Toyota 4A-FE Instrucciones de funcionamiento

TOYOTA

4A-FE, 4A-GE

NGINE REPAIR

MANUAL

TOYOTA MOTOR CORPORATION

not

reproduced or copied, in

whole

in part.

without the

written

permission

Toyota

Motor Corporation.

INTRODUCTION _

ENGINE

MECHANICAL

EFI

SYSTEM

COOLING

SYSTEM

LUBRICATION

SYSTEM

IGNITION

SYSTEM

STARTING

SYSTEM

Eli

CHARGING

SYSTEM

SERVICE SPECIFICA,"IONS

STANDARD BOLT TORQUE SPECIFICATIONS

SSTANDSSM

Tune-up data

Valve Clearance

Ignition Timing

Idle Speed

Compression Check

Timing Belt

IN-1

INTRODUCTION Page

HOW

TO USE

THIS

MANUAL

................................

IN-2

IDENTIFICATION

INFORMATION

..........................

IN-4

GENERAL REPAIR INSTRUCTIONS ..

.. ..

...........

.......

IN-4

PRECAUTIONS

FOR

VEHICLES EQUIPPED

WtTH

CATALYTIC

CONVERTER

...............................

IN-7

ABBREVIATIONS

USED

THIS

MANUAL

..........

IN-8

\1-2

Pulley

Seat

Water

Pulmp

Pulley

• : Non-reusable part

INTRODUCTION -

How

Use This Manual

+Bearing

HOW

TO USE THIS

MANUAL

assist you

finding

your

way

through this manual, the Sec-

tion Title and major heading

are

given at the

top

every page.

INDEX

is provided on the

1st

page

each section to guide

you to the item to be repaired.

the beginning

each section, PRECAUTIONS

are

given

that

pertain to all repair operations contained in

that

section.

Read these precautions before

starting

any

repair task.

TROUBLESHOOTING tables are included

for

each system to

help you diagnose the system problem and find the cause. The

repair

for

each possible cause is referenced in the remedy col-

umn

quickly lead you to the solution.

REPAIR PROCEDURES

Most

repair operations begin

with

overview illustration.

identifies the components and

shows

how

the parts

fit

together.

Example:

Water

Pump Suction Cover

0-Ring

•Seal

+Rotor

•Gasket

Water

Pump Body

C00499

INTRODUCTION -

How

Use This Manual

IN-3

Illustration:

what

and where

The procedures are presented in a step-by-step format:

• The illustration

shows

what

and where

• The task heading tells

what

do.

• The detailed

text

tells

how

perform

the task and gives

other information such

specifications and warnings.

Example:

/ Task heading:

what

to do

3. DISCONNECT CONNECTING ROD FROM PISTON

Using SST, press

out

the pin

from

the piston.

SST

09221-25022

(09221-00050,

09221-0~1-00140)

Set

part

No.

Component

part

No.

Detail text:

how

(d)

Install and alternately tighten the cap nuts

several

passes.

Torque:

500

kg-cm

(36

ft-lb.

N·m)

Specification

This

format

provides the experienced technician

with

a FAST

TRACK

the information needed.

can read the task head-

ings and only refer to the detailed

text

when

needs it. Impor-

tant specifications and warnings always stand

out

in bold type.

REFERENCES

References have been kept to a minimum. However, when they

are

required, you are given the page to go to.

SPECIFICATIONS

Specifications are presented in bold type

throughout

the

text

the applicable step. You never have

leave the procedure

look

up your specifications. All specifications are also found in

Appendix A,

for

quick reference.

CAUTIONS, NOTICES,

HINTS:

• CAUTIONS are presented

bold type, and indicate the

possibility

injury to you

other people.

• NOTICES are also presented in bold type and indicate there is

a possibility

damage to the components being repaired.

• HINTS are separated

from

the

text

but

not

appear in bold

type. They provide additional information

help you

effi-

ciently perform the repair.

\1-4

4A-FE Engine

INTRODUCTION

Identification

Information, General Repair Instructions

4A-GE Engine

INOl

IN0035

IDENTIFICATION

INFORMATION

ENGINE SERIAL NUMBER

The engine serial

number

is stamped

the

left

side

the

cylinder block.

GENE_RAL

REPAIR INSTRUCTIONS

1. Use fender, seat and

floor

covers

keep the vehicle clean

and prevent damage.

During disassembly, keep

parts

order

facilitate

reassembly.

3. Observe

the

following:

{a)

Before performing electrical work,

disconnect

the

negative cable

from

the

battery terminal.

(b)

is necessary

disconnect

the battery

for

inspec-

tion

repair, always

disconnect

the cable

from

the

negative

(-)

terminal

which

is grounded to the vehi-

cle body.

(c)

prevent damage

the

battery terminal post,

loosen

the

terminal

nut

and raise the cable

straight

without

twisting

prying it.

(d)

Clean

the

battery terminal

posts

and cable terminals

with

shop

rag. Do

not

scrape

them

with

a file

other

abrasive object.

(e)

Install the cable terminal

the

battery

post

with

the

nut

loose, and

tighten

the

nut

after

installation. Do

not

use a hammer

tap the terminal

onto

the post.

(f)

sure the cover

for

the

positive(+)

terminal is pro-

perly in place.

4. Check hose and wiring connectors to make sure

that

they

are secure and correct.

5. Non-reusable parts

(a)

Always

replace

cotter

pins gaskets,

0-rings,

oil seals,

etc.

with

new

ones.

(b)

Non-reusable parts are indicated in

the

component

illustrations by

the

symbol

"+".

WRONG

INTRODUCTION

-General Repair Instructions IN-5

Seal Lock Adhesive

IN00:16

CORRECT

IN0001

6. Precoated Parts

Precoated parts are the bolts, nuts, etc. which are coated

with

a seal lock adhesive

the factory.

(a)

a precoated part is tightened, loosened or caused

move

any way,

must

be recoated

with

the

specified adhesive.

(b)

Recoating

Precoated Parts

(c)

(1) Clean

off

the

old adhesive

from

the part's

threads.

(2) Dry

with

compressed air.

(3)

Apply

the specified seal lock adhesive

the

part's threads.

Precoated parts are indicated

the

component

mustrations by the symbol "*

When

necessary, use a sealer on gaskets to prevent leaks.

8. Carefully observe all specifications

for

bolt

torques.

Always

use a torque wrench.

9. Use

special service tools (SST) and special service

materials (SSM) may be required, depending on the nature

the repair.

sure

use SST and SSM where specified

and

the proper

work

procedure. A list

SST and

SSM

can be found

the back

this manual.

10.

When

replacing fuses, be sure the new fuse is the

correct

amperage.

NOT exceed the fuse

amp

rating

use one

lower

rating.

11. Care

must

be taken when jacking up and supporting the

vehicle.

sure

lift

and

support

the vehicle

the

proper locations.

(a)

the vehicle is

be jacked up only at the

front

rear end, be sure

chock

the wheels in order

ensure safety.

(b)

After

the vehicle is jacked up, be sure

support

stands.

is extremely dangerous

do any

work

the vehicle raised on ajack alone. even

for

a small

job

that

can be finished quickly.

12. Observe the

following

precautions to avoid damaging the

parts:

(a)

not

open the cover

the case

the

ECU

unless

absolutely necessary.

{If

the

terminals

are

touched,

the

may be destroyed by static electricity.}

(b)

disconnect vacuum hoses, pull on the end

the

hose,

not

the middle.

(c)

pull apart electrical connectors, pull on the con-

nector itself,

not

the wires.

~-6

INTRODUCTION

-General Repair Instructions

Example

IN0002

(d)

When

steam cleaning an engine/

protect

the distribu-

tor, coil, air filter, and VCV

from

water.

(e)

Never use

impact

wrench

remove

install ther-

switches

thermo

sensors.

(f)

When

checking continuity at the wire connector,

insert the tester probe carefully

prevent terminals

from

bending.

{g)

When

using a vacuum gauge, never

force

the hose

onto

connector

that

too

large. Use a

step-down

adapter instead. Once the hose has been stretched,

may leak.

13. Tag hoses before disconnecting them:

(a)

When

disconnecting vacuum hoses, use tags to iden-

tify

how

they should be reconnected.

(b)

After

completing a job, double check

that

the

vacuum hoses are properly connected. A label under

the

hood

shows

the

proper layout.

INTRODUCTION

-Precautions

for

Vehicles Equipped

with

a Catalytic Converter

IN-7

PRECAUTIONS

FOR

VEHICLES EQUIPPED

WITH

CATALYTIC

CONVERTER

CAUTION:

large

amounts

unburned

gasoline

flow

into

the

converter,

may

overheat

and

create

fire

hazard.

prevent

this,

observe

the

following

precautions

and

explain

them

your

customer.

Use

only

unleaded

gasoline.

Avoid

prolonged

idling.

Avoid

running

the

engine

fast

idle speed

for

than

minutes

and

idle speed

for

than

minutes.

Avoid

spark

jump

test.

{a)

Perform

spark

jump

test

only

when

absolutely

necessary and as

quickly

as possible.

(b)

While

testing, never race

the

engine.

Avoid

prolonged

engine

compression

measurement.

Engine

compression

tests

must

made

quickly

possible.

not

run

engine

when

fuel

tank

nearly

empty.

This

may

cause

the

engine

misfire

and create

extra

load

the

converter.

Avoid

coasting

with

ignition

turned

off

and

prolonged

braking.

not

dispose

used

catalyst

along

with

parts

con-

taminated

with

gasoline

oil.

-8

INTRODUCTION

Abbreviations

Used in

This

Manual

ABBREVIATIONS USED IN THIS

MANUAL

A/C

ACV

Approx.

A/T

BTDC

BVSV

ECU

EFI

EGR

ESA

Ex.

FIPG

llA

ISC

LHD

LLC

M/T

0/5

PCV

RHD

SSM

SST

STD

TDC

TEMPO

TWC

UIS

VSV

w/o

2WD

4WD

Air

Conditioner

Air

Control

Valve

Approximately

Automatic

Transmission

Before

Top

Dead Center

Bi-metal

V8cuum

Switching

Valve

Dash

Pot

Electronic Controlled

Unit

Electronic Fuel Injection

Exhaust

Gas Recirculation

Electronic Spark

Advance

Exhaust (manifold. valve)

Except

Formed in Place Gasket

Fusible Link

Ignition

Integrated Ignition

Assembly

Intake (manifold, valve)

Idle Speed Contro.

left-Hand

Left-Hand Drive

Long Life

Coolant

(Year Around Coolant)

Multipurpose

Manual Transmiss!on

Oversized

Positive Crankcase Ventilation

Right-Hand

Right-Hand Drive

Special Service Materials

Special Service

Tools

Standard

Switch

Top

Dead Center

Temperature

Three-Way

Catalyst

Undersized

Vacuum

Switching

Valve

With

Without

Two

Wheel

Drive

Four

Wheel

Drive

EM-2

DESCRIPTION

4A-FE ENGINE

ENGINE

MECHANICAL

-Description (4A-FE)

The

4A-FE engine is

in-line

4-cylinder

1.6 liter DOHC 16 valve engine.

EM7830

EM7831

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