Disconnect the variable resistor connector. Using an ohmmetar, measUl'1l the resistance between 6 kn � n3ls and E2. Resiltll n ee: Turn the idle midure adjusting screw lully coun­ tllrclockwise. Conncet an ohmmeter to terminals VAF and lo o n Tum Ihe adjusting screw fully clockwise 8nd check thai the resistance valve changes from approx.
  • Page 160 FI-100 EFI SVSTfM Electronic Control System Intake Air Temperature Sensor (wID Air Flow Meter) INTAKE AlR TEMP. SENSOR • � • , .. � " The,miSlOt -20 0 2 0 40 60 BO lim i (-4) (32) (66)(I 04KI40K176X21 2K248) TEMPERATURE'C I'F) INSPECTION OF INTAKE AIR TEMPERATURE SENSOR...

  • Page 161: Inspection Of Oxygen Sensor

    fl-10l Oxygen Sensor (wI TWC) INSPECTION OF OXYGEN SENSOR WARM UP ENGINE Allow the engine normal operating temperature. INSPECT fEEDBACK VOLTAGE (VF) r � Connect the positive probe of a vollmeler to terminal VF of the check and negative ter­ probe to connector.
  • Page 162 FI-l02 • CONTtNUED FROM PAGE fl-I01 ® �all"OClion codlt(') cOOo FI·261 2 1 1 Rud .nd record dillgnollic codll. page Normlll code and code T eOO UO.hort lcrmin.l. check CON\tH;lor. tile Musure voltage between I..-mlnals o;scoonect the hose Meas",.. voltage between tenn�� VF IIOd Disconnect the wlte.
  • Page 163 FI-103 ohmmeter, mellSure the re INSPECT HEATER COIL RESISTANCE OF OXYGEN SENSOR Using an between the termin ls +8 lind HT. ATandAW Realatance: 6.1 - 6.3 n resistance is specified, replace the sensor. ��T not lIS...
  • Page 164 EFI SYSTEM FI·104 EIeeU'Onl c Control System Electronic Controlled Unit (ECU) 11M! INSPECTION OF ECU lind NOTE: The EFI checked by measuring circuit ,niltlnee voll9g e 91 Ihe connectors of tilt wiring ECU. INSPECT VOLTAGE OF ECU Check the voltag e betwe8f"! e9ch terminal of the wiring •...
  • Page 165 SYSTEM Beetronic C System FI·l01S Voltage at ECU Wiring Connectors T.m>ine!. (TCCS ECU wI Air Flow Meter) Condition - 1 4 lIollaII' 9lition BATT - E' - 1 4 - E2 Throttl. valve fully closed 'ITA Ignition Th.onle valve fu�y open 4 5 - 5.5 Cranking id�n'il...
  • Page 166 FI·11)6 INSPECT RESISTANCE OF EeU • CAUTION: • Do not touch the fCU terminell, wifing The teltar probe Ihould be Inserted into the connector from the wiring aide. Chsck the resilience between each terminal of the wiring connectors, Disconnect the connectors from the ECU, e Measure the res;stllnce termon,,!.
  • Page 167 FI·l07 Resistance of ECU Wiring Connectors ml ..{TCeS ECU wI Air Flow Meter} Co<KIltIon Infini ty IOL - 3,300 10,000 3,000 - 7,000 Measuring 20-400 - E2 plate fully cloud Measuring opeo pate fully - E2 2,000 - 3.000 200 - 400 CooIanl lemp.
  • Page 168 EFt SYSTEM Electronic ContrOl S'(1.tem A 108 Fuel Cut RPM mY" INSPECTION OF FUEL CUT RPM WARM UP ENGINE All o w the engine to reach normal operating tempefltur.. INSPECT FUEL CUT RPM • 1 throttle Disconnect the connector from the position sensor.
  • Page 169 FI·10G High-temperature line Pressure up System (Europe) To Cin:uit Opening Relay To HI Main RlNv Fuel P'8SSurt IISV Wete. Temp. Sensor INSPECTION OF HIGH-TEMPERATURE LINE PRESSURE UP SYSTEM INSPECT WATER TEMPERATURE SENSOR IS .. plgl FI·96] INSPECT FUEL PRESSURE VSV thllt be·...
  • Page 170 t o · C t OI S Fl l l O EFI SY$TEM operation pipe F . Ine!Met ChICk the' ail does not flow from pipe E 10 ..(�� AppI.,. batter.,. voltltgtl acron the te.minals. Ch�k that flows from pipe to the filter...
  • Page 171 Idle-up System gn ition SWI,ch To Ster,er IAWI a(l(l Idle·up INSPECTION OF IDLE·UP SYSTEM INSPECT BATTERY VOLTAGE OF IDLE·UP VSV All secessories swilch&d olf cheek VOllmel8l", that il Indicates battery during crenking seconds \foliage ,fI,r Sliming. INSPECT loLE·UP VSV Inspect VSV fat open circuit Using an there...
  • Page 172 FI-112 Inlpect VSV operation Check Ihel eir flows from pipe E to pipe /"" (b� Apply beuery Yollage across the terminals. Check that air flows from pipe pipe E 10 operation is not 85 specified. replace Ihe VSV.

  • Page 173: Engine Overheating

    EM-11 (4A-GE) ENGINE MECHANICAL Trouble.hooting TROUBLESHOOTING (4A-GEI ENGINE OVERHEATING ..Problem Pouibl. ce ..,. Et>gi". overh.al, CooNng sy em " �Ity Tro�bllshoot cooling Iystem CO-5 1ne00rect ignit,on timing l t im EM-31 HARD STARTING Rom ." , Probl.m Ponlb', CIUt.
  • Page 174 ROUGH IDLING (Cant'd) A.mad., Pa,. Probl ..POlilbl. cau .. Rough idle, 811h .. aIt, Vacuum l'\aceuaIY Repeil P C'tI �,.. mitsft (Cont'dJ • ,yateml • EGR lina m"';loI<I tntllke • in"h chlmbat' • control Y81v.1 lInl8h ai' • Th,ottll body Br'�.

  • Page 175: Excessive Oil Consumption

    nute ENGINE DIESELING Probllm Pos,ibll Pigi Remedy huom, " h.nled 0111 [ngine d .. ",1Ing EFI ,,,,tern probMmf Repair nlCIfMty Check wlMltO ignit!Ol1 IncOfTtct 'llfli t ion timing Resel timing EM-31 ,witch IYI'lm ' ..Iy {wI EGR SV.te"" EGR .",Iem AFTER FIRE, BACKFIRE ClUte ..

  • Page 176: Excessive Fuel Consumption

    EM-14 EXCESSIVE FUEL CONSUMPTION ceuM Pag. Probl.m P", .. lbl. Poor gasoline miIuge Fuel INk ReptMl' nKOIUDry &1 .. cIH.- cloHed Check air d • .ner [M_34 mCOff.cl EM-37 A.MI timing igni60n timing R.pair., OKHsa"l Sfft... , problem, • Injec or fau O'C.I ..
  • Page 177 ENGINE TUNE-UP (4A-GEI INSPECTION OF ENGINE COOLANT (See Itepi l ind 2 page CO-SI INSPECTION OF ENGINE OIL (See Itepl l ind 2 on plge LU-SI INSPECTION OF (See stepi , and 2 Stlndard lpeciflc g •• vlty; , .26 1 .21 whln tully chlrgld It 20·C (6S'F) INSPECTION OF AIR FILTER INSPECT AIR FILTER...

  • Page 178: Adjustment Of Valve Clearance

    ADJUSTMENT OF VALVE CLEARANCE NOTE: Adjust the valvlI cillarance while the engine is cold. REMOVE CYLINDER HEAD COVER EM-l02) (See �g. NO.1 CYLINDER TO TDC/COMPRESSION .."0" Tum the cr..,klh.ft pulley Imd align its groovlI with the timinlj m . of thll No.1 timing belt cover lAE 81'11 or AT) or timing pointllr...
  • Page 179 EM-38 ENGINE MECHANICAL Tune_up 14A-GE) adjusting .him with a small • Remove the screwdriver and m linger. .ilt the replacement adjusting ..tIim • Using a micrometer. measure rmine following Formu'- Charts: ess o f:th · shim which • thlckne$, so the val 01 a specified value.
  • Page 180 ENGINE MECHANICAL I4A-GE) EM·31 Engine Tune-up ADJUSTMENT OF IGNITION TIMING WARM UP ENGINE A'ow eoglll4l to normal Operating temperaU"e. CONNECT TACHOMETER (AE. AT ..Connect IISI probe a lachOmll1tf terminill lG cheek connector. !Re' .. LOCATION: See page FI·8S eo�. AWlI enc, IAT and r to...
  • Page 181 ine Tune-up EM-3' ENGINE MiECHANICAL I4A-GEI UNSHORT TERMINALS T AND El Remol/e the wire f!'(lm the check connector. Mrvice FURTHER CHiECK IGNITION TIMING timing: 16' BTDC Of lenit ion more @ ldle...
  • Page 182 EM-3g ADJUSTMENT OF IDLE SPEED Iwl TWC) INITIAL CONDITIONS Engine 8t rellch normal operating ternpereture (1)1 deaner installed All pipes lind hoses of air induction system con- necled lines connected Y8C\Jum NOTE: hoses for EGR SystemB, etc. Bhould YKuum be propllfly connected. EFI system wiring connectors fully plu g ged Ignilion liming sel correclly All accessories swilchitd OFF...
  • Page 183 Engine Tune-up (4"·GE) EM ... ENGINE MECHANICAL IDLE HelCO CONCENTRATION CHECK METHOD (wI TWcl NOTE: This ChKk I, used onlv to determine whelher or nol the idll HCICO complies with regulltions. INITIAL CONDITIONS Engine reach norm.l oper.ling tempe.,tu,e Air ele_r onltalled AI pipes and hoses of ai, indue,ion system con- -'"...
  • Page 184 ENGINE MECHANICAL - EM .. , Engine tune-up {4A-GEI Troubleshooting High Rough Ineor'U�1 idle �aulty ignition: liming • • Fouled, .horted or irnproperty gepped plug. VDIv. • Open . ed ignition w"" CtlIC�ed di.t.ibutor cap • Inl ..,it cQnltol IIfId 'nco"eet velve clearance Le.ky EGR valve {wi EGR .yltem1...
  • Page 185 Tune-up 14A·GEI EM-42 ENGINE MECHANICAL EngiM ADJUSTMENT OF IDLE SPEED AND IDLE MIXTURE (w/o TWC) INITIAL CONotTIONS reach tempera lure E"9ine " normel oper8ling dlll n er instened lell All pipe, hOMa 01 induclion system con- el\d nected liM. vacuum oper y conne<:ted system w...
  • Page 186 testing probe et le"l 40 cm 11.3 ft) ioto the ENGINE MECHANtCAL - nQlnI Tune-up 14A GEl Int.n Menure the concenlretion with 1 - 3 millutes ,fUr uilpipe. rKing the engine 10 l/Iow the COncentfitiorl to sllbil - 1.& % 0.6 % ire.
  • Page 187 ..• ENGINE M.CHA NleAL Turn-up (4A-GEI l� OF DASH POT ADJUSTM lOP) SETTING " Flo w SPEED WARM P ENGINE UP AND STO "1llne to reach oormal perature. Allow the operating tem EM-3el CHECK IDLE SP fED (See pilge AP, FILTER AND SEPARATER FROM OP REMOVE C...
  • Page 188 ENGINE MECHANICAL Tune-up t4A-GEl Engine INSPECTION OF TOYOTA·VARIABLE INDUCTION SYSTEM (T-VIS) WARM UP AND STOP ENGINE Allow the engine to re&Ch normal operating lemperature. CONNECT TACHOMETER (SH EM-371 plge CONNECT VACUUM GAUGE Usiog . 3-wav COnl\eClor, conoeel . v&Cuum gauge to the hose betwetln lhe and actuator.

  • Page 189: Cylinder Block

    Cylinder Block ENGINE MECHANICAL EM·125 CYLINDER BLOCK COMPONENTS Re., End PlaiD Cy�r>de, Block...
  • Page 190 EM-US PREPARATION FOR DISASSEMBLY REMOVE CLUTCH COVER AND DISC IMIT onlyl REMOVE FLYWHEEL (MIT) OR DRIVE PLATE IAIll REMOVE REAR END PLATE INSTALL ENGINE ASSEMBLY TO ENGINE STAND FOR DISASSEMBLY REMOVE AlC COMPRESSOR MOUNT [A/C only) REMOVE ALTERNATOR AND BRACKET REMOVE RH MOUNTING BRACKET ••...
  • Page 191 fM·127 DISASSEMBLY OF CYLINDER BLOCK (See page EM-126) REMOVE AEAA OIL SEAL AETAINEA Remove the six bolts. fear oil seal retainer and gasket. MEASURE CONNECTING AOD THAUST CLEARANCE Using a dial indicator. measure the thr�t clear�nce while tt)fUlt moving the back and forth.
  • Page 192 cap. U!Jing ' plastic· laced Mmmet. lightly tap lhe con· con­ ntellng rod bolls and �fl th' connecting rod NOTE: Keep the be.ring ;n,efled with the nKtinog rod ClIp. •. COY'" Ihe conn&cling bolts wilh .hort plec. of hOle to protlK:t lhe cr.nklh.ft from damag Clean the Cl.nk pin end be'rlng.
  • Page 193 EM-12.t procedUAI Remov. lhe co�ting cap. !h) and lei .bove) .. 1 Muwre lhe Plasligagl al il' wid POinL StlndM"d e�a'.ne.: 0.020 0.0151 10.0008 C).OO20 in.1 U/S 0.25 0.011 0.073 mm 10.0007 - 0.002t In.) Mallimum 0.08 )0.0031 in.1 ell.ranet: If Ihl oil ell.,..
  • Page 194 EM.130 CHECK CRANKSHAFT THRUST CLEARANCE Using the thru$l cleMence while e diel indicator. prying the b.ck .nd forth with a se,ewdriver cranksh.1I 0.02 - 0.22 mm Stenderd thrust cl.elenCI: mel<imum. - 0.0087 in.1 (0.000 8 0.30 (0.0 1 1 8 In.) Mexlmum thrust cleerence: If the clearllflce is...
  • Page 195 EM-13' NOTE Gr«luelly loosen .nd remove the belring Clf, numeocll boll. in three p.sses .nd in the order shown. U.ing the removed belling bolts. WW" the be.ring cep bltk Ind forth, .nd remov. with the lower beilringS and thrutl Wllners !No.3 only).
  • Page 196 EM·132 �I Remo"e the bearing caps with the lower bealing and thrust wnh8f1l !No.3 �p only!. (See procedure leI end Ibl eboye) &I �.sure the PLutigege its wid"t point. Stend.,d oit cl.aran-e.; 0.016 - 0.033 0.0013 (0.0006 In.J 0.215 0.013 0.053 (0.0006 0.0021 tRoJ...
  • Page 197 EM-133 INSPECTION OF CYLINDER BLOCK REMOVE GASKET MATERIAL Using " gesket scraper. remove all the �sket material from the cylinde< block surface. CLEAN CYLINDER BLOCK Using a SOlt brush and solvent. clean the block. INSPECT TOP OF CYLINDER BLOCK FOR FLATNESS 0.
  • Page 198 EM·134 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES esoo pogo EM·1UI CHECK FIT BETWEEN PiSTON ... ND PIN b.ek to movo the pi.ton .nd lonh on the pilton pin. Iny movement ;s 'IIIL rllpl..ee th. pl$lon .nd pin II' • HL REMOVE PISTON RINGS U.ing .
  • Page 199 EM-US 14A-GE) Using needle-nose pliers, remove the snap r ings. - BO°C tl58 - Gradulllly heat th" pistOl'! to 176"F1. �t, Using plastic-faced hammer and brll5S �9htlv the piston pin end remove the connect i ng '00. • � � NOTE' •...
  • Page 200 Using a solt brush end solvent thoroo.t!l h lV clean Ih. CAUTION; Do not damege the piston. INSPECT PISTON DIAMETER AND OIL CLEARANCE 4A-f 3B.� Using e m romele and with the piS10fl l.lpside down. 4A-GE 42.0 mm measl.I .
  • Page 201 Dlfact ion diameter measurement. 1�:�on <ll A.iel 7" PI'ton oil clearance: TA e ' t." 4A-F 0.06 - 0.08 10m {0.0024 - 0.0031 in.1 4A·GE 0.10 - 0.12 mm (0.0038 - 0.0047 inJ Middle ot within specification, replace the piston •.
  • Page 202 EM-138 ENGINE MECHANICAL Cylinder Block '4A·OE) INSPECT PISTON PIN As Be>-C 117S-F) you should be to push the piston pin inlO lhe piston pin hole wilh your thumb. INSPECT CONNECTING AOoS Using rod .tigner. check the connecting rod illignment •• Check lor bend.
  • Page 203 EM-13S O.OOS Subtract the piston pin diameter measurement from bushing inside dii!lmeter mei!lsurement. Standllrd 011 clearance: 0.004 10.0002 - 0.0003 In.) 0.06 (0.0020 fl8i;tlS$Bry, cleari!lnee: In.) Maximum 011 If clearance is bushing. greatef than maximum, feplace the piston assembly. replace the piston afld {"A·GE) IF NECESSARY, REPLACE CONNECTING ROD SUSHINGS...
  • Page 204 BORING OF CYliNDERS NOTE: 10tK cylinders for t pist outside • Bore to metch diameter. OVllr5iud rirlllS with Repl.clI th-e piston the Over' Siled pistons. dilmetl': KEEP OVERSIZED PISTON .. llIId 4A·F DIS 0.&0 81.43 - 81.� mm (3.2058 - 3.2071 InJ 81.3 g - 81.42 4A-GE DIS 0.60...
  • Page 205 INSPECTION OF CRANKSHAFT INSPECT CRANKSHAFT FOR RUNOUT •• Place the crankshaft on V·bIocks. Using dial indicato ml!&sure thl! circle runout at the ce In.l Muimum circle runout; 0.06 mm (0.0024 crflP"lksholt. If the circle runout is greater than maKimum. rep/ace the INSPECT MAIN JOURNALS AND CRANK PINS Using micrometer.
  • Page 206 EM 142 REPLACEMENT OF CRANKSHAFT OIL SEAL NOTE: There al1l two methods replact the oil seal depllnding on whether the l1Iar oil seal retainer i$ to Ihe Moine « nOL ilSsembied REPLACE CRANKSHAFT REAR OIL SEAL Using a screwdriver and hammer, lap oot the oil ..its .urface is lIush with the 'ear oil 'NI retainer eOgoe.
  • Page 207 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES (CavIty) front ASSEM8LE PISTON AND CONNECTING ROD 14A-FI Mark Align the Iront mark, of the piston and connecting 'od. oil. Coat the piston pin with SST . Using ptess in the piston pin. 09221-25022 109221 -00050.
  • Page 208 *"CI "· 0' pin with e e oi �I Align front mil"". conn.ctin9 of the pilton IC�I rod, end push in the piston pin with your thumb. e new Ihe pi.ton snip ring on the other lid. of pin hole. CPIOIrutionI ncler ,nc! INSTALL PISTON RINGS...
  • Page 209 ENGINE MECHANICAL Cyli r Siock ASSEMBLY OF CYLINDER BLOCK ISee EM-1251 �e NOTE: Thoroughly CleM all parts to be • assembilld, • Belore i!1stalling the parts. engine oil to all y new sliding and rotating surfaces. Replace all gaskets. O-rings end oil with new •...
  • Page 210 Apply light coal engil'\(l o Ihe Ihrellds and le U il o n ul'\der the helld. of Ihe cap boili. Torque: Install uniformly tighten the boilS al'\d ten cap several passes. he sequence shown. in t kg·cm 1« ft-Ib. N'm) Check that the turns oothly...
  • Page 211 Instell the ftywheel or pli l le on the ct1mkshalt T l{jhten the bolts to the specified torque in two or thre e pesses In sequence shown. Torque: Flywheel 4A-F kg-em -Ib. 78 N·ml 4A-GE 750 kg-cm ft-Ib. 74 N·m) (4A.-F)
  • Page 212 EM-ill ENGINE CYLINDER H COMPONENTS ••• �::: Slav Mou n l � ing � _ .. ���:;'g ..COVIrI' No 2...
  • Page 213 EM-100 ENGINE MIECHANICAL Cylioo8l" Head (""'·GEI .. P'gl REMOVAL OF CYLINDER HEAD EM-UI DRAIN ENGINE COOLANT (S �ge COoS or 71 REMOVE DISTRIBUTOR boilS, REMOVE EXHAUST MANIFOLD null Remove the end upper heet four IniWl.tor ,tll Y '· (b) !AE .nd A TI R.move the bolli, nut, RH end menifold...
  • Page 214 EM-10l Iwl EGR SYSTEMI REMOVE EGR VALVE AND MODULATOR Disconnect the vaCl,ll,lm hoses from the VBCl,ll,lm pipe. Remove the boll end EGR vacuum modulalor. Remove the union bolt four bolts. the EGR valve. pipe. assembly and gaskets. REMOVE COLO START INJECTOR PIPE ISee atepI 2 and 3 pell' Fl·...
  • Page 215 EM-'02 Remove Ihe PCII hote_ Remove the ,even Iwo nuls. inle�e menifold. boIIS_ elr controL velve and gaskels. 1 1 . REMOVE WA1l:R OUTlET ANO BY-PASS PfPE boilS lind alternator drive belt Remove the lh,... !II ) adjusting bar. bolt s . Remove the three the water ootlet.
  • Page 216 ENGINE MECHANICAL Cylinder Heed 14A·GE) 17. DISCONNECT TIMING BElT FROM CAMSHAFT TIMING PULLEYS Plac:: e matchmarks on the camshaft timing pulleys and timing bell. Loosen thlll idlflf pulley bolt and shill the pulley !til toward the leI! as far a5 it will temporarily tighten Remove the timing belt from the camsh.ft liming pulleys.
  • Page 217 EM.104 REMOVE CAMSHAFTS Uniformly loosen and lemove the bearing cap bolts in iIll sl'lvelll pa.se •. in thl'l seQul'lnce .ho ..Remove the bearing caps. seel and camshaft. Arrange the intake and exhaull camshafts. NOTE: REMOVE CYLINDER HEAD U.if\g SST. uniformly loosen and remove the cylinder head bolts in several paSSl'll.
  • Page 218 DISASSEMBLY OF CYLINDER HEAD .. �. EM·ee) REMOVe VALVE LIFTERS ANO SHIMS NOTE: Arrange the valve lifter, ar.d ,him! correct oroer. 0 0 0 0 0 0 0 0 " 88 89 89 88 0 0 0 0 0 0 0 0 "...
  • Page 219 INSPECTION. CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS 10 lOP CLEAN TOP OF PISTONS AND TOP OF BLOCK Tum the crankshaft and bring each piSlon dead center !TOC). Using galket scraper. remove" (Ill mille n ill from Ihe carbon from Ihll piSion lOp. Remove all Ihe gasklill Ih' lOP cylil'lder...
  • Page 220 L - Cvlinder Head ENGINE \4A·GE) EM·tOl Uie. INSPECT CYLINDER HEAD FOR FLATNESS the striac" contacting the cvtindet' block man old. Using a po-llCi s ion 'traighle� and feeler g' menu ... 10< warpag'. Ma.lmum warplga: 0.011 (0.0020 in.) Cvllndar block aide 0.011 10.0020 in.)
  • Page 221 Using a micrometer. measure the diameter 01 the EM-108 valve stem Valve stem diameter: Intake 6.9'20 - 6.986 (0.2360 - 0.2366 In.) Exhaust 6.966 - 5.980 in.) (0.2348 - 0.2364 Subtract Ihe velve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearanCfl: Intake 0.025 - 0.060...
  • Page 222 EM-tOll Ihe bushing caliper gauge. menure bore diameter of the cylinder helld. 0/5 0.05), size Select . new guide g (STD Sushi"" size 1/ Ihe bushing bore diameter of Ihe cylindllf held is grealer mm 10.4341 in.!, machine the bushing bore 1 .027 to the following d ,ion:...
  • Page 223 EM-110 St.nderd thlckn Check IhfI valve hflad ma'lilin thickn ..m.<gln 0.8 - 1.2 mMgln (0.031 0.047 kn ... : 10.020 I Minimum the mergin thickness is less than minimum. r.place the valve. Check the valve ove,.II "nglh. hh�U Standard ov.rall I.ngtl'l: 99.60 (3.9213 In.J Intake...
  • Page 224 ENGINE MECHANICAL Cylinder He,d (4A GEl not. correcl the vllive seats lollows: Ihe sellling is high on Ihe v.lve lace. 1 0 -1 lind cutte� t o correct ,he seal 411''' '' ' the sellting is 100 low on the vllive I&ce, use 60' and 45' cutler$ COfTIlCt the se'I.
  • Page 225 01 11'1. Using a Ipring tester, musu.e Ihe ten.ion valve spring 14.6 - 17.0 kg 132.2 - 3Ui Ib, 143 - 161 lhe speeifie d inSIOlied length. Inll.lled lension: 34.7 11.366 In.1 Ihe Insla"ed tension is nOI as speelfied, reploce the valve spring.
  • Page 226 (4A-GEJ ENGINE MECHANICAL - Cylinder Head EM-l13 1�I9.ct cem h.ft journal oil cl •• r.�c. Clean th. bearing caps and camshaft journals. camshafts on Ihe cylinder he&d. Place Lay a strip of Plasl igage aerOIl each of the clmshaft journal. Inslall Ihe bealing caps.
  • Page 227 E"h.u.t m.nifold 11.1 ..0.05 mm (0.0020 inJ If wII'p.eg' i. grelller thin m repl.c. the m'fII old. INSPECTION OF TOYOTA - VARIABLE INDUCTION SYSTEM (T·VIS) kpaJ 01 lI.cuum 111.81 INSPECT AIR CONTROL VALVE With rnmHg In.Hg, 40.0 control .pptied...
  • Page 228 ENQINE MECHANICAL EM-l 1 Cylinder Head 14A·GEI INSPECT VACUUM VALVE IVSVl SWITCHINO In.pect VSV for Open circuit Using en ohmmeter. ChflCk thet there is continuity bllt­ ween the terminats. ICold): Re.lltlnce If the e I. no continuity, replace the VSV. n.pect for ground U.ing on Ohmmeter.
  • Page 229 · ASSEMBLY OF CYLINDER HEAD pIg. EM·111 •• Tho r oughly cllan all parIS 10 installiog the pa"s, apptv 'ogi"" oil 10 .. • asMmbled. • Beforl • .tiding all d rotating ",rfaus. Repllce all gaskets and oil lellt Wllh new ones.
  • Page 230 EM-1 1 7 INSTALLATION OF CYLINDER HEAD (See page EM-Ul INSTALL CYLINDER HEAD Place cylinder head cyllnd,r block gasket Piece e new cylinder heed in position 0tI Ihe cylinder block. CAUTION: dirktion. carefUl 01 the instan.tlon Place lhe cylinder head in position on the cylinder head gasket, Tighten cylinder...
  • Page 231 retighten the ten cylinder bolts 90· in the n shown . ordar Third. head retighten the ten cy boilS by an itio 90·, 3 . d the paint mark is now facing rearward. that INSTALL CAMSHAFTS Place the camshafts position on the cylinder head shown in the figure.
  • Page 232 to II ENGINE MECHANICAL Cylinder Heed (4A-GE) EM-'19 Apply grease new oil lui lip. '.» in thlP; Igl Ulln; oil seal. SST, 09223-50010 INSTALL NO.4 TIMING BELT COVER InSlal1 the bolt eover with the seven bolts. Torque: 95 kg·em (82 In.-lb. 9.3 N·ml INSTALL RH MOUNTING BRACKET Install the mounting braeket with the three bolts.
  • Page 233 oEM·1Z0 Cylinder Head !4A·GE) ENGINE MECHANICAL CHECK VALVE TIMING AND TIMING BELT DEFLECTION Slowly loosen the idler pulley boiL .he cranl<shaf. pulley two revolutions from TOC to TDC. NOTE: ways turn the crankshal' clockwise. Check that each pulley aligns with the timiotg markJ as shown in the ligure.
  • Page 234 )1 the t IS lIdjus, with the klier pullev· page INSTALL SPARK PLUGS (See 10-211 Torque: kg-em ft-Ib, 1 a N·ml INSTALL CYLINDER Hf:AD COVER to the cvlioder head shown ApplV seBI packing P.rt No.Oa82S-000ao Seal packing: or .quivllent Install the gaskets to the head covers.
  • Page 235 ENGINE MECHANICAL Cylinder He&d (4A·GEJ 13. INSTALL INTAKE MANIFOLD (ao) Instan II new gaoskel. the a;. control valve. II ne ..gasl<.et and the intake manifold with the $liven bolts aond two nuts. TOI'que: 280 kg·em N'm) It·lb, PC'll Install the hose.
  • Page 236 ENGINE MECHA.NICA.L EM·123 Cylinder Head lolA-GEl EGR SYSTEMI INSTAll EGR VALVE AND MODULATOR Install a new gasket. the valve and pipes assem­ bolts. bly with the four Torque: 100 kg·em (61 69 N'm) Union bold ft·lb, 190 kg·em (14 ft-Ib, 19 N· Bolt modulator Install t...
  • Page 237 •• INSTALL DISTRIBUTOR IS page IG·26) FILL WITH ENGINE COOLANT IS.e page CO·, Capacity (wI Heater): AE and AT 16.3 US 6.0 lit.rs qts, 5.3 Imp. qtsl Imp. '13.1 US 12.4 11tets qu. 10.9 qts' 23. START ENGINE AND CHECK FOR LEAKS PERFORM ENGINE ADJUSTMENT the valve cleaterlce.
  • Page 238 ENGINE MECHANICAL ng Belt (4A-GEI EM-57 TIMING BELT (4A·GEI COMPONENTS Guket Btl" Cover Timing NO 3 Btlil Cover Timing Orive Bolt punev Specified torq ... t .." REMOVAL OF TIMING BELT REMOVE WATER PUMP PU LLEY AND DRIVE BELT REMOVE SPARK PLUGS (See �lIe IG-20) SET NO.1 CYLINDER TO TOe/COMPRESSION Tum the crankshol1 pulley end 'Iign ils groo...
  • Page 239 REMOVE CRANKSHAFT PULLEY UIirIg SST, remove the pulley mount boll. SST 09213·70010 and 09330·00021 Usmg SST, remove tha puUey. SST 09213·31021 COVi ..and REMOVE TIMING COVERS 8ELT Remove the ten bolt, the No.2, No.1 belt No.3 ge.ket •. REMOVE TIMING SEl GUIDE REMOVE TIMING BELT NOTE:...
  • Page 240 EM-SI REMOVE IOlER PULLEY AND TENSION SPRING Rlmove thl bolt. plJlley end 'Insion sPfing. REMOVE CRANKSHAFT TIMING PUlllY lOll 10. REMOVE CYLINDER HEAD COVERS [See etlp on peg' EM· 1 1 . REMOVE CAMSHAFT TIMING PULLEYS the tIe�3gonal wrench nead portion of the SICU"...
  • Page 241 INSPECTION OF TIMING BELT COMPONENTS No l INSPECT TIMING BELT CAUTION : ;/jjjp> not bent. twl.t or turn the nlid. out. • • Do nol Iflow the timing belt to com. into contlcl ", with oil, wet.r or netm.., •...
  • Page 242 Timing ENGINE MECHANICAL !4A GEl Belt EM 6' liming there is noticeeble wear on the belt teeth. check cover for darTl8ge check for correct Chec k gasket installation. foreign meteriel on Ihe pulley teeth. n9Co ary. replace the timing belt. INSPECT IDLER PULLEY Check the turning smoothness of the �er pulley.
  • Page 243 INSTALLATION OF TIMING BELT plgl EM.57) INSTAll CAMSHAFT TIMING PULLEYS POSition the pin of the cemlhafts shown in knock the figure_ Align Ih, eam.n..1t knock pin wilh the knock pin of the pulley. and slide the pulley. IlICing groollll liming mar1o: upward. Secure the huagonal wrench head portion c.msoalt.
  • Page 244 EM-63 INSTALL TIMING BElT CAUTION: Th. engln hould be cold. • • NOTE: If reusing the timing bell align the poin" marked during removal. and itlstall the belt with the a!TOW pointing in the direction engine revolution. Install the liming belt. insuring the teflsion between lhe inta�e camshaft and craflkshaH timiflg pulleys.
  • Page 245 EM-64 let) T OrqUII the idler pullev bolt. Tl1«Iue: N'm) 3711 kg-em ft-Ib, Cheek thll' thetll is belt denllction at the position indicated in the fig",e. O.f"etio": [0.16 in.! 20 NI 14.4 ,he de specified. adjust with the idler puNllv. Remove the tllmpaflfilv installed crankshaft pullev """...
  • Page 246 (4A-GE) EM-S6 ENGINE MECHANICAL - Timing Belt 10. INSTALL CRANKSHAFT PULLEY (.Il Align groove of the pulley set ke.,. with the key pulle.,., 54ide the pulle.,.. Using SST, ins�ll and torqlle the the bo lt. 09213-70010 and 09330-00021 137 N - m) Torque;...
  • Page 247 Compression Check 14A-GEl ENGINE MECHANICAL EM-4' COMPRESSION CHECK (4A-GEJ tion Of poor fuel economy. measure the compression NOTE: there is IlIck of power. e_cessive oil consump­ pressure. WARM UP AND STOP ENGINE DISCONNECT SOLENOID RESISTOR CONNECTOR DISCONNECT COLD START INJECTOR CONNECTOR DISCONNECT DISTRIBUTOR CONNECTOR REMOVE SPARK PLUGS ISee Pig.
  • Page 248 10·16 Do not 1.lv. the Ignition Iwltch on for more than 10 PRECAUTIONS minut If the engine will not Itert. •• nect the t .. t probe of 1M! tachomalar to t81mlnellG With e tachomet.r i, connect.d to the .ylt.m. con· of the check connectOf.
  • Page 249 TROUBLESHOOTING P,oblem Pille • £ng,ne wiH not start! Inco,rect ignition timing Re,,' liming hard 10 I1B.t • Ignltior1 prohl.ma krtonks ignition coil In$pect coW IG-22 • Igniter In,pect igniler • !G-23 Dir.uibutor Inspect dj,Tributo. Ki-23 Higf!-t ..sion cords !G-20 Inspect hio;ltHen5IOf\ cords Ign'tlOn Mri"ll dosconnect or brollen m'j,lecl w';"11...
  • Page 250 IG-18 IGNITION SYSTEM (4A-GEI ignition Syllem Circuit IGNITION SYSTEM CIRCUIT tgnilioo Swi1(:h Ignitioo Coil Spar1<; Plug Oi.tnbutor Firing Order: 1-3-4-2 Signal Rolor IGT IGf Ignition SWItch Ign;hor, Coil Spark Plug AM2 7 5 A ' ..M Fusible Link �in Firing OrOOr: 1 .25B Reley...
  • Page 251 10NITION SYSTEM 14A-GEI 10-19 On-Vehicle Inspection ON-VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS Disconnect the high-tension cord from the distribu- •. Hold the end 12.5 11/2"1 ebout from car. See il sp,rk occurs white engil'l8 is betog c.anked. then 1 from To prevent gasoline from being injected NOTE:...
  • Page 252 10-2:0 INSPECTION OF HIGH· TENSION CORDS CARfFUlLY REMOVE HIQH·TENSION CORDS BY THEIR RUBBER BOOTS FROM SPARK PLUGS In.tdl. CAUTION; Pulling on or IHnding the cord. IN'j' damlge thl conductor INSPECT HIOH·TENStoN CORD RESISTANCf. maNurl thl res�tancl without d. In ohmmete!". di,lributor CIP.
  • Page 253 IGNITION SYSTEM (4A-OEJ IG·21 On· Vehicle Inspection ADJUST ElECTROOE CAP Carefully bent the outer elect. ode to obtain the correct electrode gap. Correct electrode gap: 1 . 1 mm [0.43 INSTALL SPARK PLUGS Using SST. inSlI1I the spil.k plug. 09155·16100 TorqUI: 180 kg-em [13 18 N·m]...

  • Page 254: Inspection Of Ignition Coil

    10-22 tGNITION SYSTEM (4A-GE) On-vehicle Inapectiol'l REMOVE SPARK PLUGS (S.e st.p 1 on psg. !G-G) VISUAllY INSPECT SPARK PLUGS Check the spark plug for thread il'lsuLation damage. If abnomul. reploce the _park plug. Recommended _park plug: ND P016R NGK eCPR6EP11 INSPECT ELECTRODE GAP plug.
  • Page 255 IG·23 INSPECT SECONDARY COil RESISTANCE ----- rnistance between the Using an ohmmelar. measure the (;£I positive erld Second.ry coil r.sistanc. [Coldl: 13.8 AT .nd AW " .ti - l I U i k n the ignitiOn the rU�tance replace i s s coil.
  • Page 256 10-24 IGNITION Distributor DISTRIBUTOR COMPONENTS . O-Ri., • . O-R. , Driven Gelll • Streight Pin---- -- -.-;: :? Non-r"IIHbie IJiIrt l � � , - , - Distributor Cap (wilh High-lens ion Cordi Dust Cover COld Clamp...
  • Page 257 10-26 REPLACEMENT OF DISTRIBUTOR DRIVEN GEAR REMOVE DRIVEN GEAR Using a grinder. grind the driven gear and straight pin. CAUTION: Be c:: a reful nol to dam.g. the governor ,h.ft. Mount the dr i ven gllar in 8 vtc:: 8 . •.
  • Page 258 IG·26 INSTALLATION OF DISTRIBUTOR • .,. " SET NO.1 CYLINDER TO TDC/COMPRESSION t pull Turn align itl groove with the c the "0" m"k liming cover (A[ No.1 AT! or timing pointer (AWL aod ch8(:k Ihal Remova the Oil filler cap. you can Ihe crankShaft ooe (360°!.
  • Page 259 LU B RICATION SYSTEM Plge DESCRIPTION LU-2 LU-" TROUBLESHOOTING LU-S OIL PRESSURE CHECK REPLACEMENT OF ENGINE OIL AND OIL FILTER lU-6 Oil PUMP lU-7 • . OIL COOLER AND PRESSURE REGULATOR LU-17...
  • Page 260 LU-2 DESCRIPTION A fully pressurized. fuliV filtered lubriCEltion system has been adopted fOf this engine. 4A·F 4A-GE �: t� �� �� � .., �,...
  • Page 261 pr1!ssure feeding lubrication .ystem has been OIL FILTER PIPIt PI'\. IIiOpled sYpply oil Ihe mo ... ing pan. Ihis The oil fille< is a lull ftow lyPl! loiter w.th bultt­ w!ll el l oil 10 "",ine. The lubricelion .ystem consisl5 of an oil filler element.
  • Page 262 TROUBLESHOOTING ..•• 1ory PIg, Remedy head. cylinder block Of 001 pump o.I le'kage Aepoir r>ece oil .u' lU-12. body damaged 0< cricked O� al f.ultv Replace EM-142 Gasket fauly Replace gasket LU-l0.13 pressu,,, Rep'i. IS necen.ry Oil le&kBge LU-' Relief VII"'_ Rep.;'...

  • Page 263: Oil Pressure Check

    OIL PRESSURE CHECK Recommer.,1iId Viscosity (SAEI CHECK ENGINE OIL QUALITY If th of w&ter. Cheek the oil deterioration. entry discoloriog thinning. qU81ity is poor. re�aee the oil. or beuer Use API gr8de SC. SO. SE. SF and recommended viscosity Oil. TEMPERATURE RANGE AN(TIC(PATED SEFORE NEXT Ol...
  • Page 264 LU-8 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filler REPLACEMENT OF ENGINE Oil AND Oil FilTER DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug drain the oil into · tainer. REPLACE OIL FILTER Using SST, remove the oil filter Ilocated on left Iide the engine block).

  • Page 265: Oil Pump

    OIL PUMP COMPONENTS Ooven Rotor !4A_F) • (4A_GEI Guket Retaine. Spring _ ---- -- Snap finQ 0,1 Pan.
  • Page 266 LUBRICATION SYSTEM Oil Pump LU . REMOVAL OF OIL PUMP NOTE: r.pairing the oil pump. the oil pan When strainer and clellned. should be removtld DRAIN ENGINE OIL a CO!\­ Ia) Remov. the oil filler cap. Removi Ihl oil dr.in plug and drain the oil into tainer.
  • Page 267 REMOVE TIMING BELT. IDLER PULLEY ANO CRANKSHAFT TIMING PULLEY 4A·F ISee p.g •• EM-4' 4A·GE EM-57 •• p." .. REMOVE OIL OIPSTICK GUIDE AND DIPSTICK REMOVE OIL PUMP Remove the liven •. bolt U.ing . p Ihe cit tie-faced hammer. e,rafully lop pump body.

  • Page 268: Disassembly Of Oil Pump

    LU-'O DISASSEMBLY OF OIL PUMP (5 •• pIIge LU-7) COVII. REMOVE DRIVE AND DRIVEN ROTORS (GEARS) Remove the five boilS lind pump body ROlor Remove lhe drive and driven 101015 (gearsl. lGear) Drive ' o,� IG ' REMOVE RELIEF VALVE Using snl:lp ring pliers, lemove snap ring.
  • Page 269 LU·ll INSPECTION OF RELIEF VALVE INSPfCT RfLIEf VALVE Imoothtv not, necessary. Coel Ih. r.li.t v,l�e wIth eng,ne 001 check that il II1Is hole by ,ts own the wllve weoght does .,pIKe the .aloef valve II replKe the oil pump nsembly. INSPECTION OF OIL PUMP 14A-FI MEASURE BDOY CLEARANCE...
  • Page 270 lU·12 MEASURE TIP CLEARANCE fleler .. d ct •• ng a gHuge. me(lSuNl lhe clearance bet ..een bo:h tips gear and Clll�ceni. Stand rlll n c.: Driv. g.ar crescent o.on in.! 0.101 - 0.248 (0.0042 - 0.0088 In.! Driven geer to crescent 0.310 10.0023 - 0.0122...
  • Page 271 LU·13 ASSEMBLY OF OIL PUMP lU· 71 [See plge INSTALL RELIEF VALVE . � � , ; [j-Aeli e f Insert Ihe relief \lal\le, spring and relainer inlo the : I- Spri llg pump body. C:>-Aetllin ... (1:)) Using snap ring pliers. inslall Ihe snap .Ing. All DRIVE AND DRIVEN ROTORS (GEAR Insert the dri\le and driven rOlon;...
  • Page 272 Install a new O-ring tl\e oil guide. the oil Install the rnoul"lling bolt. Insert dipstick. INSTALL CRANKSHAFT TIMINO PULLEY, IDLER PULLEY AND TIMING BELT 4A-F (See page. EM-53 4A·GE EM-62 (See pages material and be [4A-GE) INSTALL OIL PAN BAFFLE PLATE beffle...
  • Page 273 LU-16 • Clean bo $taling surlaces with non·'esid ..C ... UTION; e .olvenl which wll1 8f1ect the paint8d lur'ece J - S mm •. 10.1 2 - 0.20 inl Apply seal packing lI\e shc;Jwn ttMt e plate as figu18. B·B' A·A' Pa,t No, 08826·00080...
  • Page 274 lU-l& NOTE: Avoid applying an excess amount the lurf&ce. Be particullrly careful near oil panages . Parts must be assembled within minutes o f • application. Otherwise. the INIterial must rein"" removed and reapplied. Immediately remove nozzle from tube cap. bto&...
  • Page 275 Oil Cooler � nd Pressure egu lalOoI LUBRICATION S YSTEM � �� �� �� A N D PRESSURE COMPONENTS Ga$lce, r ' c'li9 " � .. ' o.c,.".., v .,� " $p r'na •• mOon PIpe G."...
  • Page 276 LUBRICATION SVS ,;,. Cooler Cooler...
  • Page 277 LU8RICATION SYSTEM Oil Cooler lind Pressore Regull1lOf LU·10 COMPONENTS (Cont'd) No 2. Oil "'" .. 'OK'. No. I O� fill,r B'itCk,' Union SoIl OW f�Ier Cool ,r Ho O i l O� Cooler...
  • Page 278 LU-20 REMOVAL AND DISASSEMBLY OF OIL COOLER AND PRESSURE REGULATOR p.8i' (AE and AT) IS,. LU-17 REMOVE UNION PIPE Remove the union boll. gaskets and pipe. REMOVE OIL fiLTER SST. the oil filler. Using 09228-05500 REMOVE OIL fiLTER BRACKET lOlL PRESSURE REGULATOR! O_ring.
  • Page 279 LU-21 REMOVAL AND DISASSEMBLY OF OIL COOLER AND PRESSURE REGULATOR (AW) LU-HlI IS-. ptlg. DISCONNECT OIL COOLER PIPE Remo\le tile boll. union boll cooler pipe and two gasket. REMOVE OIL FILTER !S •• pig. LU-20! REMOVE NO.2 OIL FilTER BRACKET Remove the two bolts.
  • Page 280 LU-22 LUBRICATION SYSTEM Ojl Cooler and Pressure Regulator ASSEMBLY AND INSTALLATION OF OIL COOLER AND PRESSURE REGULATOR (AE and AT) (S.e page LU-17 Of 18) ASSEMBLE OIL FILTER BRACKET lOlL PRESSURE Insert the spring. REGULATOR) relief valve, new gasket end screw on TOrQl'e rlJliel valve p the plug.
  • Page 281 LU·23 LUBRICATION SYSTEM 0;1 Cooler end Pressure Regulalor ASSEMBLY AND INSTALLATION OF OIL •• �. COOLER AND PRESSURE REGULATOR (AW) LU-Ut' ASSEMBLE NO.1 OIL FILTER BRACKU lOlL PRESSURE REGULATOR) ISe, pig. LU-221 Torqu.: 375 kg-em 127 37 N'm) "·Ib, INSTALL NO.1 OIL FILTER BRACKET lOlL PRESSURE REGULATOR) with InSIal1...
  • Page 282 (4A-Gf) SERVICE SPECIFICATIONS - Engine Mechenical ENGINE MECHANICAL 14A·GE} Specifications (Cont'd) ('9"- Drive belt (Altlmllor) tune-liP Deflectoon New bll l l 4 - 5 mm 0.16 - 0.20 In. 7 mm 0.24 - 028 in. Us«t bell Tension (Refllfence) Nlw bell 10 - 80 kg Us8d belt 30 - 15 kg...
  • Page 283 SERVICE SPECIFICATIONS Mechanical !4A-GE) Engine Specifications (Cont'd) "ngth kl� Free PUlley 43.5 1 . 7 1 3 in. tension 9.91 kg (22.0 lb. 98 N) 50.2 mm n.916 in.l Io<Jd Installed sprIng e< Werpage Cyil\Oe< V� bIo<:: k side """ 0.05 mm 0.0020 in.
  • Page 284 SEflVtC£ SPECIFICATIONS 14A-GEI Engine M&chanical Specifications ICont'dl NOOU I Limi! di.�le. 26.949 - 26965 1.01510 - 1.0616 in. C.., I ,,-I, Journal 0.04 0.0016 (Coo,'d) Cirelli 35.41 0 - 35.510 1 3823 - 1.3980 C.., Iobt ne'gh, S'" 35 1 1 1.3823 �Itd "...
  • Page 285 SERVICt: SPECIFICATIONS t4A-GEJ Engine Mechanical Specifications (Cont'd) Crankshaft " �in bearing e.ntllr thiek ..wall ICOI'IfdJ 2.002 2.005 0 0788 - 00789 No. I 00789 - 0.079 1 2.005 - 2,008 ..0.079\ - 00192 2008 - 2 0 1 1 m.n No.
  • Page 286 A-10 (4A-GE) SERVICE SPECIFICATIONS System EFI SYSTEM (4A-GE) Specifications One drop 01 reguletor In;.. c to< ,njector Fuel leakage len ptr minutll Appto., w/ A Appro� 1 3 8 U ilow meter per 1 5 InJflction vok>me WID Ai< flow rneter 1 2 8 CI,) In,1...
  • Page 287 SERVICE SPECIFICAnONS (4A-GEI System Specifications (Cont'd) • Perform ell vo�age and resistance measurements with the computer connected Veri t y thet tM bettery voltage I I V with the • or B� igni�on swilch is Vol t aga miller) (TeeS flow Terminals STD vol t age...
  • Page 288 EFI S�stem !4A,·GEI A·12 SERVICE SPECIFICATIONS Specifications (Cont'd) <CU YoU age !TCCS wI Aor flOw meterl (ColiI'd) Terminels Condillon STO voUell1l - 1 4 IG SIW ON - " " £2 fuRy Tl>rOllle ... lvI fully el o sed IG SfW ON Tl>rottle VIIYe open Cranking or o<IinQ...
  • Page 289 A..1l Specifications cut .pm meter FlHIl fuel cut rpm flow 1.800 !Coord) (����u?e �"(j !c 11 � 76"fl) wI Art flow 1.400 rpm MIT mill. N-ISC 1.1100 N·ISC ON] 1.1100 .pm Fuel 'Itum rpm wlo flow met . . 1.400 wi AI.

  • Page 290: Lubrication System

    II Idle speed More psi. I"-n 0.3 kg/em' (4.3 29 kP.) 3.000 2.6 - 5.0 kglem' (35.8 - 71.1 1'$1.245 - 490 kPal pump 4A-F Body clearance 0.080 - 0.0031 - 0.0053 lImil 0.20 mm 0.0079 Tip clearance 56 mm 0.0048 - 0.0061...
  • Page 291 SERVICE SPECIFICATIONS Startil'l9 System. Charging System STARTING SYSTEM Sta.ter Conv.ntional Rft(Iuoction " " lind output POwe< 1 2 11 0.8 kw Raled vollali' 1 2 11 1 0 kw ",m Mor. Ihltfl 5.000 rpm Mo.e than 3.000 'Pm du •• A.m.1tre th.u$t 0.05 - 0.60 mm {0.OO20 - 0.0236 in.!
  • Page 292 SSM - SST (Sp&{.:ial Service Tools) SST (SPECIAL SERVICE TOOLS) NOTE: Classitication A ,. SST requited for vehicle ,"spectio,,_ minor rep.irs and multipurpose SST. B ,. SST reQ<.lired for major repairs involving di&8ssemblv of com­ ponentt. SST required for rather special, tess frequent work nOl cI8ssifiabie either A or Nole...
  • Page 293 SST (SPECIAL SERVICE TOOLS) (Cant'd) Section � � � 8 Part Name Note Pan No. illustration OI2IH11G2D • • rs.·.T._ G..,. 0121""" . �'Io_C.�oI • • • a e , ..,. (:::. :." & �) 1ll U1·2i022 IISZ2I-«1O§ O) - - - - - - - - - - - - ------...
  • Page 294 SST (Special Service SST AND SSM Too'!) SST (SPECIAL SERVICE TOOLS) (Cont'd) Section . � ; o Note Part Name ..P" ""'O" ,1I N lIUlI-t0 1 81 ..'oo< S ..-..;� -------- ------ -------- blZJl-1S1)'OI IIINt-ongSIWi'. c::: :J •...
  • Page 295 SST AND SSM SST (Special Servici Tools) C·, SST (SPECIAL SERVICE TOOLS) (Cont'd) Siction Plrt Heme CLilni f icltlon No'" Part IIlustr.tion .."..� , (=.on;:;�) Cflnkihlit pu.ey • • 011 Hlal _11·3011 1 1 (:-s:;=) C ..Shlfll.onl •...
  • Page 296 SST AND SSM SSM (Special Service Malerial,) SSM (SPECIAL SERVICE MATERIALS) Pin Phml P.rtNo. U . . . te. CIWotI Cvlindl' head Camshaft bflaring UP Halt cifcle plug (for lA-F) IFor Seal packIng or lIquovalenl 08826-00080 O� 0.1 pan balllo plale 4A-GEI Ignition coil Wale.
  • Page 297 ST·' STARTING SYSTEM '''' 5T-2 TROUBLESHOOTING STARTING SYSTEM CIRCUIT 5T·3 CONVENTIONAL TYPE STARTER ST·4 TYPE 5T·14 REDUCTION STARTER STARTER RELAY (AW) ST-23...
  • Page 298 ST·2 TROUBLESHOOTING CIU." Pl'obt"m Po .. ibl" Bottery ch.rge Checlc balle.y �fic g.avity CH.4 Engil\fl will nol crank worn Cha,� or .ePllo c e b,Uery ,wllch Bauery Clb Repeir or 'eplace cobies IA/T Neulral 511rt only Adjus' or repl.ce ,witch !.ully link Fusiblfl link blown...
  • Page 299 Starting ST-3 STARTING SYSTEM Circuit STARTING SYSTEM CIRCUIT Igrj t ion SwilCh Newtral S t art Fvsl� Link "m Switch AM, eOA S T l IAE. An AM1 1AE. STI AM2 lAWl 5T2 lAW) Ignition SWilch AM1 40A tAE. AT) AM2 1.!'iA Fusible U"k "WI...
  • Page 300 Sr-< CONVENTIONAL TYPE STARTER COMPONENTS Rubbt. lOCk Plate 'ru"' '''' '' Commutator Frame Th'OUIjlh Boll DISASSEMBLY Of CONVENTIONAL TYPE STARTER lelld REMOVE MAGNETIC SWITCH Remove the nul, and disconnect the wire from eogo the magnetic; switch terminal. loosen the two nulS holding the .witch the drive housing.
  • Page 301 STARTING SYSTEM - Convlnlional TVpe SllIrter ST·5 lell Remove the lock plate. spring and rubber. Removi two throogh boht and pu" oul the com­ mutator frame REMOVE BRUSHES AND BRUSH HOLDER r.:--- Using pioce steel wirll. lepllrate the brush springs. and remove tM brushes from the brush holder.
  • Page 302 ST-6 INSPECTION OF CONVENTIONAL TYPE STARTER Armature Coil CHECK THAT COMMUTATOR IS NOT GROUNOED Using an ohmmeter, chacko that there is no continuity bet· ween the commutator and armature coil core. there is continuity. replace the armature. tf1.e CHECK COMMUTATOR FDA OPEN CIRCUIT Using an ohmmeter.
  • Page 303 If&(! CHECK SEGMENT arli Check Ihal Ihe segment is clean and of foreign cles. • Stlndard undercut depth; 0.6 mm [0.024 11'1.1 nimum undarcut depth: 0.2 mm (0.008 inJ If the undercu depth is less than minimum, correct with hacksaw blade and smooth out the edge, Coil Field CHECK fiELD COil FOA OPEN CIRCUIT...
  • Page 304 ST-' PERFORM HOLD·IN COIL OPEN CIRCUIT TUT Using an ohmmeter. check for continuity between tenninal and the switch body. If there ;s no continuity. replace the IYWIgnetic 'WiICh. Starter Clutch INSPECT PINION GEAR AND SPAtHE TEETH Inspect the pinion gear and spline teeth for wear damage.

  • Page 305: Brush Holder

    5T-9 Brush Holder 1'10 CHECK INSULATION OF BRUSH HOLDER Using an ohmmetar, cheek for continuit y betwel51l the positive IMld negative brush holders. If there is continuit y . repair repla(;e the brush holder.
  • Page 306 ST·10 ASSEMBLY OF CONVENTIONAL TYPE STARTER NOTE: ST -41 ISee page Use high-temperature grene to lubricate the bearings and sliding parts when assemblying the slIlfter. ASSEMBLE STARTER CLUTCH TO ARMATURE Piece a ew stop col18l" on the armature. Drive in the snap ring with , 14 mm (0.55 inJ soekel wrench.
  • Page 307 ST·11 INSTALL BRUSH HOLDER AND BRUSHES Place Ihe brush holder, over armalure shah. Using piflce Sleel wire. hold the brush spring back and in.tall Ihe brush i n the b holder, Insta� brushes. lour the INSTAll END FRAME grene to Iha end frame bushing.
  • Page 308 ST-,2 PERFORMANCE TEST OF CONVENTIONAL TYPE STARTER d. 10 CAUTION: These be performed within lUt. mu.t oid burning out the coil. to 5 PERFORM PULL-IN TEST Di.conntK:1 'he field coil lead from t8rminal C. Coonect the batlMy to the magnetic switch as shown.
  • Page 309 ST·13 STARTINO SYSTEM Conventionlll Type SllIrter sieck Move the pinion gear tOward the Ilfmatu� to remove and measure the clearance the pinion between enol and stop collar. Standard clearance: 10.004 0.016 in.} lure PERFORM NO·LOAD PERFORMANCE TEST connect the field coit lead to terminal C. Make the lead is not grounded.
  • Page 310 ST -1 . STARliNG SYSTEM Starte, Type REDUCTION TYPE STARTER COMPONENTS DISASSEM BLY OF REDUCTION TYPE STARTER ��� REMOVE FIELD ME WITH ARMATURE FROM from thI : t G NEliC SWI emove wif e ,wilCh magnetic bolt$, Pul l out, the field Remove the through In&gneliC...
  • Page 311 REMOVE STARTER HOUSING FROM MAGNETIC SWITCH ASSEMBLY Remove the screws and remove the starter housing with the idler gaar and clutCh assembly. REMOVE CLUTCH ASSEMBLY ANO tOLER GEAR FROM STARTER HOUSING REMOVE STEEL BAll AND SPRING Using magnetic finger. remove the spring and steel ball the clutch from...
  • Page 312 ST-18 INSPECTION OF STARTER Armature Coil INSPECT THAT COMMUTATOR IS NOT GROUNDED bel· an ohmmete •• cheek that there is no U,ing continuity the commutator and armature coil core. If there is continuity. replace the annalure INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check for continuity between tt>e segments the commutator.
  • Page 313 STARTING SYSTEM - Reduction Type Starter CHECK SEGMENT Check Ihat the segmenl is clean and free of foreign parti· cles. undercut 0.6 mm (0.24 in.1 Standard depth: in.1 Minimum 0.2 mm (0.008 undarcut dapth: deplh is less than minimum. correct it with Ihe undercul hacklllw blade arld smooth the edge.
  • Page 314 Brush Holder It ... INSPECT INSULATION OF BRUSH HOLDER hoIW. Using an ohmmeter. check for continuity Mtween pOsitiye .nd negative brush holders. there is continuity, repair or raplace the brush Clutch and Gears INSPECT GEAR TEETH .150 Check Ihe gear teeth on the pinion ge.r. Idle< gear and clutch assembly for we.r or damage.
  • Page 315 STARTING SYSTEM ST-HI Reduction Type Starter $�Ift. end a install new frOnt press_ bearjng onto the lell 09285-76010 Using press, install bearing onto th rlltr s�alt. Magnetic Switch PERfORM PULL-IN COIL OPEN CIRCUIT TEST Using o�mmeter. c�f1ck lor between terminal cont inuily 50 and tarminal C.
  • Page 316 ST-20 ASSEMBl V OF REDUCTION TVPE STARTER NOTE: (5 •• ST-14) page Use high-temperature grease to IUbricilte tha beElrings and gaars when assembling the statter. PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings and insert ermature into the field frame INSTALL BRUSH HOLDER AND BRUSHES Using a screwdriver, hold the brush spring back, itlstall the brush into the brush...
  • Page 317 ST-21 INSTALL GEAR AND CLUTCH ASSEMBLY Apply grease gear and as$8mbly. CIUI4;h bean assembly. idler gear and ng in Place the clutch the starter housing. INSTALL STARTER HOUSINO Place the starter housing on Ihe magneti4; switch and in'lall the two screws INSTALL FIELD FRAME WITH ARMATURE IN MAGNETIC SWITCH Match the protrusion of...
  • Page 318 ST-:za PERFORMANCE TEST OF STARTER The.e t.,u mu.t within 3 CAUTION: be pertormed to 6 .econd. to Ivold burning out the coil. PERFORM PULL-IN TEST !a l Disconnlct the field coil teed from lermln.1 C. Connecl the to Ihe m swilch &...
  • Page 319 ST·23 STARTER RELAY (AWl INSPECTION OF STARTER RELAY LOCA nON: In Ihe No. junction block of the engine compartment INSPECT RELAY CONTINUtTY Using an ohmmeter. check that there is continUity IMotween termiNlS Ch&Ck that there is no contln-uity IMotween terminals continuity is not as specified.

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