Toyota 2GR-FE Manual de usuario

2GR-FE ENGINE MECHANICAL – ENGINE EM–1

ENGINE

ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT

(a) Inspect the engine coolant (See page CO-1).

2. INSPECT ENGINE OIL

(a) Inspect the engine oil (See page LU-1).

3. INSPECT BATTERY

(a) Inspect the battery (See page CH-4).

4. INSPECT SPARK PLUGS

(a) Inspect the spark plugs (See page IG-5).

5. INSPECT AIR CLEANER FILTER ELEMENT SUB-

ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly.

(b) Visually check that there is no dirt, blockage, and/or

damage to the air cleaner filter element.

HINT:

• If there is any dirt or a blockage in the air cleaner

filter element, clean it with compressed air.

• If any dirt or a blockage remains even after

cleaning the air cleaner filter element with

compressed air, replace it.

6. INSPECT VALVE LASH ADJUSTER NOISE

(a) Rev up the engine several times. Check that the

engine does not emit unusual noises.

If unusual noises occur, warm up the engine and

idle it for over 30 minutes. Then repeat this

procedure.

HINT:

If any defects or problems are found during the

inspection above, perform lash adjuster inspection

(See page EM-87).

7. INSPECT IGNITION TIMING

(a) Warm up the engine.

(b) When using the intelligent tester:

Check the ignition timing.

(1) Connect the intelligent tester to the DLC3.

(2) Enter DATA LIST mode with the intelligent

tester.

Ignition timing:

8 to 12°BTDC at idle

HINT:

Refer to the intelligent tester operator's manual

for help when selecting the DATA LIST.

Intelligent Tester

DLC3 CAN VIM

C110200E02

EM–2 2GR-FE ENGINE MECHANICAL – ENGINE

Check the ignition timing.

(1) Using SST, connect terminals 13 (TC) and 4

(CG) of the DLC3.

SST 09843-18040

NOTICE:

• Confirm the terminal numbers before

connecting them. Connection with a

wrong terminal can damage the engine.

• Turn off all electrical systems before

connecting the terminals.

• Perform this inspection after the cooling

fan motor is turned off.

(2) Remove the V-bank cover.

(3) Pull out the red lead wire harness.

(4) Connect the tester terminal of the timing light to

the red lead wire as shown in the illustration.

NOTICE:

Use a timing light which can detect the first

signal.

(5) Check the ignition timing at idle.

Ignition timing:

8 to 12°BTDC at idle

NOTICE:

When checking the ignition timing, the

transmission should be in neutral.

HINT:

Run the engine at 1,000 to 1,300 rpm for 5

seconds, and then check that the engine rpm

returns to idle speed.

(6) Disconnect terminals 13 (TC) and 4 (CG) of the

DLC3.

(7) Check the ignition timing at idle.

Ignition timing:

12 to 22°BTDC at idle

(8) Confirm that the ignition timing moves to the

advanced angle side when the engine rpm is

increased.

(9) Remove the timing light.

8. INSPECT ENGINE IDLE SPEED

(a) Warm up the engine.

(b) When using the intelligent tester:

Check the idle speed.

(1) Connect the intelligent tester to the DLC3.

(2) Enter DATA LIST mode with the intelligent

tester.

Idle speed:

600 to 700 rpm

NOTICE:

• When checking the idle speed, the

transmission should be in neutral.

• Check the idle speed with the cooling fan

off.

910111213141516

2345678

DLC3

TC A122830E14

Red Lead

Wire

Tester Terminal

A129620E01

Intelligent Tester

DLC3 CAN VIM

C110200E02

2GR-FE ENGINE MECHANICAL – ENGINE EM–3

• Switch off all accessories and air

conditioning before connecting the

intelligent tester.

HINT:

Refer to the intelligent tester operator's manual

for further details.

Check the idle speed.

(1) Using SST, connect the tachometer test probe

to terminal 9 (TAC) of the DLC3.

SST 09843-18030

(2) Check the idle speed.

Idle speed:

600 to 700 rpm

9. INSPECT COMPRESSION

(a) Warm up and stop the engine.

(b) Disconnect the injector connectors.

13).

(d) Remove the 6 ignition coils.

(e) Remove the 6 spark plugs.

(f) Check the cylinder compression pressure.

(1) Insert a compression gauge into the spark plug

hole.

(2) While cranking the engine, measure the

compression pressure.

Compression pressure:

1.4 MPa (14 kgf/cm2, 199 psi)

Minimum pressure:

0.98 MPa (10 kgf/cm2, 142 psi)

Difference between each cylinder:

0.1 MPa (1.0 kgf/cm2, 15 psi)

NOTICE:

• Always use a fully charged battery to

obtain an engine speed of 250 rpm or

more.

• Check the other cylinders' compression

pressure in the same way.

• This measurement must be done as

quickly as possible.

(3) If the cylinder compression is low, pour a small

amount of engine oil into the cylinder through

the spark plug hole and inspect again.

HINT:

• If adding oil increases the compression, the

piston rings and/or cylinder bore may be

worn or damaged.

• If pressure stays low, a valve may be stuck

or seated improperly, or there may be

leakage in the gasket.

(g) Install the 6 spark plugs.

Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

910111213141516

2345678

DLC3

TAC

A122830E15

A129621

EM–4 2GR-FE ENGINE MECHANICAL – ENGINE

(h) Install the 6 ignition coils.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

(i) Install the intake air surge tank. (See page FU-17).

10. INSPECT CO/HC

(a) Start the engine.

(b) Run the engine at 2,500 rpm for approximately 180

seconds.

(1.3 ft) into the tailpipe during idling.

(d) Check CO/HC concentration at idle and/or 2,500

rpm.

HINT:

Check regulations and restrictions in your area

when performing 2 mode CO/HC concentration

testing (engine check at both idle speed and at

2,500 rpm).

If the CO/HC concentration does not comply with

regulations, perform troubleshooting in the order

given below.

(1) Check A/F sensor and heated oxygen sensor

operation.

(2) See the table below for possible causes, and

then inspect and repair.

CO HC Problems Causes

Normal High Rough idle

1. Faulty ignitions:

– Incorrect timing

– Fouled, shorted or improperly gapped plugs

2. Incorrect valve clearance

3. Leaks in intake and exhaust valves

4. Leaks in cylinders

Low High Rough idle

(fluctuating HC reading)

1. Vacuum leaks:

– PCV hoses

– Intake manifold

– Throttle body

– Brake booster line

2. Lean mixture causing misfire

High High Rough idle

(black smoke from exhaust)

1. Restricted air filter

2. Plugged PCV valve

3. Faulty SFI system:

– Faulty fuel pressure regulator

– Defective ECT sensor

– Defective MAF meter

–FaultyECM

– Faulty injectors

– Faulty throttle position sensor

2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–5

ENGINE2GR-FE ENGINE MECHANICAL

DRIVE BELT

COMPONENTS

V-BANK COVER SUB-ASSEMBLY

V-RIBBED BELT

FRONT FENDER APRON SEAL RH

A134931E01

EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT

REMOVAL

1. REMOVE FRONT WHEEL RH

2. REMOVE FRONT FENDER APRON SEAL RH

3. REMOVE V-BANK COVER SUB-ASSEMBLY (See

page EM-23)

4. REMOVE V-RIBBED BELT

(a) Using SST, release the belt tension by turning the

belt tensioner counterclockwise, and remove the V-

ribbed belt from the belt tensioner.

SST 09249-63010

(b) While turning the belt tensioner counterclockwise,

align with its holes, and then insert the 5 mm bi-

hexagon wrench into the holes to fix the V-ribbed

belt tensioner.

SST

A129622E01

A095070

2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–7

INSPECTION

1. INSPECT V-RIBBED BELT

(a) Visually check the V-ribbed belt for excessive wear,

frayed cords, etc.

If any defect has been found, replace the V-ribbed

belt.

HINT:

Cracks on the rib side of a V-ribbed belt are

considered acceptable.

If the drive belt has chunks missing from its ribs, it

should be replaced.

HINT:

• A "new belt" is a belt which has been used for

less than 5 minutes with the engine running.

• A "used belt" is a belt which has been used for 5

minutes or more with the engine running.

2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY

(a) Check that nothing gets caught in the tensioner by

turning it clockwise and counterclockwise.

If a malfunction exitsts, replace the tensioner.

INSTALLATION

1. INSTALL V-RIBBED BELT

(a) Install the V-ribbed belt.

(b) Using SST, turn the belt tensioner counterclockwise

and remove the bar.

SST 09249-63010

following procedure:

(1) Put the V-ribbed belt on every pulley except the

tensioner pulley as shown in the illustration.

(2) While releasing the belt tension by turning the

belt tensioner counterclockwise, put the V-

ribbed belt on the tensioner pulley.

NOTICE:

• Put the backside of the V-ribbed belt on

the tensioner pulley and idler pulley.

• Check that the V-ribbed belt is properly

set to each pulley.

(3) After installing the V-ribbed belt, check that it

fits properly in the ribbed grooves. Confirm that

the belt has not slipped out of the grooves on

the bottom of the crank pulley by hand.

REPLACE

CORRECT INCORRECT

A131418E01

SST

A129622E01

Crankshaft

Vane Pump

Water Pump

Generator

Tensioner

Idler

A/C Compressor

A129623E01

EM–8 2GR-FE ENGINE MECHANICAL – DRIVE BELT

2. INSTALL V-BANK COVER SUB-ASSEMBLY (See

page EM-52)

3. INSTALL FRONT FENDER APRON SEAL RH

4. INSTALL FRONT WHEEL RH

Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL

ENGINE2GR-FE ENGINE MECHANICAL

ENGINE FRONT OIL SEAL

COMPONENTS

CRANKSHAFT PULLEY

TIMING CHAIN CASE OIL SEAL

V-BANK COVER SUB-ASSEMBLY

V-RIBBED BELT

FRONT FENDER APRON

SEAL RH

250 (2,550, 184)

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

A134932E01

2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–9

REMOVAL

1. REMOVE FRONT WHEEL RH

2. REMOVE FRONT FENDER APRON SEAL RH

3. REMOVE V-BANK COVER SUB-ASSEMBLY (See

page EM-23)

4. REMOVE V-RIBBED BELT (See page EM-6)

5. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley bolt.

SST 09213-70011 (09213-70020), 09330-00021

(b) Using SST, remove the crankshaft pulley bolt and

crankshaft pulley.

SST 09950-50013 (09951-05010, 09952-05010,

09953-05020, 09954-05021)

6. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.

HINT:

Tape the screwdriver tip before use.

NOTICE:

After the removal, check the crankshaft for

damage. If it is damaged, smooth the surface

with 400-grit sandpaper.

SST

A119083E01

SST

A119085E01

Protective Tape

Cut Position

A132241E01

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