TOYOTA 4A-F, 4A-GE ENGINE REPAIR MANUAL May, 1987INTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL To assist you in finding your way through this manual, the Sec- tion Title and major heading are given at the top of every page An INDEX is provided on the 1st page of each section to guide you to the item to be repaired. At the beginning of each section, PRECAUTIONS are given that 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 to quickly lead you to the solution. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Pulley Seat Water Pump Pulley © Non-reusable part ‘Water Pump Suction Cover O-Ring : 2 @ Rotor Gasket Water Pump BodyINTRODUCTION — How to Use This Manual Mustration: what to do and where The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it. © The task heading tells what to do. ‘© The detailed text tells how to perform the task and gives other information such as specifications and wamings. Example: _7Task heading: what to do Fai 3. DISCONNECT CONNECTING ROD FROM PISTON Using SST, press out the pin from the piston. SST 09221-25022 (09221-00050, 09221-00130, 09221-00140) Set part No. Component part No. Detail text: how to do it (d) Install and alternately tighten the cap nuts in several passes. Torque: 500 kg-cm (36 ft-Ib, 49 N-m) ‘Specification This format provides the experienced technician with a FAST TRACK to the information needed. He can read the task head- ings and only refer to the detailed text when he 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 in the applicable step. You never have to leave the procedure to look up your specifications. All specifications are also found in Appendix A, specifications, for quick reference. WARNINGS, CAUTIONS, NOTES: ® WARNINGS are presented in bold type, and indicate the Possibility of injury to you or other people © CAUTIONS are also presented in bold type and indicate there is a possibility of damage to the components being repaired. © NOTES are separated from the text but do not appear in bold type. They provide additional information to help you effi- ciently perform the repair.INTRODUCTION — Abbreviations Used in This Manual ABBREVIATIONS USED IN THIS MANUAL AAP AIC AS AT BTDC cB DP ECU EFL EGR ESA x Ex. FIPG HIC HAI IG A IN Isc LH LHD we uP M/T o/s PCV RH RHD RON PS ssm SST sTD s/w Toc TP T-vIS TVSV Tw u/s vsv w/o Auxiliary Acceleration Pump Ai Conditioner Air Suction Automatic Transmission Before Top Dead Center Choke Breaker Dash Pot Electronic Controfled Unit Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Exhaust (manifold, valve) Except Formed in Place Gasket Hot Idle Compensation Hot Air Intake Ignition Integrated Ignition Assembly Intake (manifold, valve) Idle Speed Control Left-hand Left-hand Drive Long Life Coolant (Year Around Coolant) Multipurpose Manual Transmission Oversized Positive Crankcase Ventilation Right-hand Right-hand Drive Research Octane Number Power Steering Special Service Materials Special Service Tools Standard Switch Top Dead Center Throttle Positioner TOYOTA-Variable Induction System Thermostatic Vacuum Switching Valve Three-way Catalyst Undersized Vacuum Switching Valve With WithoutEM-4 ENGINE MECHANICAL — Description (4A-GE) DESCRIPTION 4A-GE ENGINE ‘The 4A-GE engine is an in-line 4-cylinder 1.6 liter DOHC 16 valve engine.ENGINE MECHANICAL — Description (4A-GE) The 4A-GE engine is an in-line 4-cylinder engine with the cylinders numbered 1-2-3-4 from the front. The cranksheft is supported by 5 bearings specified by the inside of the crankcase. These bearings are made of aluminum alloy. The crankshaft is integrated with 6 weights which are cast along with it for balancing, Oil holes are built into the center of the crankshatt for sup- plying oil to the connecting rods, pistons and othar components. This engine's ignition order is 1-3-4-2. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with Pent roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. The intake manifold has 8 independent long ports and utilizes the inertial superchorging effect to improve engine torque at low and medium speeds. Exhaust and intake valves are equipped with imegular pitch springs made of oil tempered silicon chrome steel wire which are capable of following the valves even at high engine speeds. Both the exhaust side cam shat and the intake side cam shaft are driven by 2 single timing belt. The cam journal is supported at 5 places between the valve lifters of each cylinder and on the front end of the cylinder head, Lubrication of the cam journal and cam is accomplished by oil being sup- Plied through the oiler port in the center of the camshatt. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve litters. This permits replacement of the shims without removal of the camshafts The resin timing belt cover is made in 3 pieces. ‘A service hole is provided in the No.2 belt cover for adjusting the timing belt tension. Pistons are made of highly temperature-resis- tent aluminum alloy. and a depression is built into the piston head to prevent interference with valves. Piston pins are the full-floating type. with the pins fastened to neither the piston boss nor the connacting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of stee! and the No.2 compression ring is made of cast iron The oil ring is made of a combination of steel! and stainless steel. The outer diameter of each piston ‘ing is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder wells when they ore mounted on the piston, Compression rings No.1 and No.2 work to prevent the leakage of gas from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the com- bustion chamber. The cylinder block is made of cest iron. It has 4 cylinders which ere approximately 2 times the length of the piston stroke. The top of the cylin« ders is closed otf by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition. the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bot- tom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and thus shifting the oil away from the oil pump suc- tion pipe.———_ dé 4104 peay uoBexoH iv ou oq uoBexey 419 Buipnnoid sega Gal oq eBuey, 3104 POPIOM, uoBexeH A souy Fl 1s Bulpnnoid A omy oq peay A uoBexoH ig Ba A lod uobexey B i” yew on saysem/m parcoig — oq aBuey uoBexaH A iy sew ON oO p| | iv tJ A | dd =e B (49 |-9 ~ ew oN 413 —S ON peoy Me 3J0q pesy wapms | \ip j-p We uobexeH sselp, ew sso. yew HLON3YLS 1108 3NIWH3L30 OL MOH SNOILVOISIDAdS INOYOL 110d GYVGNVLS SNOILVIISIDIdS 3NOYOL 1108 GYVANVLS caSTANDARD BOLT TORQUE SPECIFICATIONS B-3 SPECIFIED TORQUE FOR STANDARD BOLTS Specitied torque Class | Olameter | Pitch Hexagon head bolt Hexagon flange bolt kg-em fel Nm kg-em fttp Nm 6 1 55 48 in-Ib 54 60 52 in-Ib 59 8 1.25 130 9 13 145 10 14 10 1.25 260 Wg 25 230 20 28 aT 12 1.28 480 36 47 540 39 53 14 1S 760 55 75 B50 61 83 16 18 1,150 83 113 - 6 1 65 56in-b 64 - 8 1.25 160 12 16 - 10 1.28 330 24 32 - sT 12 1.25 600 43 59 | = 14 15 | 930 67 ai - 16 18 1,400 101 137 | - 6 1 80 69in-b 7.8 80 7Bin-b 88 6T 10 1.28 400 29 39 440 32 43 12 i 1.26 730 53 72 810 59 19 a | - | 1.260 90 123 6 | 1 110 8 WW 120 9 12 8 1.25 260 19 25 1 280 21 28 10 1.25 530 38 52 580 43 58 ™ 12 1.28 970 70 95 1,050 76 103 14 15 1,500 108 147 1,700 123 167 16 | 15 2.300 166 226 miFUEL SYSTEM @ INJECTOR @ COLD START INJECTOR INJECTOR SOLENOID COIL TERMINAL, NEEDLE VALVE SPRING The injector performs the injection of fuel accordance with @ computer calculated injection signal. When # pulke from the computer is received by the solenoid coil, the plunger is pulled agains: spring tension. Sinaa the neodle valve and plunger are a single unit, the valve is also pulled off of the seat and fuel is injected as shown by the arrows fixed, injection Because the needle valve stroke continues as long as the needle valve is open and fuel volume is controlled by the duration of the electrical pulse COLD START INJECTOR rue SOLENOID SPRING PLUNGER A cold start injector, installed in the center aree of the ir distribution chamber, is provided to improve starting when the engine is cold. This injector tunctions in ercordance with direc- tions from the start injector time switch and only during engine cranking when the coolant tem: perature is bolow 35°C. The injector tip employs a special design to improve mist spray. When the start injector time switch signal is applied to the solenoid coil, the plunger is pulled against spring tension. Thus, the valve will open and fuel will flow over the plunger and through the injector tip. 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INSPECT BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL {a} Check the specific gravity of each cell Standard specific gravity when fully charged at 20°C (68°F): 1.25 — 1.27 If not within specifications, charge the battery. {b) Check the electrolyte quantity of each cell If insufficient, refill with distilled (or purified) water. 2. CHECK BATTERY TERMINALS AND FUSIBLE LINKS (a) Check that the battery terminals are not loose or cor- roded. (b) Check the fusible links for continuity. \Upper Level Lowa Leva! SSS 3. INSPECT DRIVE BELT s (a) Visually check the belt for separation of the adhesive rubber above and below the core, core seperation from the belt side, severed core, separation of the rib from the adhesive rubber, cracking or separation of the ribs, torn of wom ribs or cracks in the inner ridges of the ribs. If the belt has any of the above defects, replace it. cea cH0029) aa (b) Check the drive belt deflection of pressing on the belt Alternator at the points indicated in the figure with 10 kg (22.0 1b,98 N) pressure Drive belt deflection: 4A-F sietreume New belt 85 ~ 10.5 mm (0.335 — 0.413 in) Used belt 10.0 — 12.0 mm (0.39 — 0.47 in) 4A-GE New belt 4—5 mm (0.16 ~ 0.20 in) Used belt 6 — 7 mm (0.24 - 0.28 Crankshatt lf necessary, adjust the drive belt deflection. 4A-GE Water Alternator [Cerise oadCHARGING SYSTEM — On-Vehicle Inspection H-—~ SSTB = SSTA 2 bl =P 0093 €co00 laseaal easaar! Wanaal CORRECT WRONG — WRONG x06 (Reference) Using SST, check the drive belt tension SST A 09216-00020 SST B 09216-00030 Drive belt tension: 4AF New belt 60-70 kg Used belt 40 — 55 kg 4A-GE New belt 70 — 80 kg Used belt 30 — 45 kg NOTE: © “New belt” refers to a belt which nas been used less than 5 minutes on a running engine. © "Used belt” refers to a belt which has been used on a running engine for § minutes or more. © After installing the drive belt. check that it fits properly in the ribbed grooves, © Check with your hand to comfirm that the belt has not slipped out of the groove on the bottom of the crank pulley. © After installing the belt, run the engine for approx. 5 minutes and recheck the deflection or tension. CHECK FUSES FOR CONTINUITY CHARGE 7.5A (AE and AT), 5A (AW) © IGN 10A (AE), 7.58 (AT) ¢ ENGINE 7.5A (AE), 10A (AT and AW) © AM2 7.5 (AW) VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES {a} Check that the wring is in good condition. tb) Check that there is no abnormal noise from the alter- nator while the engine is running, INSPECT DISCHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and turn it off. ob) Tum off all accessories. (c}_ Turn the ignition switch to ON. Check that the dis- charge warning light is lit (@) Start the engine. Check that the light goes out. If the light does not operate as specified, troubleshoot the warning light circuit.CH-6 Disconnect Wire from Terminal B CHARGING SYSTEM — On-Vehicle Inspec 135-151V Voltmeter Less than 10. A we edo 5 ay Ammeter an Voltmeter 0 8 e, hore Vv More than 30 A ye 2, 30 fo = a Ammeter 2 n CHECK CHARGING CIRCUIT WITHOUT LOAD NOTE: If a battery/alternator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions. (2) If 2 tester is not available, connect a voltmeter and ammeter to the charging circuit es follows: © Disconnect the wire from terminal B of the aiterna- tor and connect the wire to the negative (~) ter- minal of the ammeter. © Connect the test lead from the positive (+) te minal of the ammeter to terminal B of the alterna- tor. © Connect the positive (+) lead of the voltmeter to terminal 8 of the alternator. © Ground the negative (--) lead of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: Less than 10 A Standard voltage: 13.9 — 15.1 V at 25°C (77°F) 13.5 — 14.3 V at 115°C (239°F) Wf the voltage reading is greater than standard voltage, replace the IC regulator. If the voltage reading is less than standard voltage, check the IC regulator and alternator as follows: © With terminal F grounded, start the engine and check the voltage reading of terminal B. © If the voltage reading is higher than standard voltage, replace the IC regulator. © If the voltage reading is less than standard voltage, repair the alternator. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, tum on the high beam headlights end place the heater fan con- trol switch at Hl (b) Check the reading on the ammeter. Standard amperage: More than 30 A if the ammeter reading is less than 30 A, repair the alter- nator. (See page CH-7) NOTE: If the battery is fully charged, the indication will sometimes be less than 30 A.CHARGING SYSTEM — Alternator CH.7 ALTERNATOR COMPONENTS Boaring Cover Retainer Rear Bearing Fron: Bearing Rotor j 9 Rubbar insulator Diive End Frame Pulley © CIRS @)o T Rectifier Holder we" + * Brush Holder with Cover % IC Regulator Terminal Insulotor Rectifier End Frame DISASSEMBLY OF ALTERNATOR 1. REMOVE REAR END COVER {a} Remove the nut and terminal insulator. (b) Remove the three nuts and end cover.CHS CHARGING SYSTEM crosa0] ssra ssta ¥ ENTS \ 2 Alternator REMOVE BRUSH HOLDER AND IC REGULATOR Remove the five screws, brush holder and IC regulator. REMOVE RECTIFIER HOLDER (a) Remove the four screws and rectifier holder. (b) Remove the four rubber insulators. REMOVE PULLEY (a) Hold SST A with a torque wrench, and tighten SSTB clockwise to the specified torque. SST 09820-63010 Torque: 400 kg-em (29 ft-lb. 38 N-m) (b) Check that SST A is secured to the rotor shaft. {c)_ As shown in the figure, mount SST C in a vise, and install the alternator to SST C. {d) To loosen the pulley nut turn SST A in the direction shown in the figure. CAUTION: To prevent damage to the rotor shaft, do not loosen the pulley nut more that one-half of a tun. (ec) Remove the altemator from SST C. {) Turn SST B and remove SSTs A and B. (g)_ Remove the pulley nut and pulley. REMOVE RECTIFIER END FRAME (a) Remove the four nuts. (b) Using SST, remove the rectifier end frame. SST 09286-46011 REMOVE ROTOR FROM DRIVE END FRAMECHARGING SYSTEM No continuity Alternator c INSPECTION AND REPAIR OF ALTERNATOR Rotor 1 INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- ‘tween the slip rings. Standard resistance (cold): 2.8 — 3.0 0 If there is no continuity, replace the rotor. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity be- tween the slip ring and the rotor. If there is continuity. replace the rotor. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using calipers, measure the slip ring diameters. Standard diameter: 14.2 — 14.4 mm (0.559 ~ 0.567 in.) Minimum diameter; 14.0 mm (0.551 in} If the diameter is less than minimum, replace the rotor. Stator 1 INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- ‘tween the coil leads. If there is no continuity, replace the drive end frame assembly. INSPECT STATOR FOR GROUND. Using an ohmmeter. check that there is no continuity be- ‘tween the coil leads and crive end trame, if there is continuity, replace the drive end frame assemb- y.CH-10 CHARGING SYSTEM — A\temator Pesitive Stud Rectifier Terminal Brushes 1. MEASURE EXPOSED BRUSH LENGTH Minimum exposed length: 4.5 mm (0.177 in) If the brush length is less than minimum, replace the brushes. 2. IF NECESSARY, REPLACE BRUSHES fa) Unsolder and remove the brush and spring. (b) Run the wire of the brush through the hole in the brush holder, and insert the spring and brush into the brush holder. fc) Solder the brush wire to the brush holder at the exposed length Exposed length: 10.5 mm (0.413 in) {d) Check that the brush moves smoothly in the brush holder. le) Cut off the excess wire. f) Apply insulation paint to the soldered point. Rectifier 7 1. INSPECT POSITIVE SIDE RECTIFIER la)_Using an ohmmeter, connect one tester prove to the Positive stud and the other to each rectifier terminal (b) Reverse the polarity of the tester probes. (c) Check that one shows continuity and the other shows no continuity. It not, replace the rectifier holder.CHARGING SYSTEM — Altemator 2. INSPECT NEGATIVE SIDE RECTIFIER fa) Connect one tester probe to each rectifier terminal and the other to each rectifier negative terminal (b) Reverse the polarity of the tester probes. {cl Check that one shows continuity and the other shows no continuity If not, replace the rectifier holder. Bearings 1, INSPECT FRONT BEARING Check that the bearing is not rough or worn. 2. IF NECESSARY, REPLACE FRONT BEARING {a) Remove the four screws and bearing retainer. (b) Using a press and socket wrench, press out the front bearing.CH-12, CHARGING SYSTEM — Altemator (c)_ Using SST and a press. press in a new front bearing into the drive end frame. SST 09608-20012 (09608-00030) {d) Align the claws of the bearing retainer with the slots of the drive end frame, (e) Install the bearing retainer with the four screws. INSPECT REAR BEARING Check that the bearing is not rough or worn. iF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover and bearing. SST 09820-00021 (b) Using SST and a press, press in a new beering and the bearing cover. SST 09285-76010CHARGING SYSTEM — Alternator ASSEMBLY OF ALTERNATOR (See page CH-7) 1. INSTALL ROTOR TO DRIVE END FRAME 2. INSTALL RECTIFIER END FRAME {a) Using a plastic-feced hammer, lightly tap in the end frame. (b) Install the four nuts. 3. INSTALL PULLEY fa) Install the pulley to the rotor shaft by tightening the Pulley nut by hand. (b) Hold SST A with a torque wrench, and tighten SST B. clockwise to the specified torque. ‘SST 09820-63010 Torque: 400 kg-em (29 ft-Ib,39 N-m) (c) Check that SST A is secured to the pulley shoft. (d)_As shown in the figure, mount SST C in a vise, and install the alternator to SST C. fe) To torque the pulley nut tum SST A in the direction shown in the figure. Torque: 1,125 kg-cm (81 ft-tb, 110 N-m) {f) Remove the alternator from SST C. (g) Turn SST B and remove SSTs A and 8. 4. INSTALL RECTIFIER HOLDER (2) Install the four rubber insulators on the lead wires, {b) Install the rectifier holder with the four screws.CH-14 CHARGING SYSTEM — Alternator cv0630| 5. INSTALL BRUSH HOLDER AND IC REGULATOR {a) Place the brush holder cover to the brush holder. (b) Install the IC regulator and brush holder to the rear end frame horizontally as shown in the figure. NOTE: Make sure the brush holder's cover doesn’t to one side during installation. {c} Tighten the five screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector. INSTALL REAR END COVER (a) Install the end cover with the three nuts. {b) Install the terminal insulator with the nut. 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To Radiator Woter Pump From Radiator Water inlet Pipe Y Thermostat 4A-GE Thermostat Ss}COOLING SYSTEM — Description co-3 The cooling system is composed of the water jscket (inside the cylinder block and cylinder head), Radiator, water pump. thermostat, electric fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which an electric fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is @ network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders are com- bustion chambers which become the hottest dur- ing engine operation. RADIATOR Ex. MR2 The radiator pertorms the function of cooling the coolant which has pessed through the water jacket and become hot, and is mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank, and a core which connects the two tanks. The upper tank contains the inlet for coolant from the water jacket and the filter inlet. It also has a hose attached through which excess coolant or steam can flow. The lower tank contains the outlet for coolant and the drain cock. The core contains many tubes through which coolant tlows from the upper tank to the lower tank as well as cooling fins which radiate heat away from the coo- ‘antiin the tubes. The air sucked through the radia- tor by the electric fan, as well as the wind gener- ated by the vehicle's travel, passes through the fadiator, cooling it. Models with automatic transmissions include an automatic transmission fluid cooter built into the lower tank of the radietor. A fan with an electric motor is mounted behind ‘adiator to assist the flow of air through the radia- tor. The fan operates when the coolant tem- perature becomes high in order to prevent it from becoming too high. Mrz The radiator performs the function of cooling the coolant which hes passed through the water jacket and become hot, and is mounted in the front of the vehicle. The radiator in the MR2 is different from that in other models, in that it is a cross flow type in which the coolant flows horizontally. It includes side tanks and a core which connects them. The inlet for coolant from the water jacket and the drain cock for draining out coolant are located in the left side tank. The outlet for coolant and an air drain, which facilitates the supply of coolant to the engine, are located in the right side tank. The core contains many tubes through which coolant flows from the left side tank to the right- side tank as welll as cooling fins which radiate heat, away from the coolant in the tubes. Air sucked in by the electric fan, as well as the wind generated by the vehicle’s travel, passes through the redie- tor, cooling the coolant heated by the water jacket as it passes through the tubes in the core. Models, with automatic transmission include an automatic transmission fluid cooler incorporated into the cooling pipes. A fan with an electric motor is mounted behind the radiator to assist the flow of air through the radiator. The fan operates when the coolant temperature becomes high in order to prevent it from becoming too high. The radiator cap is the same as those used with ordinary vehi- cles, but due to the layout of the MR2, it is located on a coolant pipe in the engine space. RADIATOR CAP The radiator cap is a pressure type can which seals the radietor, resulting in pressurization of the radiator as the coolant expands. The pressuriza- tion prevents the coolant from boiling even when the coolant temperature exceeds 100°C (212°F) A relief valve (pressurization valve) and 2 vacuum valve (negative pressure valve] are built into the radiator cap. The relief valve opens and lets steem escape through the overflow when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110 - 120°C, 230 - 248°F, pressure: 0.3 - 1.0 kg/ om? , 43 - 14.2 psi, 29.4 - 98.1 kPa). The vacuum valve opens to alleviate the vacuum which develops in the coolant system after the engine is stopped and the coolant temperature drops. The valve's opening allows the pressure in the cooling system to return to the coolant in the reservoir tank. RESERVOIR TANK The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to the radiator when the coolant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be rep- lenished. WATER PUMP The water pump is used for forced circulation of coolant through the cooling system. 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If low, check for leaks and add coolant up to the FULL line CHECK ENGINE COOLANT QUALITY There should not be any excessive rust deposits or scales around the radiator (water outlet) cap or radietor (weter outlet} filler hole, and the coolant should be free from cil If excessively dirty, replace the coolant. Replacement of Engine Coolant (AE and AT) REPLACE ENGINE COOLANT fa) Remove the radiator cap, (b) rein the coolant from the radiator and engine drain cocks. {c]_ Close the drain cocks. Torque (Engine drain cock): 130 kg-om (9 ft-lb, 13 Nem) (d} Fill the system with coolant Use a good brand of ethylene-glycol base coolan’, mixed according to the manufacturer's directions. We recommend more than 50% ethyleneglycol and alcohol (But not more than 70%) be used for your system, Capacity (w/ Hea 4AF M/T Europe 5.2 liters (5.5 US ats. 4.6 Imp. ats] Hi General 5.6 liters (6.9 US qts, 4.9 Imp. gts) AIT 5.5 liters (5.8 US qts, 4.8 Imp. ats} 4A-GE 6.0 liters (6.3 US ats. 6.3 Imp. ats! (e} Install the radiator cap. (f) Start the engine and check for leaks {g) Recheck the coolant level and refill es necessary.