Мануал 4a ge blacktop

• Applicable Models

  4

• Caution

  5

• Contents

  6

• Introduction/Contents

  8

• How to Use this Manual

  9

• General Repair Instructions

  11

• Engine Serial Number

  11

• Precautions for Vehicles Equipped with a Catalytic Converter

  14

• Abbreviations Used in this Manual

  15

• Engine Mechanical/Contents

  16

• 4A-FE Engine Description

  17

• 4A-GE Engine Description

  19

• Troubleshooting (4A-FE)

  21

• Engine Overheating

  21

• Rough Idling

  22

• Engine Hesitates/Poor Acceleration

  23

• Engine Dieseling

  23

• After Fire, Backfire

  24

• Excessive Oil Consumption

  24

• Poor Gasoline Mileage

  25

• Unpleasant Odor

  25

• Troubleshooting (4A-GE)

  26

• Hard Starting

  26

• Excessive Fuel Consumption

  29

• Engine Tune-Up (4A-FE)

  30

• Inspection of Engine Coolant/Oil

  30

• Inspection of Battery/Air Filter

  30

• Inspection of Spark Plugs/High Tension Cords/Alternator Drive Belt

  30

• Inspection and Adjustment of Valve Clearance

  31

• Adjusting Shim Selection Chart/Intake

  33

• Adjusting Shim Selection Chart/Exhaust

  34

• Inspection and Adjustment of Ignition Timing

  35

• Inspection and Adjustment of Idle Speed (W/Twc)

  37

• Inspection and Adjustment of Idle Speed and Idle Mixture (W/O TWC)

  38

• Troubleshooting

  39

• Engine Tune-Up (4A-GE)

  40

• Idle HC/CO Concentration Check Method (W/Twc)

  48

• Inspection and Adjustment of Dash Pot (DP) System (4A-FE)

  50

• Inspection and Adjustment of Dash Pot (DP) System (4A-GE W/Air Flow Meter)

  52

• Compression Check

  53

• Timing Belt Component (4A-FE)

  54

• Removal of Timing Belt

  54

• Inspection of Timing Components

  57

• Installation of Timing Belt

  59

• Timing Belt (4A-GE)

  62

• Inspection of Timing Belt Components

  65

• Cylinder Head Components(4A-FE)

  71

• Removal of Cylinder Head

  73

• Disassembly of Cylinder Head

  82

• Inspection, Cleaning and Repair of Cylinder Head Components

  83

• Assembly of Cylinder Head

  93

• Installation of Cylinder Head

  95

• Cylinder Head Components (4A-GE)

  107

• Cylinder Block Components

  132

• Preparation for Disassembly

  133

• Disassembly of Cylinder Block

  134

• Inspection of Cylinder Block

  140

• Disassembly of Piston and Connecting Rod Assemblies

  141

• Inspection of Piston and Connecting Rod Assemblies

  143

• Boring of Cylinders

  148

• Inspection and Repair of Crankshaft

  149

• Inspection of Check Valves and Oil Nozzles

  149

• Replacement of Crankshaft Oil Seals

  150

• Replacement of Union (4A-GE)

  151

• Assembly of Piston and Connecting Rod

  152

• Assembly of Cylinder Block

  153

• Assembly of Engine

  158

• EFI System/Contents

  160

• EFI System Description

  161

• Maintenance Precautions

  167

• When Car Is Equipped with a Mobile Radio System (HAM, CB, Etc.)

  168

• Air Induction System

  168

• Electronic Control System

  169

• Fuel System

  170

• Troubleshooting Hints

  173

• Engine will Not Crank or Cranks Slowly

  174

• Difficult to Start or no Start (Cranks OK)

  174

• Engine Often Stalls

  176

• Rough Idling And/Or Missing

  178

• High Engine Idle Speed

  179

• Engine Backfires (Lean Fuel Mixture)

  180

• Muffler Explosion (after Fire) — Rich Fuel Mixture

  181

• Engine Hesitates And/Or Poor Acceleration

  182

• Diagnosis System Description

  184

• Check Engine Warning Light Check

  184

• Output of Diagnostic Codes

  184

• Cancelling Diagnostic Code

  186

• Diagnosis Indication

  186

• Diagnostic Codes (4A-FE)

  187

• Diagnostic Codes (4A-GE)

  188

• Inspection of Diagnosis Circuit

  191

• Troubleshooting with Volt/Ohmmeter

  193

• Location of Fuses and Fusible Links

  193

• EFI System Check Procedure

  195

• Terminals of ECU (4A-FE 2WD)

  196

• Voltage at ECU Wiring Connectors (4A-FE 2WD)

  197

• Terminals of ECU (4A-FE 4WD)

  210

• Voltage at ECU Wiring Connectors (4A-FE 4WD)

  211

• Terminals of ECU (4A-GE W/O Air Flow Meter)

  224

• Terminals of ECU Wiring Connectors (4A-GE W/O Air Flow Meter)

  225

• Terminals of ECU (4A-GE W/ Air Flow Meter)

  238

• Terminals of ECU Wiring Connectors (4A-GE W/ Air Flow Meter)

  239

• Fuel System/Pump

  253

• On-Vehicle Inspection

  254

• Removal of Fuel Pump (AE 92, 95, AT171)

  258

• Installation of Fuel Pump (AE 92, 95, AT171)

  259

• Removal of Fuel Pump (AT180)

  260

• Components (AT180)

  261

• Disassembly/Assembly of Fuel Pump (AT180)

  262

• Installation of Fuel Pump (AT180)

  263

• Cold Start Injector

  264

• Inspect Resistance of Cold Start Injector

  264

• Removal of Cold Start Injector

  264

• Inspection of Cold Start Injector

  265

• Installation of Cold Start Injector

  267

• Fuel Pressure Regulator

  268

• Removal of Fuel Pressure Regulator

  268

• Inspect Fuel Pressure

  268

• Installation of Fuel Pressure Regulator

  269

• Injector

  270

• Removal of Injectors

  272

• Inspection of Injectors

  273

• Installation of Injectors

  275

• Air Flow Meter (4A-GE W/Air Flow Meter)

  279

• Inspect Resistance of Air Flow Meter

  279

• Removal/Inspection/Installation of Air Flow Meter

  280

• Throttle Body (4A-FE)

  281

• Removal of Throttle Body

  282

• Inspection of Throttle Body

  283

• Installation of Throttle Body

  285

• Throttle Body (4A-GE)

  286

• Removal/Inspection of Throttle Body

  287

• Auxiliary Air Valve

  290

• Inspect Air Valve Operation (W/O Air Flow Meter)

  290

• Removal of Auxiliary Air Valve

  291

• Installation of Air Valve

  291

• Location of Electronic Control Parts

  292

• EFI Main Relay

  293

• Inspection of EFI Main Relay (AE/AT)

  293

• Circuit Opening Relay

  294

• Inspection of Circuit Opening Relay (W/O Air Flow Meter)

  294

• Inspection of Circuit Opening Relay (W/ Air Flow Meter)

  295

• Start Injector Time Switch

  296

• Inspection of Start Injector Time Switch

  296

• Water Temperature Sensor

  297

• Inspection of Water Temperature Sensor

  297

• Intake Air Temperature Sensor (W/O Air Flow Meter)

  298

• Inspection of Intake Air Temperature Sensor

  298

• Vacuum Sensor (W/O Air Flow Meter)

  299

• Inspection of Vacuum Sensor

  299

• Variable Resistor (W/O TWC)

  301

• Inspection of Variable Resistor

  301

• Inspection of Oxygen Sensor

  304

• Inspection of ECU

  306

• Voltage at ECU Wiring Connectors (4A-FE)

  307

• Voltage at ECU Wiring Connectors (4A-GE W/O Air Flow Meter)

  308

• Voltage at ECU Wiring Connectors (4A-GE W/ Air Flow Meter)

  309

• Resistance of ECU Wiring Connectors (4A-FE)

  310

• Resistance of ECU Wiring Connectors (4A-GE With/Without Air Flow Meter)

  311

• Inspection of Fuel Cut RPM

  312

• Fuel Pressure Control System (4A-GE Europe)

  313

• Inspection of Fuel Pressure Control System

  313

• Idle-Up System (W/ Air Flow Meter)

  315

• Inspection of Idle-Up System

  315

• Idle Speed Contro (ISC) Valve (4A-FE)

  317

• Inspection of ISC Valve

  317

• Air Control Valve (ACV) (4A-GE W/O Air Flow Meter)

  319

• Inspection of ACV

  319

• Cooling System/Contents

  322

• Cooling System Description

  323

• Cooling System Troubleshooting

  325

• Check and Replacement of Engine Coolant

  326

• Water Pump Components

  327

• Removal of Water Pump

  327

• Inspection of Water Pump

  328

• Disassembly of Water Pump

  329

• Assembly of Water Pump

  330

• Installation of Water Pump

  332

• Removal/Inspection/Installation of Thermostat

  334

• Cleaning/Inspection of Radiator

  336

• Radiator Components

  337

• Disassembly of Radiator (AE, AT171)

  337

• Assembly of Radiator (AE, AT171)

  339

• Installation of Radiator

  341

• Radiator Cooling Fan System Circuit/Components

  342

• Low/High Coolant Temperature

  343

• Inspection of Electric Cooling Fan

  344

• Lubrication System/Contents

  346

• Lubrication System Description

  347

• Lubrication System Troubleshooting

  350

• Oil Pressure Check

  351

• Replacement of Engine Oil and Oil Filter

  352

• Oil Pump Components

  354

• Removal of Oil Pump

  355

• Disassembly of Oil Pump

  356

• Inspection of Oil Pump

  357

• Replacement of Crankshaft Front Oil Seal

  357

• Assembly of Oil Pump

  358

• Installation of Oil Pump

  359

• Oil Cooler and Pressure Regulator Components

  362

• Ignition System/Contents

  364

• Ignition System Precautions

  365

• Ignition System Troubleshooting

  366

• Ignition System Circuit

  367

• Electronic Spark Advance (ESA)

  367

• Check that Spark Occurs (4A-FE)

  369

• Inspection of High-Tension Cords

  370

• Inspection of Spark Plugs

  370

• Inspection of Ignition Coil

  371

• Distributor

  371

• Inspection of Igniter

  372

• Check that Spark Occurs (4A-GE)

  373

• Inspection of Spark Plugs (Conventional Tipped Type)

  374

• Inspection of Spark Plugs (Platinum Tipped Type)

  375

• Inspection of Distributor

  377

• Integrated Ignition Assembly (IIA) (4A-FE) Components

  378

• Disassembly of IIA

  378

• Inspection of IIA

  379

• Inspect Governor Shaft

  379

• Installation of IIA

  381

• Distributor (4A-GE) Components

  382

• Installation of Distributor

  382

• Starting System/Contents

  384

• Starting System Troubleshooting/Circuit

  385

• Planetary Type Starter Components

  386

• Disassembly of Planetary Type Starter

  387

• Inspection of Planetary Type Starter

  390

• Armature Coil

  390

• Commutator

  390

• Field Coil (Field Frame)

  391

• Inspect Brush Length

  391

• Inspect Brush Spring Load

  392

• Inspect Brush Holder Insulation

  392

• Starter Clutch and Gears

  392

• Magnetic Switch

  392

• Planet Carrier Shaft and Center Bearing

  393

• Assembly of Planetary Type Starter

  394

• Performance Test of Planetary Type Starter

  398

• Reduction Type Starter Components

  400

• Disassembly of Reduction Type Starter

  401

• Inspection of Starter

  402

• Field Coil

  403

• Measure Brush Length

  404

• Mesure Brush Spring Load with Pull Scale

  404

• Inspect Insulation of Brush Holder

  404

• Clutch and Gears

  404

• Bearings

  405

• Assembly of Reduction Type Starter

  406

• Performance Test of Starter

  408

• Charging System/Contents

  410

• Charging System Precautions/Troubleshooting

  411

• Charging Circuit

  411

• Alternator Components

  416

• Disassembly of Alternator

  417

• Inspection and Repair of Alternator

  418

• Rotor

  418

• Stator

  418

• Brushes

  419

• Rectifier

  419

• Assembly of Alternator

  422

• Service Specifications/Contents

  424

• Engine Mechanical (4A-FE) Specifications

  425

• Torque Specifications

  428

• Engine Mechanical (4A-GE) Specifications

  429

• EFI System (4A-FE) Specifications

  433

• Cooling System Service Specifications

  438

• Lubrication/Ignition System Service Specifications

  439

• Starting/Charging System Service Specifications

  440

• Standard Bolt Torque Specifications

  442

• How to Determine Bolt Strength

  443

• Specified Torque for Standard Bolts

  444

• SST and Ssm/Contents

  446

• SST (Special Service Tools)

  447

• SSM (Special Service Materials)

  451

• How to Use this Manual

  2

• Charging Circuit

  13

• Coolant Circuit

  32

• Water Pump

  35

• Table of Contents

  61

• System Description

  62

• Electronic Control System

  64

• Maintenance Precautions

  65

• Precautions

  66

• Troubl.eshooting • • •

  70

• Diagnosis System

  82

• Troubl.eshooting with Volt/Ohmmeter

  89

• Fuel System

  126

• Fuel Pump

  127

• Cold Start Injector

  132

• Fuel Pressure Regulator

  136

• Injectors

  137

• Air Induction System

  142

• Throttle Body

  144

• Electronic Control System

  149

• Solenoid Resistor and Injector Relay

  153

• Cold Start Injector Time Switch

  155

• Inspection of Oxygen Sensor

  161

• Engine Overheating

  173

• Hard Starting

  173

• Rough Idling

  173

• Excessive Oil Consumption

  175

• Excessive Fuel Consumption

  176

• Adjustment of Valve Clearance

  178

• Cylinder Block

  189

• Inspection of Ignition Coil

  254

• Oil Pressure Check

  263

• Oil Pump

  265

• Disassembly of Oil Pump

  268

• Lubrication System

  290

• Brush Holder

  305

Brand: Toyota
|
Category: Engine
|
Size: 7.76 MB

• Introduction

  2

  • Valve Clearance

    1

  • Ignition Timing

    1

  • Timing Belt

    1

  • Table of Contents

    2

  • How to Use this Manual

    3

  • Identification Information

    5

  • General Repair Instructions

    5

  • PRECAUTIONS for VEHICLES EQUIPPED Wttha CATALYTIC CONVERTER

    8

  • Abbreviations Used in this Manual

    9

• Efi System

  76

  • System Description

    77

  • Inspection Precautions

    80

  • Precautions

    80

  • Troubleshooting

    85

  • Diagnosis System

    96

  • Troubleshooting with Volt/Ohmmeter

    103

  • Fuel System

    120

    • Fuel Pump

      120

    • Cold Start Injector

      125

    • Fuel Pressure Regulator

      129

    • Injectors

      131

  • Air Induction System

    140

    • Throttle Body (4A-FE

      140

    • Auxiliary Air Valve

      145

  • Electronic Control System

    147

    • Location of Electronic Control Parts

      147

    • Circuit Opening Relay

      149

    • Start Injector Time Switch

      151

    • Water Temperature Sensor

      152

    • Intake Air Temperature Sensor (W/O Air Flow Meter

      153

    • Vacuum Sensor (W/O Air Flow Meter) (Manifold Absolute Pressure Sensor

      154

    • Variable Resistor (W/O TWC

      156

    • Oxygen Sensor (W/ TWC

      159

    • Engine ECU

      161

    • Fuel Cut RPM

      165

    • Idle-Up System (W/ Air Flow Meter

      166

    • Idle Speed Control (ISC) Valve (4A-FE

      168

• Cooling System

  170

  • Description

    171

  • Troubleshooting

    173

  • Check and Replacement of Engine Coolant

    174

  • Water Pump

    175

  • Thermostat

    182

  • Radiator

    184

  • Electric Cooling Fan

    185

    • Lubrication System

      189