Co On cenyN COROLLA 1997-2002 E110 PykoBoAcTBo no aKcnnyaTaunu, TexHu4eckomy OG6cAy»KUBaHHIO M peMOHTyContents LIVING WITH YOUR TOYOTA COROLLA Safety fist! Page 05 Introduction Page 0-6 Roadside repairs Introduction Page _ 0:7 If your car wont start Fage O07 ‘Jump starting Page 08 ‘Wheel changing Page Oro Identifying leaks: Page _ 0-10 Towing Page 0-10) Weekly checks Introduction Page 0-11 Underbonnet check points Page OTT Engine oil level Page 0-12, ‘Coolant level Page 0-12 Brake and clutch Fd level Page O13 Washer fuid level Page O13 ‘Tyre condition and pressure Page O14 Power steering Fuid level Page 0-15 Wier blades Page 0-75, Battery Page 0-16 Bulbs and fuses: Page 0-16 Lubricants and fluids Page 0-17 Tyre pressures Page O17 MAINTENANCE Routine maintenance and servicing Sewing specifications Page 1:2 Maintenance schedule Page 4 Maintenance procedures Page 158REPAIRS & OVERHAUL Engine and associated systems Contents Engine in-car repair procedures Page _2A+t Engine removal and overhaul procedures Page 2B+4 ‘Cooling, heating and air conditioning systems Page 3+ Fuel and exhaust systems Page 4At Emission control systems Pago 4B+1 Starting and charging systems Page SA-t Ignition systems Page SB+t Transmission Clutch Page 6+ Manual tansmission Page TA+t Automatic transmission Page 78+ Driveshats Page et Brakes and suspension Braking system Page ort Suspension and steering Page _10+4 Body equipment Bodywork and fittings Page 114 Body electrical system Page 124 Wiring diagrams Page 12-20 REFERENCE Dimensions and weights Pege _REFs1 ‘Conversion factors Page _REF2 Buying spare paris Page REFS Vehicle identification Page REF ‘General repair procedures Page_REF-4 ‘lacking and vehicle support Page REFS Tools and working facilties Page _REF-6 MOT test checks Page _REF-8 Fault finding Page REF+12 Glossary of technical terms Page REF+22 Index Page REF+270-4 Advanced Driving Advanced driving Many people see the words ‘advanced crving’ and believe thet it wont interest fem forthe tie 2 ste of drvng beyond their onn abilties. Nothing could be further from the truth. Advanced driving is strsightfoneara Selo, sensible dnving ~ the sort of dhving we should all do every lime we gel behind the wheel ‘An average ot 10 peop are killed every day fn UK roads and 870 more ere inured, some Senously Lives are runed daly, usualy because scmetody did something stupid Something ike 95% of al acciderts are due te human eer, mostly erwver failure Sometimes we maka genuine mistakes - ceveryene does, Sometimies we hee lapses of Sancertration Somelimes we. galieratay take make, For many people, the process of ‘esming to tive! doesnt go’ much futher than learning how to pass the ariving test because of & ‘common tei that good divers are made by ‘expenence Lssining to chive by ‘experiance! teaches tine diving ss + Quick reaations close!) ‘Ga0d handling skills. (Hem, swewe, brake, her} + Ralianco on vehicle technology. (Groat stuffthis ABS, stop inno distance even in the wet.) [twhoops, that wees Divers whose sills are ‘expenence based’ generally nave a lot of near misses and the ‘dl accident. The results oan be secn every day in our courts snd our hospital casualty apartments ‘Aivanoed divers have learnt to. control the nsks by central the postion and sped of thairwehide, They avoid accidents end near misses, even ifthe drivers around them make mistakes The kay skils of agvaneed tiving ere concentration, effective alhround observation, anticipation and planning \nhen goed vehicle handling is eedod 10 these skis, all driving situations can be approached and negotiated in a sate, math dical way, leaving nothing to chance, ‘Concentration means spin your mind to Safa diving, complataly excluting anything that's ma relevant Drang is usualy the most dangerous eclivty that most of us undertake in our dally routines. It deserves our full attertien Observation meens ct just looking, but seaing are covlang oub the nformaten found inte ding environment, Anticipation mears asking yourself hat is happening, wht you can reasonably expect tov happen and what could happen Lnexpeotedly. (One of the commonest words used in compiling accident reports is “sudaeniy") Planning Is the link batwsen seeing someting and tsiing the appronriste faction. For many drivers, planning is the missing Ink, you went to become a safer and mare sku ctiver and you vantto ency your enving more, forkael the Insttula of Aavenees Motors a eee iem org.uls, phone 0208 898 8500, or ‘wate ta Takd House, 510 Chiswiak High Road, Landon Wl SRG feran information pack\Worng on your earcan be dangerous. “This page shows ust some ofthe potential naks and haze, mith the am of crating @ safely.consacus afte General hazards Scalding + Dont ramave the radator ar expansion tank can while the engine i hot * Engne oll, automatictransmission uid or power steering fuid may also be dangereusly hot ithe orgie has recertly been rurming, Burning + Beware of burrs from the exhaust system ‘and from ary part ofthe engine, Broke discs land drums ean also be exremely hot Immeciztely after use. Crushing + when weerking under or reer araseavanice aos Srolomert he /y iatatnawe” /Y stands, oF Use {2 rams wg | ever iim venue Tnlra cer union irony supported by ack + Taka care if loosening ortightening high- Torque nuts when the vehiieis on stands Initial loosening and fina tightening should be {one vet the wheels onthe around Fire + Fut is hight flemmeble; fuel vapour is, explosive + Dont et fuel spill onto ahot engine * Do not smoke or alow naked lights [netting plot touts) anywnere near a ‘chide being warked on Also beware of cresting sparks {aloxtncaly or by use oftoats) * Fuel vapour is heavier than dir, 90 don't work an the fue system wth the varie aver an inspection pit + Another cause offre is an electrical ‘overload or short-cut. Take care when repainng or modifying the vehide vering + Keep aire extinguisher handy, ofa type Gutable for use on fuel and olacical res. Electric shock 2, 57, signiion HT ‘, wattage cen dengarous especialyio people ith heart problems ora pacemaker. Don't work on or rearthe ignition systarm with the engne runing ee the igntion svete on + Mans voage is also dangerous. Make Sure thet ny mains-aperated equipment is correctly earthed. Mains powsr points should be protected by’ residual current device (RD) eieut breaker. Fume or gas intoxication + Exhaust fumes ore poleonous; thay often fantain carbon, monoxide, wich is rapidly fetal fined Never un the engre in jeantined space vith the doors shut Fuel vepouris alsa posonous, ase tho vapour from some Saening sowveris ang part inners Poisonous or irritant substances + Avoid skin contact with batory acd and ath ary fuel, fui or Libncant, especialy arutraaze, brake hydraulic fd and Diesel Tual- Dont syshon inem by mouth I'sueh substenee Is Swalowed or gots into the aves, Seek medial advice. {= Prolenged contact with used angine ail can Cause sla cancer. WWoar gloves or use a barrier cream ifnecessary. Change out of oi- soaked elathes and do nat keep aly rags in our pocket + Airconditioning refigerant forms 8 poisonous gas if exposedto a naod tare [including a igartle}.Itcan also cause sian bums on contact Asbestos + Asbestos dust can cause cancer finhaled ‘or swallowed. Aebestos may be found in ‘gaskets andin brake andl ekéch linings when dain wih such componerts itis Seles 1 assume thal hey contain asbastas Safety First! 0- Special hazards Hydrofluoric acid + This tremely corrosiva aed formed \when certain types of synthetic rubber, found in some O-rings, ol seals, fue hoses ste, re exposed to temperatures anove 400°C. The uber changes into a charred or sticky substance certaining the acid. Once formed, he aod somains dangsrous for years ft gets onto ihe akin, may os necessey 10 arpurat the sind concerned. = Vien dealing with a versie which hes sufered a fre, orwith components salvaged trom such avericle, wear protective gloves and discard them ater use The battery + Batteries contain sulohune acid, wrich ailacks clothing, e485 end shin Tako care When topaing-up or eamying the battery +The trogen gas given off bythe battery Is righ expioshe. Never cause a.spatk or ‘lon aneked light nestby. Be careful when connecting snd disconnecting battery chargers or jump leas Air bags + i bags ean cause injury they go ott bocidantaly: Take cere when removing the steeting weal ander facia. Special storaoe instrucions may apely, Diesel injection equipment + iss injection pumps supplyuel at very high pressure, Take care when woring on ‘ne fuel injectors and fuel pipes. Waring: Never expose the herds, face or any other pat ofthe body toinjector spray; the fuel can penetrate the skin with potentially fatal results, Remember. Do + Do use eye pretection when using power tools, and when working underine vehicle + Do wear gloves or use barier cream to protact your hands whan nocassary. + Do gat semaone to check penadically that all swell whan werking alone cn the vice + Do keep loose clothing and long har well but ofthe way of moving mechanical pars + Do remove rings, wristwatch ete, before ‘wariang an the vahiole - especially the ecincal system + Do ensure thst ary lifting erjaciong equpment has a safe werking loed rata adequate forthe job DON'T + Dont attempt to lit a heavy component which may be beyond your eapabilly- gat assistance + Don'trush te fish ajab, orto lrwented shert cuts + Dont use iting tools which may slip and cause injury + Dont lnave toals orpartsIving around ‘here someone can tip overthem. Mop up ol and fual spills at once + Dont alo chileren or pets to playin or near 8 aisle boing worked on.0°6 Introduction ‘Toyota Corolla 3 door Hatchback Continuing the tradition of the "World's best-seling car’, the range of Coralla medals ‘eovered by this manual offer a wide range of body siyos ena engines, win tne emphasis on raven, solid engineering, further reinforena Toyotas deserved reputalion fer outstanding relly. Inreduced in June 1997, the Cera vas avalebla as @ 3-door Hatchback, -door Liteack, 4-door Saloon and a 5-coor Estat, vith @ dear Hatchbsok version introduoed In October 1988, In October 1999, tne range Lnderent @ facelift, with cosmetic revisions to the Font bumper, headlights, bennet and front gile. To comncide with fre felt, anew Tange of petrol engines, with variable intake camshaft timing, was introduced, replacing the eating units “The pete engines are lie injected, nino, fourcylinier unts of 1332 ¢0, 1368 ce, 1 or 1808 ce displacement with double overhoad ‘amshat and Tevaives. All engines are rexrally aspirated, with tna 14 lare and 18 the WT frginas (Octaber 1800-0n). inearparating fn hydraulically controlled mechanism on the irtaka camshaft which vanes the valve timing. This faciity improves the driveabilty, sffciancy and emissions of the ergines. All ngines feature a comprehensive engne management system wilh extensive emission control equipment. Although two diese! engines were avaiable, nether are covered inthis manual. 5- oF S-speed manual ransmicsions were avaiable, dong with 2 or 4-spoed auternetic options. Although a foursiheel-dnve model ‘Was avalable in some mariats,onlythe frant- ‘wheel-dnve versions are covered by this marvsl Toyota Corolla §-door Liftback Braking is by discs at the front, and by drums or dises at the rear Hydraulicaly opereted powarassisted steering fs standard fon al models, with ABS avaiable as an option ‘A wide range of stenderd and optional equipment ic available within the ranga to suit vrually all tastes. Both drivers and passengers aitbag were ftied as standard, wath 6140 airbags, incorporated into the ont Seals, and freni seatbelt pretensioners, avallable as an option on some models ater the October 1998 facat Provided that regular servicing ts camied out in accordance with the manufacturers recommendations, the Toyota Coralla wil provide the enviable reliably for which this marque is tameus The angne compartment 's relatively spacious, and most of the items requinng frequent attention are easily aenescibla Your Toyota manual The em ofthis manual ist helo you get the best vale fom your venige, kan 0 fo in several woys, toon nen you device sinat work must be done [oven should you Choose tooo t cone by acarge) il ao provi information on rate mainteneno® nd coreg, and quo a logisl curso of atin and agnosis wen random fats oca, Honey tis faved ut yuri ee the marvel by toeting the work yoursalt On simpler obs may ever bo caer than coin the sara 3 osreae and aura ree twlee, fo bow and oslo’ Pemnape most indo. /a bt ot money oan be saved By avoirg ine costs garege must charge 9 vor fe labour and ovorncace. The manual” nse cravings and dosenptions to show the function of the rious compenonts co that thir layeut an be understood Tass ee destibed id netoprented fa cle cegyetes Seauence. The iustetiens are numbered oy ine Secon number snd paragraph name to Dich they wate there ie mere thon one ilvtrafon per parearagh, the sequanoe is Sonitad apnstetealy ronoss 19 tne ett oF ‘ight! of tne vehicle are inthe sonse of pesen in He avers seat, acing fnwarcs Acknowledgements Thanks are due to Draper Tools Limited! vn provided some of the vortshep Tool, ‘nd fe all those peodte al Sparird who helped inthe production ofthis manual ‘We take great pride In the accuracy of information given In thie manual, but Yonicle manufacturers: make alterations ‘nd design chenges during the production fin of a particular vehicle of which they 6o fot inform us. No lablity can be accepted by the authors. or publisners for loss, csamage or iury eaused by any eros in, ‘or omissions from the information given.Roadside repairs 07 The following pages are intended to help in dealing with common roadside emergencies and breakdovins. You wall find more ‘etaled fault finding information st the back of Ihe manuel, and repair infarmation inthe main chapters If your car won't start and If your car won't start even the starter motor doesn't though the starter motor turn turns as normal + 1 ts a model wen automate transmission, make sure the sector «is thre fuel nthe fark? isnP oN 1b tners moisture on eletnel components under the bonnet? + Open tne Beant an make sure tnt th betes tints are Sten ofthe non, thon wap of ay obuous dernpnens ith loan ene tt rydoh. Spry avalerepoten aeresl produc (WD-40 or « Switch on the heodights and iryto sta the engine. ithe uve) on grin and ual yet elect conno rs ike "eaignts go vey sin when youre tring to stan, hw batenyis those shaw nth ptos. probably fat Get out of rouble by ump starting (see nest page) Using a tand's cat Ax Ste tne security tthe ition colts) 3 Check he secunty ofthe artow meter (CS Check thet al fuses are stl in good slectnical connectors. ting Bg ‘cendtion and none have Blown (Check the secunty and condition of the Dallery connections ts eo om asf a Check thet electrical connections are secure (wh the ignition suitched off) and spray therm with Check the seaunly ofthe HT leads (non ‘meter cispersanl spray lke AD-A0 if you suspect a problem due to damp e wri ‘ngres]0°8 Roadside repairs Jump starting ‘wen jump-stating a carusing 2 booster battery, ooeoIve th folowing precautions: Eefore connecting the bocster battery, ‘eke sure that the ignition is switched oft + Ensure that al elsetnical equipmart (arts, hese, wipers, eto is Switched off + Take note of any special precautions pnted on the battery ease, ICarnect ona ena ofthe reajump inad to ie postive (+}term'na ofthe fat batty Make sure thatthe booster battery Is the ‘samo voltage a the discharged one in tho veniclo ithe battery is bsing jump-started from the batlery In encther vehicle, the wo vehices MUST NOT TOUCH each other Make sure thatthe traremission is in neutral for PARK, inthe case ef automatic vrensmissien) [Connact the other end aFiha rea lead to tne postive (+) terminal ofthe booster Jug starting wit getyou out oftroupie, butyou must correct whatever made the battery 90 fat inthe firstplace. There are three possibilities: The battery has been drained by repeated attempts to start, orby leaving the tghts on. The charging system is net working propery (eltemator drivebelt slack ‘or broken, alternator wiring fault or ‘altemator itself faulty). The battery itsefis at faut (electrolyte low, or battery worn out) [Carnect ane end atthe baekcjump wean i the negatve (terminal ofthe booster bsitery [Carnect the ether ard ofthe bladejump lead fo a bolt or bracket on the engine fon the vehicle to be stated Mako sure the the jump leads wll nt [came inta cantact withthe cooling fen, arivezels or other moving parts ofthe onaine. Stat the engine using the booster battery and run & at ido speed. Switch on the lights, rear window deeister and ester blower moter, then aisconnect tne jump Isads inthe reverse order of ‘connection, Turn off the lights eeRoadside repairs 0°9 Wheel changing Waming: Do not change a whee! in 2 situation where you risk being hit by other traffic. On busy roads, ty t0 stop in a lay-by or ‘2 gateway. Be wary of passing trafic while changing the whee! «It's easy to become distracted by the jeb in hand. Preparation + nen apunetur occur, stop ae soon az + Ifyou have ana, use avaming tanglet> + Chock the whee! dlagenaly opposite tne iin sateto do so alot ather vers of vur presence tne being removed =a culo of lane Peron fm love ground, tpssable. ane) Apply the nandereke and engage fret Hones will go ferns. wl out ofthe nay of ahr re rovers gaat [or Parcon models wih + Ifthe gaurd ie sol, use 2 fat pico of + Use hazard warning lights cessor Sutera transmission) \wood fo spread the fod under he jack Changing the whee! From inside the luggage compartment, for lif the panel in the luggage Lit the cerpet then unsorew the spare Famave the tin parel ane remave the ‘ompartment foor. On some models the SD wheel retanor from the contre of te Jack tools are stored withthe spare whee ‘wheel ana ME out the wheal Tum the hende clockwise unt the whee! is raised claarofthe ground, then unscrsw the wines! bots ana ramave he wes Pre off the wheel trim fvhere fitted, f& Engage the jack heed with the reinbroed than slacken ach winsel nut by @ halt SD bradcet located atthe end ofthe sil (dont tum, using te wneelbrace. rine nuts are Jack the vehicle a any otner point ofthe too tight, DONT stand on the brace to unde sil tham ~ call Tor assictano On madele sith Finally, cloy wheels, a Tovots socket may be needed : to remave the secunty ru -the socket should ba ith glovebox or took Remove the wheel chocks. Stow the jack and tools back in the or ‘Chock ihe tye prassure on the whos just ‘tad. Its ow, or yeu dont nave a prossura gauge with you, dive siowlyto the nearest garage and inate the tyr to the correct pressure Note: Sars movelsare supped wit 9 soectat Ighivraght S030e-save? spare wheel, tha fy Fithe spere heel, then fit and screw on flehig namower than etemism, and maried ‘ho nuts. Ligfeytghton the nuts with the TEMPORARY USE ONLY. The soace-caver vwhesbrace, then lover the vehicle tothe snare wes nisnded only tr fampavary use, ‘ground. Securely ignten te wheel nuts inthe and must be placed wih a standard whee! as Saquence shawn, then reft tne wheal tnm or soon aspassbe. Drive wih pariculrcare wih hubcap, as plicable. The whee! nuts should thiswhealfted, especialy though corners.and be sladeened and relightaned tothe specified when Breaking Tayola recommend a maximum torqus (103 Nm) 2 the afliest possible speed of 80 mor (80 Amin) whan she spac! ‘opportunity,0°10 Roadside repairs Identifying leaks Pudeles on the garage foor or drive, oF fopvigus walnass under the bonnat or undemeah the cer, suggest a leak that needs investigating. t can sometimes ba dificut to fecide where the leak i coming fom especially ifthe engine bay is vary diy ‘rescy Leaking oer fuld can also be blown reanvards by the pastaye of ar uwarthe cat ging 2 false impression of where the probiom ls, Enghe oll may leakrom the cra plus Antifreeze Leaking antiteeze often leaves a crystaline ‘post ike this. Towing {hen all else fails, you may find yoursell having to get a tow ame ~ oF of course you maybe helpng somebody eso. Long-distance recovery shoul only be done by 8 garage oF breakdown servicg. For sharerdstances, DIY toning using anather car is easy enough, but serve the flowing points + Use a proper tow-rope - they are not expensive. The vehicle being faved must ‘isplay an ON TOWsign in is rearndow + Always turn the ignition key to the "ont position when the vehicle is being towed, Waming: Most automotive oils and ud are poisonous. Wash them off skin, and change out of contaminated clothing, without delay. A Oil from filter The smell of @ fluid teaking from the car may provide 2 clue to what's teaking. Some fulds are aistinetively coloured. 1 may help to clean the car caretully and fo park it over some clean paper overnight as an ald to locating the source ofthe leak. Remember that some Ieoks may only ‘occur while the engine is running. Gearbox oil ‘leak occurring at awh is lost, certainly brake so thatthe stoering lock is roloasod, ard the firacbon incest end brake ights wor +4 towing eye Is provided below each bumps + Bofors being towed. release the handbrake ‘ane selec neutral onthe transmission, Tayots ‘advise thal aulomatic transmission modals, Shou only be lowed for ‘shor astances at low speed + 'Note thal greeter thanusual peda pressure vill be requred to operate the brakes, sinoe ‘he vacuum servo unt is only operational with the engne running, Inboard ends ofthe drweshts Power steering fluid Power stoerng lid ney lak rom te lp | cconnectars on the steering rack + Because the power stooring will not be operational, greatortnanrusual steering ett vill dso be reauired “The dnver of the car being towed must hap the tow-rope taut at all times to avoid snatching + Mala sure that bath divers know the route berore salting ot + Oniydrie at maderate speeds ard keen the flstance towedte @ minimum. Drive smoctniy ‘and allow plenty of time fer slowing dwn at iunetions,Introduction There ate some very simple checks yhich need only take 3 few minutes to cary out, but hich coud save you a lot of meonvenience and expanse “These Westy checks requrs no great siil or special tools, and the small amount of ime they take to perform could prove to be very well spent, or example Underbonnet check points aC ‘Keeping an eye on tyre condition and pressures, wil not oriy help to stop them wearing cat premaitrsly, but Could aso Saco your ie ‘ieny breakdowns are coused by olecttioal problems: Bulteryreled faults ae parieulary ‘comman, are @ quick chack on aregule basis will often prevent ine majonty ofthese Weekly checks 0+11 Your car develops brake fui leek, the frsttime you might know about itis wnen your brakas dont work property. Checking he leal regulatyell gve advance warring ofthis kind of problem *Irtha al oF coalare levels nun tv, tha east of repainng any engine damage will be fe ‘greater than fixing the leak, for exerple 41.3 litre 4E-FE (non-VVT- engine (others similar) A Engine oil level dipstick B Engine oi filer cap C Coolant expansion tank D Brake fuid reservoir | E Power steering fhuict F Screen washer fluid reservoir 41.4 litre 4ZZ-FE -i) engine (others similar) A Engine oil evel cipstick B Engine ol filer cap © Coolant expansion tank D Brake fluid reservoir E Power steering fluid reservoir reservoir G clutch uid reservoir0*12 Weekly checks Engine oil level Before you start + Mako sre tet your cartoon lel ground + Checktne o lve before tne care aren or at least 5 minutes arte ange hos boon Sted of It the oll is checked Immediately after driving the vehicle, some of the oll wil remain in the upper engine components, resulting in an inaccurate reading on the dipstick The correct oil Modem engines place greet demancls on their oil tis very important thatthe correct of for your car's used (sea Lubricant and usc) Car care + tyou hve to ead all equenty, you shout check whether you have any ail leaks. Place seme dean paper under the car overnight and check for stains in the moming. Ithers fre no lees, hen the engine may be burring ol, + Always meintain tho level botwean the Uupor and lower dipstick marks, tthe level is too kay, severe engine damage may gocur. Oi seal falure may resut ifthe engine i overiled by adding too much ol Coolant level Woming: Do not attempt to A rere ne rater prea cap Sagan tank op hen ae trainee ha there let voy rea fe orang” Do notices pan conaier cf Sool abou, seal polsoncs - ae So The dipstick tap 18 brightly ecloured for Nata the al evel entha andar the dips easy identification (see Underbonrel) 2uchich should be between the maximum fneckomts for exact looaten). urteraee ne: minimum marks (arrowed), the dipstick, and using @ cleen reg or paper {wel femave ell of fart the alps, eet the clean dipstick iio the tube 36 far asi il (9, en witheran t egein } Low vel fine Full lel fine — 7 = Gr nthe hatched area incicating Wax 4 Oll is added through the filer cap ‘and MIN between the Laper F) markand F Unscraw the cap and top-up th leva lower () mare Approximately 10 lire ot a funnel may help 10 reduce spllege ‘il will raise the vel from the lower mak to Add the all slowly, checking the level on the the upper mark Aipstick onan. Dott over (see Carcare), Car Care FW Spee SaingiapAeM. Bing © NGRiipeaNEtaSeE BIGEES TA Wie codlant should not be necessary on a regular cooling systern all year round, not just during bass. Iffrequart tapping-up is required, t & the winter morths. Donft top un with water ley there is a feake Check the radiatr, all alone, asthe antiteeze wil become ciluted hoses and joint faces for signs of staring or wetness, and recy as necessary. 1 Tie cartel esos sted nthe ft hand sd othe engine) eeu ue pssst, al ul tae cold and one parimant. The caclare level ie vile through te recarvor, the cap fom the rsenair Add a mture of water and arireeze to the resowair untl the coolant Isat the correct level. Rel the cap ‘are ign Ie securslyBrake and clutch* fluid level “Manual trans mission models only. Waring: Brake uid can harm A ‘your eyes and damage painted Surfaces, s0 use extreme caution when handling and pouring i. De not use fluid which has been ‘standing open for some time, as absorbs moisture from the al, which can cause a dangerous loss ofbraking effectiveness. Before you start + Male sure thatthe car Is on vel ground The thud Jove! in the brake reservoir will droo slightly 2 the brake pads wear down, but the fluid fevel must never be allowed to drop below the AHN ‘mark. Safety first! ste resevon}requre repeats topnino- tp. this @ an indication of a fd. lak Stmenhere i the system, which should be investigated mimeo ita leak suspected, te cer should not be chver unt the Boling syst has been Sheaves’ Nevers ony ns wer traces ‘roconoemad Washer fluid level + On models 50 equipped, the screen washer ‘uid 16 also used to clean the talgete rear winder = Sereenwash additives rot only keep the vindsereen clean during bad weather, they ‘also prevent the washer system freezing in fold weather - which is whan yau ae tkelyta need it most. Dont tap-up using plain wiser, 2s the screerwach wil become diluted, and Wal freeze in cold weather Caution: On no aecountuse engine coolant ‘antifreeze in the screen washer system + this may damage the paintwork. The MAX and MIN marks a indicated on the reservoirs, The brake fuid reservoir (MAK and MIN mates rowed) is located in the righthand rear corner of the engine compartment unsere bre brave Tuld raservakr cep enc caret it it out of position. The dutch fuld reservar cap peels off Inspect tne reservar, st he tid is ety, the hycrauke system should be otained and refed (see Chaptor 1 or) week toes The washer fuid resewair filer is located atthe fort righ-hand sxe of he engine compartment Weekly checks 08 Dig at esr acre to it The fluid bal must ba kapt batwean the marks (erowed) al all times. If topping-up is necessary, ‘ist wipe clean te atea around the flier cap to prevent ait fertering the hyarauic system CCarauily ada td, taking care not to sp it onto the surrounding components. Use rly tne spacifed lua, ming alferert types can cause demage to the system. After tapring-up fo he correct level, securely reft the cap and wips off ary spit fuid. Reconnect ‘he Mud level ving connector. Release the cap and top-up the reservoir, a screanvash addtiva should be added Inthe quanliies recommended en the bottle0°14 Weekly checks Tyre condition and Tb vary important nek bres ean. good conciton and ele cared presse hes siya aura sary spond = ony dangerous Tyre erie nusnesd by arg se nersh braking end acceleration o fest comenng, walla produce more rapid ro woar Aa 6 Tioeral fa: the Pork Wren wet ed fasta fon the wears “hlerchagng the tyres rom front to rear (‘retating’ the tyres) may resut moreover woer Howover, Iss completely effective, you may have the expense of repiauing ail fourtyras at oncel Remove ary nals or slones embedded in the tread before they penetrate the tye to cause ddefaton. Irremval ofa nall das reveal that 1 Tread Depth - visual check The ofginal tyes have traad woar safely banes (6), which will appear when the reed depth reaches epproxmately 16 mm. The band positions are incicated by a angular marian the tyr sidewall (A). pressure theyre has been punctured, refilthe nail so thet its point of penetration Is marked. Then Imenedialey change tne whe, nd have tne tyre repaired by 5 tyre desler Requary check the tyres for damage in the form of cuts or bulges, especialy in the sidewalls. Periodically remove the wheels, and cian any dit er mud fom the inside and Sutside surtaces Exerine tna wheal rns or signs of rusting, carrasion or ether damage Lite alloy wneels ee easily damaged by kerbing" whilst parking, steel nheols may ‘also became dented or buckled, A new whee! Is very often the only way to averoome severe samane 2 Tread Depth - manual check Altematively, tread weer can be monitored mith 2 simple, Inexpensive device Ivcwn as 6 read depth indicator gauge Tyre tread wear patterns Hew tyes should be balanced when they are fittad, but may become neoassary 10 19- balance them a8 they wear, or iftne balance Weights fitted to the wheel rm shoud fal off Unbalanced tyres will wear more quickly, 28 wall the slsaring and suspension componanis Wheel imbelance is normally sigrified by vibration. particulary at a osrtan speed (Qypicaly around 0 mph this wiration Is fall only through the steering, then it is thely that just the font wheels need balancing. I however, the vibration 1s felt through the ‘phole car, the rear wheels could be cut of balance ‘Wheel balancing should be earned ut by atye dealer oF garags 3 Tyre Pressure Check Check tha tyro pressures regulary with the bres cold. Do not adust the tyre pressures immediately afer the vehicle has been used, or an inaccurate sotbng wil rest. Shoulder Wear Underinflation (wear on both sides) Under-nation vill cause overheating ofthe tyre, because the tyre will fxtoe much, and the read will net si crrecty onthe road Surface. Thissulleause a loss of arp anc ‘excessive near, not to mention the danger ot Sudden 179 tale cue to neat build-up Gihaok and aul! pressures Incorrect wheel camber (wear on one side) Repair or nen suspension ports Hard comering Reduce soseat Centre Wear ‘verintlation Ovarinflaticn will cause ragid waar of the centre part of the tyre tread, coupled with eduved gnip, harsher ride, andthe danger of shock damage cecumng inthe tyre casing Cheok and adst pressures, you sometimes have to ible your car's res to the tnghrr pressures spaced for raximurn bad or sistaned hgh speed, dom? Some! to reduce the pressures to normal aemaras, Uneven Wear Front tres may weer unevenly as @ result of wheel misalignment. Most tyre dealers and garages can check and adjust the wheel alignment (ar “rackngt} for 2 modest char Incorrect camber or castor Repat or renew suspension parts Maifunetioning suspension Repair or ean suspension oaris Unbalanced wheel Balance tyros Incorrect tos setting aust front vines! aigrment Note: Te festnered coe ofthe mead vtich Iyofies foe meer hest checked by feetWeekly checks 06 Power steering fluid level Before you start + Nake surethal the carson eval ground {Sethe eeenng vines! sratnt-angad {The engi should be tumed of Safety first! “The need for frequent tonping-up indies ‘Teak, which should be investigated Ime city Forthe check to be accurate, the steering must not be ‘The raoaivair is mounted an the right viilstan thers, i'sracassary fumed once the engine hes hand side of the engine compartment. to. unscran the capidipstick from the been stopped. The HOT and COLD bavels a markodion" —reservair Wipe dean the eree aroun! the tne resenvor (arrowed) resenair filer pack, before unsoreving the flr capAapstick fom the reservcr \th the engine stopped check the level vaugh the sida ofthe reservar, er As the fluid with the reservoir canicpstick by serewing it fly beck Into place. When the engine 16 cold, the fluid leva should ba between the balween tne COLD mans, when hot t should be betwoen the HOT marks, Ack us i neceseery, ‘yen tapping-up, use the specited type ‘of flu - do not ever the reservoir When ‘the wal is earract saourely ratte cap Wiper blades Note: Fiting detats for wper fades vary accomting 20 mete| an! according fo whetier genuine Toyota wiper Dlades nave Osen Mited Use me pracedurse ani usiatins shown as 9 guiie foryourcar n Steet ns contin othe wiper aces, yTo remove a windscreen wpe lade, 3 Side the blade down the riper atm if they are cracked or shew any signs of @the wiper arm, retate the blade en the >. e, a 72.1 To change the spark plugs youll need torque wrench, extension, ratchet, Socket and a set of feeler gauges 21 Brake fluid renewal Hh Non-WT4 models « every 30 000 km or2 years WTA models - every 32 000 km or 2 years Waming: Brake hydraulic fluid can ham your eyes and damage painted surfaces, £0 use extreme caution wher handling and pouring it. Do hot use fluid that has been Standing open for some time, as ft absoros moisture from the alr, Excess moisture can cause @ dangerous loss of breking effectiveness. 1 The procedure is sinlar to that for tho bisecing ofthe hydraulic system as descnbed in Chapter 9, except hat the brake fuid reservcir shouldbe empl by sypnanng, usnig @ clean lade or similar before stating, er allowance should be made forthe old fuld to be expelled ‘hon bleeding a ssction ofthe areut 2 Working as described in Chapter 2, open the frst bleed screw in the sequence, and pump the brake pedal gently until neary all Theol! fuid has been emptied fom the master binder reservar. EINE] OF hyetraulic tut is invariably ‘much darker in colour than the new, making i eesy to distinguish the two. 2: Topp tothe OAK level ith ny ta teu conn pumping ut ely he new Hud Temete ine sent, en ret hid con be teonemergg om i eed sere afhon inescrom and topthe rear evel up foe nncteie 1 Reeth ol remain oot sows ihihe eauiotes in now futd can bs sem ako tom Bo cast to oop the mask Sp enor toppasup to wove MN ive a tine, oF may are te Sytem Sra ewreasetne lena one sen vronineopraon cont, checkin tn clec) serene re secur tatened aed tht fo a cage we rotted ach of tates oF spit fd, ar rehock the ast Gander rezenor over Gheok the operaten the erates before fargo car ohne & 8 2 Spark plug renewal Non-WT4i models - every 30 000 km or 2 years WT models - every 65 000 km ord years 1 Sparc plug renewal recures a spark plug socket which fks orto @ ralehet, This socket22.4 Measure the spark plug electrode ‘ap with a feeler gauge Is ned eth a ruber grommet to protect the porcelain insulator of the spark plug and to halcthe plug while you insert iro the soar plug nla. Yeu will 80 nead a featar gauge tp chock and adust the spark plug gap and @ Torque wrenen to tianten the new plugs fo the specifed torque (see ilustraton) 2 Ifyou aro renewing the plugs, purchase tre haw plugs, adjust nam to te proper aap arc then fil each plug one a2 time, Note: When fuying new seer plugs, its escentel that {you oblain the cored! plugs for your specie Vehicle This ifeymation can ba Tv ip the Spactteanans Section at the beginning et Chapter, orin ie owners handtook 5 Inspect each ofthe nev plugs fordefects. If ther a ary signs of cracks in the porcelain insulate ofa plug, den use 4 Check the electrode gaps ofthe new plugs. Check the gap byinsering tne feeler gauge of the proper thickness btwn the electrodss athe tp ofthe plus (see ilustration). The cap between the electrodes shauld be identical to ‘hai listed in this Chapter's Specifeations. if ‘he gap is incerect, caretuly bend the curved ‘ido electrode slightly, Caution: Some plugs are supplied with the gap preset, There fs no need to adjust them. 5 Iitha sido electrode is not exactly aver tha cenire electrode, align them Removal Non WT engines 6 To prevent the possibility of mixing up 22.108 Prise outthe fasteners atthe rear of the plastic cover. Maintenance procedures 17 Lae a re A 22.6 When removing the spark plug HT leads, pull only on the boot and use ‘twisting/pulling motion spark plug leads, work on one spark plum at & time. Remove the HT lead and boot rom one ‘spark plug, Grasp the boot ~ not the lead as shown, gi it a half twisting motion an pull ‘sYeicht up (see illustration}. 7 compressed airis avaiable, blow any dit ff foreign material away trom the spark plug area before proceeding (a common bicycle pump will aiso work). 8 Remave the spark plug (see illustration) Examination af the spark plugs wil giva a {300d indication of he condition of the engine Ifthe insulator nose of the spark plug is een and white, with ne deposits, this & indicative of 8 weak mixture orto hot a plug (a hot plug transfers heat away from the electrode slonily, 2 cold plug transfers haat away quicly} 9 the tip and insulator nose are covered ‘with hard black-loking deposits, then ths is indicative that the mixture fs too rich. Should the plug te black and ally, then it likely that the engine is fairly worn, as wall asthe mixture bbeing foo rich, Ifthe insulator nose is covered ‘vith ight tan to greyish-brown daposits, then the rikture & correct ard I is likely tat the ‘engine is in good condition WT.i engines 10 Unda the twra nuts, prise out the two plastic fasteners a the rear, then lift off Ihe plastic cover on top ofthe engne (see illustrations). 11 Disconnect the wiring plugs from the Ignition eas 12 Undo the bolts and pull the ignition coils from the top of the spark plugs (see oe 22.8 Use a spark plug socket with a long, ‘extension to unscrew the spark plug iMustration). Recover the dust seal (where ited) 13 I compressed arr avallatle, blow any dino tersign metenal anay from tha sparc plug area before proceading [a common bloycle pump vill 60 er). “4 Remove the spark plug, Examination of the spark plugs will a¥e a good ineicetion ‘ofthe coneition ef he engine. Ifthe insulator rose of ha spark plug is clean and white, Duth ne deposits, tis is indicaive of a weak rrodure or too neta plug (a hel plug Wansters heat anay tram the electrode slowly, a cold plug transfers heat away quick) 15 Irthe tp and insulator nose ae covered wath nerd bieclelooking depos, tnen ths is indicative thet the mixture Is toa nich. Should the plug be black and aly, then tf Ikely thet the enging i arty worn, 26 wel as triste being tea rich Ifthe insulator nose is covered vih ight tanto greyish-brown depos, then the misture is correct and iis ly thatthe ‘engine is in good cancion Refitting 1B Prior ta installation, ite @ good isha ta ceat the spark plug threads with antiseze compound (see illustration). Also. is olen ficult insert spark plugs Inte ther hles vithaut oross-thresding them. To avold this possialty, fo shart piece of 8 mm intemal Slamater rubber hose aver the end of tha ‘perk pug (gee illustration}. The flexible nose cls 25 a unvorsal joint to help align the plug ‘ith the plug nole. Should the plug begin to ‘rass-thread, the hose will sip on the spare 22.42 Undo the screw (arrowed) and iit ‘ut the ignition coil1°18 Maintenance procedures 22.18 Apply a thin coat of antl-seize ‘compound te the spark plug threads lug, preventing tread damage. Tighten te lug to the torque listed in this Chapters Specifications | Non-WVT-i engines 17 Attach the plug lead to the new spark plug, again using 4 twisting mation on the Boot uni itis fly seated on the end ofthe spat plug. 18 Follow tne above procecure for the remaining spark plugs, renewing them ons st atime to prevent moing up the spark plug Teas, WT engines 49 Rel the colle to the top of each spark plug, ensuring the dust seal (where fted) is correctly located. Tighten the ignition cal batts to tne spectted torque, 23 Coolant renewal NonVVT4 models - every 60 000 km ord y WT models - every 85 000 km or3 years Waring: Wait until the engine Is cold before starting this brocedure, Do not silow antifreeze to come in contact with your skin, or with the painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never feave antifreeze lying around in 23.3 Radiator drain tap (arrowed) 22.18b A length of mm ID rubber hose ‘wll save time and prevent damaged threads when installing the spark plugs ‘an pen container, or in 2 puddle in the Sriveway or on the garage floor. Children and pets are attracted by its sweet smell, but antifreeze can be fatal ifingestes. Cooling system draining 4 With tha engine completely cold, unscraw the retetor pressure cep. 2 Undo the screws and remove the right hang onine undershiald (where fltod} (see iustraton 33). 3 Postion 8 suitable container beneath the colar drain tap atthe lover right-hand side ofthe radielor, then open the dra tap, and flow the coolant tn drain irto the centainer (see Illustration). yhon tho coolant has ‘nlshed draining, ets the tap. 4 Move tha contaner to under the rear ofthe engine block, then open the block drain tap snd drain the coolant into the container (9ee lMlustration). once tne coolant nae finished sfaining close te top. Cooling system flushing 5 itecolant renewal nas besn noglocted, oF Inthe enreeze rakaute has bacama dilutes then intime, the cooing system may oredually lose efficiency, as the coslent passages become restricted due to rust, scala deposi, and other sediment. The cooling. system ficiency can be restored by fusing the systom clean, 8 The radiator should be flushed separalely fom the engine, to avoid excess contamination i : ‘28.4 There ie a coolant drain tap on the rear of the engine block Radiator flushing T Disconnect the top andl otto hoses ane ‘any other relevent hoses tom the radiator (see Chapter 3) 8 inser a garden nose into the radlator top inlet Direc flow of oloan water through the redeter, ana eantue fusting stl lac vwaler emerges from the raditor batlom ‘ute. © Tatler @ reasonable period, the water slit ‘loos not nny cher, he radiatorcan be fushod vith a good proprstery deaning aport. Is important thet their manufacturer's instnictions af followad careluly” Ifthe contamination is particulerly bad, inset the hose inthe radiator bottom outlet, and reverse ush the raceter Engine flushing 10 To ush te ange, remove tne thermostat (see Charter 3) 11 With the bate hose disconnected fram the radiator, insert 2 garden nose into the conlare housing, Direct @ dean flow of water ‘rough the engine, and cortnue fushing unt lean watar emerges om the radater batter hose. 12 When flushing is complete, ett the thermostat and reconnect the hoses (see Chapter 3} Cooling system filling 13 Before attempting to ill the cooling system, make sure thet all hoses end clips ate in good condition, and that tne clips are light. Nole that an antireeze mixture must be used al year round, to prevent comosion ofthe engine components (S99 folowing sub Section} 1M Remove the radiator pressure cap, and censure all dain taps/plugs are secured 15 Plece the heater temperature control in tha maximum heat positon 16 Slonly add new coolant (50/50 mic of antiteeze ard coolant) to the radiator unt It's full. Add coolant to the reservoir up to the lover mark. Note that Tayota genuine cnlireeze is namely supaled premiced. 47 Leave the radiator cap off, and run the engine in a wollventiiated area unbl the thermostat opens (eeolant wil begin towing through the radiator and the upper hose wl baeama hat) 18 Tum the engine off and lot it cool, Add mere codtent meture to Ering the lave back to tha lip ofthe radiator flr neck 49 Squeozo the upper rad ator hose to ‘expel af, then add more coolant miaure it necessary. Reftne filer cap. 20 Start the engine, allow it to reach normal operating temperature and chodk for leaks. Antifreeze mixture 21 The artitesze should slnavs be renened fat ha spacined intervals. This Is nssessery not only fa maintain the antifreeze properties, but also to prevert corrasion which would athenwise occur as the corrosion inhibitors become progressively less etectve22 Always use an ethulene-ciyeo! based artiraeza whioh is sutable for use i mca metal cootng systems 23 Betore adding antireeze, the cooling System should be completely drained, preferstly fushed, and al noses checked for fandlion and secur, 24 Alter filing with antirseze, @ label should be attached to he expansion tank, stating the type and concertraton ofantiteeze used, end the date installed Any subsequent topping Up should be made with tha same lype and Concentration of anitrasze 25 Do not use engine artiteare in. the JuindscrserMelgate washer sysiem, 2 it wil damage the vehicle paintwork. A screenwach addilve should be added ta the wather system in he queries stated en the bottle 24 Valve clearance check & and adjustment s Non-WVT4imodels - every 90 000 krn or 6 years WT modds - every 95 000 km or 6 years, Non-WVT-i engines Note: Tihs folowing proosoure requires the suse ofa specie oot (Toyota No 08248-52020) tice compresses the cam folowera ite fo feratie. the miovar of ihe adjustment atv \Witout the toot wllhe necnacaty remove the camshat’s) as descnted 1) Cheater 74 1 Remove the cylinder heed caver as esanbed in Chapter 25, 2 Remove the spark plugs (388 Section 20) 3 Refer to Chapter 2A and postion the umber { pision at TOC on the compression sine 4 Moacure the clearances of the indicated valves with fester gouges (see illustrations) Rocerd the moacurementsforthose which ae fu of specincation. They wil be used later to tonne the required shims. 5Tum the erankshst one complet revolution en redign the orankshat tring marks. Messure the remaining valves fe ilustrtion) 247 Keep pressure on the cam follower ‘withthe smaller tool and remove the shim with a small serewdriver... Maintenance procedures 149 ‘24.da When the No 1 piston is at TOC ‘on the compression stroke, the valve clearance forthe No 1 and No cylinder ‘exhaust valves and the No 1 and No 2 24.40 Check the clearance for each valve with a feeler gauge ofthe specified thickness - ifthe clearance Is correct, you should feel a slight drag on the gauge ae ‘you pull Rout ‘246 When the No piston is at TDC ‘onthe compression stroke, the valve clearances for te No 2 and No 4 exhaust valves and the No 3 and No 4 intake valves ‘can be checked With Toyota tool No 09248-56020 6 ter al he valves have been measured, turn the crankshat pulley untl the camshaft lobe ebove the frst valve which you Intend to adjust is pointing upward, away from the shim 1 Postionthe netchin the cam tolowertoward thaspark plug. Then depress tha cam foloner with the Taycta special tocls (see nete athe start ofthis Section) (see illustration), lace tho special cam follower tool in positon as shown, with tne longer ee oftha tool gpping the lover edge ofthe cast flower boss and the upper, shorerjaw ripping the upper edge ofthe fallower ise, Depress the osm folarer 1 palr of tweezers or a magnet, ‘as shown 24.Ta install tre cam follower tool as ‘shown and squeeze the handles together to depress the cam follower, then hold the follower down with the smaller tool ¢o the ‘shim can be removes by squoazing tha handlas ofthe cam folowsr tool togetner, then hold the cam follower own with tne smaller tool and remove the larger one. Remove the adusting shin with a sal screwthiver ot a par of weez0rs (see IMustrations). Note that tne wr hook on the endl of some cam folwerteat nendles can be Used to clamp both handles together to ksep tho eam follower dopressed while the shin 1 8 Measure the thickness ofthe shim vith = mrorneter(68e Illustration), To calculate the correct thickness of a now shin that will pls0e the vale clearance wityn the specited valu, se the falowing formula 248 Measure the shim thickness with a ‘micrometer4 Maintenance procedures Tew in eke — am OT] fe] themmece SM] thieineee T [sr oom | 8 | Ferra 3 [an oee) | aa 0.118) 3 [205 0.143) 11 [205-10 120) [am ones) P| a0 (0122) 5 | 2750.05) _| 1 | 3 1510 240) S| eo a ree |e | 320-0260) Tamra [es | ss) [2a cra) | | S20 (1265 ‘248 Valve adjusting shim thickness chart N= THAW) = Vane charance messed Thekness of he nev Sm T= Thickness of tha ot hive = Desa valve cisarance (288 198 Chapters Spsctcatons) 9 Select 6 shim with a Pickness as close 95, possible to the valve clearance calculated Shims, which are available in 17 sizes in inorements of 0050 ram, rarge in size fom 2500 mm to 3.200 mm (gee lustration) Note: Through caret analysis ofthe shim S285 naeded fo hang the cutotspecticston valve clearance witia speciation, # i atten possi b simply move @ shim that has ‘ome aut anyway to another cam follwrer requisng a shin of at nartewsar sie, Inereny recucing the eurmber of new shims thet must be purenesed. Caution: The engine must not be roteted with any shims missing. To Prats the special cam follower tool tn position (gee Hlustration 22.9), ith the longer Jaw of tne tool nipping the lower ledge of the cast foloner boss and the upper, shorter jaw grioping the upper edge of the follower ist, press down the cam fll by squeezing the nandles ofthe cam talower tool together and install the new adjusting shim (Rote thatthe wire ook on the ena of ‘one cam follower tool handle can be used to fam the hanes together to keep the doprossed wile the shim is insartod. Moasure the dearance with a feeler gaugelo make sure thal your calculations ate correct. 24.18 Measure the clearance between the ‘camhaf lobe and the cam follower 11 Repeat this procedure until all tne vyalves which re out of clearance have been carrected 12 Installation of the spark plugs, cylinder cover, spark plug leads and boots, otc is the reverse of erneval Without the Toyota tool 13 After all the valve clearances hat measured, if any require adjustment, remo te camshats as decerbed In Chepler 28. 14 Use small fat-bleded scrondriver to caretuly prise the relevant shim frem the cam fallewer 18 Select tho requred shim ab dasenibed in paragraprs 8 and 9, then placa tha shim on the lop ofthe relevant cam fallower 416 Once all the necessary shims have been charged, refit the camshafts as described in ‘Chapter 2a, WT engines 17 Remava the cylinder haad cover end position the engine ak TOC for No 1 cylinder, 185 described in Chapter 28 18 Using fooler gauges, moasuro the ‘leerance between the camshat lobes and ne ‘cam folawers ofthe inlake vahes fer cinders ‘Vand 2, and the exhaust vales fr evinces 1 and 3 No 1 oyinder Is tthe timing chain fend of ine engine. Recerd the measurements ‘biainod (eee Illustration) 19. Tum the crankshaft one complete revoluton (230°) 20 Using. fecler gauges, measure the ‘24.22 Measure the thickness of the cam follower using 3 micrometer clearanoe batween the eamshan bas ana the oan followers of the intake valves for cyinders 3 and 4, end the exhaust valves for cyinders 2 end 4 Record the measurerrerts obtained, 21 Compare the measuremerts obtained! with those given in the Specifcations. I ary meacure ig outside the specified range, emava the camchats as deseined In Chap ter 2A, 22 With the camshatis removed, use @ ‘ragnetto lit the relevant cam fallewerts) rom placa, then measure and record the thickness of the follower using a micrometer (see Iustration) 23 Determine the required thickness of the new follower using the Falling formula Intake folowers N= Tx(2-0:20 mm) Exhaust folewers N= T4(A-0.30 sm) A= Meacurea valve clearance N= Thickness of een follover T= Theknassof tha ubad fofower 24 Select a tolowerwitn a thickness as dose 5 possible to the valve cleerance cakuleted Followers, which are avaiable in 35 sizes in increments of 0.020 ram, range in size from 5.060 mm to 8740 rm 25 Wilh all the followers in their correct locations, relit the camshatls as descnbed In Chapter 28, Batere renting tha oyinder head cover, recheck the valve clearances ‘8 premously deserted, and, if necessary, remove the camshafts again and change followers as necessaryChapter 2 Part A: Engine in-car repair procedures Contents Section number ‘Section number ‘Aitery vebell- check, adusimert and renewal..See Cheler 1 Ol procure switch — _ronewal 4 Conshoto seal- renova 2 Ol pump removal. ispedion and eftng 6 Cmenate and oloners remota eeecten, and rote... 1W Of ‘sump amoral ane etn 12 Graniehat alsed ronowa 1) Reser eporabons posable win te engi iho voice 2 Giinder compression check 2. Spork pug reveal See Chanter Shines heat temord and efing 1f Ting bat ond sprees remove, nspecion and reftig. = Qlinoa heed covers removal and ting. 4 Timng cha and sprocots removal mapocton and. rfid... 8 Enghe mountings chedcond renewal 47 Top Dead Cane (0) orrumber ene pst neatrg 3 Engne oll and far change, See Chapter! vahe —clearanco. Seo Chagter t Flyaheslidiveplate - removal and” rfiting 45 VT (Venable Vata Timing) compararis - remeval, inspection enc General infOMMatioN eee 1 reftng.. Man ol seal ~ renendl 6 Degrees of difficulty Easy, suitable for J Fally easy, suitable Fairy dmeut, 2. ificut, suitable Veryaiticut, novice with little: S| for beginner with ‘sultable for competent | for experienced DIY ‘suitable for expert s experience 2 | some experience DIY mechanic ‘mechanic DIY or professional 3S Specifications General Engine pe DOHC, inne turner fourvahes pr ender Cnr ruber (ring bahia endo ransmieson "ord a4 Fang ord Vaae Era codes Tie (1032 ce) NonvVT4_ ene sere 1 te (ag oe) Vota enone tease 1 ne (1607 cel NonsvvTs end te 18 tie (808 ce) WE ron ane Compression posture ‘ma 100 a Dirac Eetisen oyinsers— reemam) tober it pump Rotsrtoec clearance standard Service tit Nonavvttengncs “3 the ergne 460 10.0210 mm 025 mm 1B ite eran 8028 09975 mm 010 mn swt engines 260 6 350 nn oa mm Retort dlerence Nona engines: "3m erane 3.000 0 159 mm 020 mm Bite enane 8.06 fo 0 19 mm 035 mm wit onan, fugab to 0.480 mm 160 nm Rotors earns ‘ont enaes: Taito. engne 201 0 297 mm 2.60 mm Site enane d.a80t0 0190 mm om mm wt engines, aste 0671 mm oat mm ol pest Non iongnes rida ss 020 ser min 323000 pm a8 nad be Wienges ‘tide speed 028 ber min ‘483000, ipm. 2.94 to 5.39 bar2A+2 Engine in-car repair procedures Timing bett “Tensioner spring fee length 13 tire ‘engine. 18 lire engine. 2 Timing bet deflection. Timing chain and sprockets Maximum chain length at 16 pins (see text) ‘Crankshaft sprocket minimum diameter (with chain), Comshat sprocket minimum clameter (with chin) Camshaft thrust clearance (endfloat) Non-VVT-i engines: 13 ire engine: ‘Siancer3, Senioe limit, maximum. 16 ttre engine: ‘Siendard Senice limi, manu, wrieng) ‘Standard ‘Senice lina, maximum, Cylinder head bolt length wriengies: Standard Maxum. Torque wrench settings Non-WT- engines Camshaft bearing cap bal. Camshaft sprocket bott 13 ire engine 18 ite engne, CCenire chassis brace bots, ‘Connecting rod (big-end)* 13 tre engiNe 16 ire engine: Stage 1 Stage 2 CCrankehaf ai seal relainer belts 13 tre engine 18 ite engine Ccranksnat pulleyto-cranksheft bot 13 lire engre.... 18 litre engne Cylincer head bots: 13.re engine Stage 1 Stage 2 Stage 3. 18 lire engine: Stage 1 Sage 2. Stage 8. Cyinder head” cover. Enginetransmission stfener bots (1.6 litre engine, Exhaust manifold brace bots (15 re engine) Exhaust manifold nutsbals: 13 ire engne, 1B ire engine Flyaheclistiveplate bolts: 13 kre engne, aares 18 ire engine Flywheel (manual transmission) Drveplate (automatic transmission). 38.4 mm 269mm 501060 mm @ 20N 1207 mm 518mm 973mm Intake camshaft 0.048 to 0100 men O42 mm 0.030 to 0.088 mm Ot mm, 0.040 to 0.096 mm O41 mm, 4156.0to 159.0 mm, 1595 mm Nm Woe 8 st 59 50 39 29 ‘Angle tonten a further 90° 7 10 155, 116 30 6 ‘Angle tighten o further 80° 29 Angle tighten a futher $0" ‘Angie tighten a further S0° 7 2 58 Exhaust camshaft 0.065 to 0.100 mm 0.12 mmm 0.035 to 0.080 mm 47 mm 0.040 to 0.098 mm On mm 14 87Engine in-car repair procedures 2A+3 Torque wrench settings (continued) Nm ot tt Non-W1H engines (continued) ler putey baits: 13 lire engine: ‘Upper pulleyto cyinder head, 2 4 Lower pulleyto eyinder block, 28 x 18 ttre ENGINE. - : a 7 Intake air chamber (plenum) cover (1.8 lize engine). 13 4 intake manifold bots, 18 4 Nein bearing cap bolts. 38 cy (8 pump bots 13 ite engine 8 6 18 fire AGN Soa 2 5 (ll pick-up/strainernuts/baits 13 live ANE ins " 8 1B ire engne, 10 7 il pressure ‘we 8 0 ‘Ol sump bats: 13 tte engine. eee 8 10 16 ttre engine, 5 4 Wengines ‘Asllary bet tensioner: Bot. 69 at Nat 2 a4 ‘Camshat beating ca No t (igh-hand) bearing cap. 2 7 Al otter bearing —_caps. 3 10 Ccamsnat positon sensor 8 7 Camsnat sprocket batts. 54 o ‘Conneeting rod big-end) bots ‘Stage 1 20 8 Stage 2 ‘Angle tighten 0 further 80° Coolant pum. 10 1 Cranks pulley bot. 138 102 Cynder heed bolts: ‘Stage 1 49 36 Sage 2 ‘Angle tighten @ turner 0° yinder head "cover. 8 7 Drveplate..— 83 at Fiyyhest Stage 1 49 36 Stage 2. ‘Angle tighten a further 90° Ignition col to cylinder head 8 7 ‘Main bearing ladder bots: Ma. 19 “ mi: Stage 1 44 22 Sage 2 “Angle tighten 2 further 90° Ol contl valve, 9 7 Ol contol valve fer 30 2 Ol dain puis. 3 2 Ol pick-up strainer 8 7 ll pressure relervaive plug 7 a i pressure switch, 13 10 1 pump. 8 1 Oil pump cover Screws, 10 z oF sump. 8 7 Timing chain cover 40mm hed 8 10 2mm head. 8 4 Timing chain guide ‘bots, 9 7 Timing chain tensioner housing. 8 7 Timing chan tensioner slipper bos. 19 4 "Da notre-uee2A*4 Engine in-car repair procedures 41. General information How to use this Chapter This Part of Chapter 2 is daveted to insvehicla engine repair procedures. All Information ccneernina engine removal and refiting, and engine block and cyindar heed overhaul can ba found in Patt 8 oF ths Chapter The fellowing repair procecuras ara based cn the assurreion that he engine is itelad inthe vehole. Ifthe engine has been removed From the vehicle and mounted on stand mary of the steps outlined in this Pat of Chapter 2 wall not apsly The Specifications incluxled in this Part of Chenier 2 apply erly lo ths praedures contained in this Part. Part B of Chapter 2 contains the Specifications necessary for ylnder heacl and engne block rebuleing, Engine description whist all the engines covered by this manual ste four cyinder, double ovemnesd camshaft (DOHC) 1Bvalve units, they can be split into te cetegaries: Those without vatlabo valve timing, and those with (ATH, The 13 live dE-FE and 16 lire 4a-Fe engines fitted from 1887 to 2000 have fied valve tiring and timing bett which eves the exhaust camchaf, which is geared fo the ‘lake camshat. The 1 lire 427-7 and 16 lire 822FE engines titad from 2000 have a variable valve liming unit filled to the intake cemshatt sprocket, and a timing chain erving both the amshatis. The engine managemant system adjusts the timing of the camshaft via a hydraulic contol system (using engine oll 36 the hydraulic tuld). The timing 1s varied ‘according to engine sped and load -retardng the timing at low and hich engine speeds to Imptove lam speed driveability and maximum ower respectnely At medium engine speeds the timings are advanced (the valves open farla)Lo increase micerange torque and {0 Improve exhaust emissions OnNonev¥T-iengres, the valve clearances 28 Use a compression gauge with a threaded fitting for the spark plug hole ara adjusted by irterohangeabla steel shins Hted to the top of the camshat folovers, scting directly on the underside of their respedtive camshafts. On VWT-i engines ne shims are fited, and fo adjust the sleerances the camchat follawers themselves rust be changed, necessitating the removal of the camshats ‘Al the loner end of the engine, the one- pieoe otankshats ae supported by fy plain beanngs retained by tracitional beenna caps on the 4E-FE and 4AFE angines, whilst the AZZ-FE and 222-FE engines ae fited with cast man bearny ‘adder fited between the engin block ard tha oll sump. A\retortype a Bump is fled drecty over the ord of and cen tirecty by the crarkshat (4AFE, AZZ-FE and S27-FE engines) or by the liming belt FE engnes) Operations with engine in car ‘The following operations can be carried cut vthout having to remove the engine rom the Yenisle 2) Rornovat and reiting of tho cylinder hoad, 2) Removal arnt retting of Re fining ohase/ bef and sproctois: 2) Removal and setting of the comanstts: 2) Rameval at setting of he ov sur 3) Removal and rating ofthe ei pure 1) Renewal of fe erginarransrssion mountings @) Removal and refiting of the Anaad? Sroetate though in theory, it Is possibie to remove the big-end bearings, cormecting rods and pistens with the engns in plaos, for reasane of access and cleanness, its recommended thatthe engine is removed. 2 Cylinder compression check 1 ¥en engine performance 1S doven, oF it misfring eceurs which cannl be attributed to the igniton or fuel systams, a compression fest can provide diagnostic clues as te the engine's condition. Ifthe test is performed Fequarty, i can give waming of Foutle betore ‘any other symptoms bacome epparert 2 The engine must ba fully warmad-up to armel operating temperature, the bettery must be tuly-charged. The aid ofan accistent Ul ao be requires Remove tho tel pump use (No 10 norm the ‘engine compartment fusebox|, ard possible Start the engine and allow Ito. run unt the Fesidud fuel in the system is exhausted Flue to do so could result in damage to the catalvte convertor 4 Remove the spark plugs as desenbed in Chapter 5 Flacomprassiontestarto ine Not ofinger spark plug hale - the type of taster wtich sorews ito the plug th {Ge illustration) 65 Hove the essistent held the throttle wide open, end crank the engine on the starter ‘moter Attar ane or two revolutions, the compression pressure should bulip to a maximurn figure, and then stabilse, Record the hignest Feeding cbtalned) 7 Repeat the test cn the remarnng evingers recording the pressure in each 3 All cylinders should produce vety similar prossuroe, 2 ciference of more than 1 bar Detwesn ary two cylinders may indicate 2 fault Note that the compression. should build-up quickly in a heathy engne: low ‘cempression on tha fist straka, flowed by ‘adually-increasing pressure on successive strokes, indicates worn piston ings. law compression reading on the tirst stroke wich doss nat build-up during suecessive Stokes, indicates leaking veWes or @ blown heed gasket (a cracked head could also be the cause). Deposits on the undersies of the valve heads can also cause ow compression, 8 Toyota minimum values for compression pressures are given inthe Spectications 4D Ifthe pressure in ery einer flow, carry out the following test to iselata the cause Introduce @ teaspoonful of alae al into thet cylinder through its spark plug hole, and repeat the test 17 Ifthe additon of ol tarporarily improves Ine compression pressure this indicates that bore of piston wear is responsible for the pressure loss, No knprovement suggests that leaking or bumt valves, ora blown head ‘paket, maybe to blame 12 A low reeaing tom two adjacort: cylinders is almost certainly due to the nead gasket having Blas batwacn them, the presence af coolant in the engne ol will confi ths 18 Ione cylinder is abaul 20 percent lcwer than the others and the engine nas a siettiy ough idle, a wom camshaft lobo could ba tne 1 Ifthe compression reading & unusuelly high, the combustion chambers are probatly coated wih cerben deposts. It this is the case, the ovlinder head should be removed ‘and decarbonised 48 On completion ofthe fast, rat tha spark plugs (see Chapter 1) and re the fuel pump & & 3. Top Dead Centre (TDC) for number one piston * locating 1 Too Dead) Certre (TDC) i he hishest point in the cylinder that each piston reaches as Ie travals up the cylinder bore. Each piston reaches TDC an the compression stoke and ‘gan on te exhaust stroke, but TOC generally Fefers to piston postion en the compression stoke. 2 Positioning the pistorfs) at TOC Is an ‘essential part of many procedures such 9s camshat and timing betichainpulley removal ‘and astnoutar [where appeal remaxEngine in-car repair procedures 2A+5 ‘36 Align the crankshaft drivebelt pulley oteh (arrowed) with the 0 (zero) on the ‘tming cover 2 Bofors boginning this pracedure, be sure fo place the transmission in Neutral ard ‘apply the handbreke or bloc the reer wheels FRareve the spark plugs (se2 Chapter 1). 4 In order to bring any piston to TDC, the crankshaft must be turned using the metho fullined bells. When Tooling et the timing bbet/chain end of ths ena, normal erankshat rotation is doclovise. Tur the crankshatt with socket and ratchet attached to the alt Tredad into the Tent ofthe erankshat. apply pressure on the bot in a clockwise clrection only. Never tum tha bolt ani-cocoise 5 Remove tho cylinder head cover as ssesonbad In Section 4 © Tum the crankshaft until the notch in the trenkshat puley is algned with tne 0 on the lining cover (see illustration) 7 Loak atthe camshat lobes for No 1 cyinder. Both the intake and exhaust camshat lobes should be pointing away Tor the eamshat Flowers, ity ere nok. use the sodebepenner to rete the crankshaft one compete reyelton a0") now the kbes should be painting ‘nay From the fllewers, Addtonally, on 13 le 4EFE and 16 lve 4AFE engines, tho marc on Ine No t cemstit heanng cap shoud be sible through the hale in te carrehelt sprocket (eee Mustation), On 14 ite AZZ-FE and 16 ie 322-FE WWT4 engines, the reference marks on the infake and exhaust camshaft sprockets ‘heuld bo aligned withthe top ofthe cylnder eo (eee iustration). B After the number one piston has been posiioned at TDC on the compression stroke, TOC for any of the remaining pistons can be 44. Remove the twa hamess cover mourting ‘bots at the ting beltend ofthe cover 374 The camshaf sprocket is at TOC ‘when the hole in the sprocket lines up with the notch In the bearing eap located by turing the cranksan 180° and follosing the ting ont 4. Cylinder head cover = removal and refiting Removal 4 Undo the two nuts, prise out the two plastic fasteners, and remavethe plastic cover (where sites) evertne engine (see Mustratons). 2 Detach the PC hoses from the eyindar heat caver. Non-WT: engines {5 Remove the HT leads rom tne sparc plugs, handing them by the caps, net puling on the tags, and release them tram ary clas on me ‘vind head cover. 4.14 Prise outthe plastic fasteners atthe rear of the engine cover ‘46a On 18 Itre engines, the cover by four nuts (arrowed). Gn 13 itre engines, there Is en adaltional nut at the front 3.7b On VVT4 engines, the marke on the ‘camshaft sprockets (arrowed) should align ‘with the top edge of the cylinder head 4 On 18 lire engines, remove bo bots at ‘he timing batt ond ofthe eyinder heat cover, then pul up the wiring hamess cover end voting (see illustration). WTiengines 5. Remave the ignition coils as dascribed in Chapter All engines 5 Remove the evindor head cover maurting rusfbolts, ther’ dataoh the esindar head ‘cover and gasket rom the cancer head (see IMlustrations). I the cyinder head caver Is stuck tothe eslinder head, burp the end with @ saa block and @ hammar to jar o0se. IF that doesnt work, by to sip a fexble putty nif between the cyindor head end cylinder head cover to bree the sel Caution: Don't lever at the cylinder head coverto-cylinder head joint or damage to 4.8. Cylinder head cover bottsinuts/studs “WT engines,2A+6 Engine in-car repair procedures ‘47a The cover gasket (ef arrow) can be re-used if it hasnt hardened ensure the ‘Spark plug tube seals (dght arrow) are In place before reiting the cover the seating surfaces may occur, leading to oll leaks afterthe valve coveris refitted. Refitting J The meting surfaces of the housing or ‘Mlinder head end cylinder head caver must be clean when the cinder head cover ls Toftted. Tha rubber seaing gasket cer De re- Used uriess i hes seen righ mileage and the Tuber has hardened or eraciad, than pull out the rubber seal and clean the mating surfaoes ith rake leaner. Instel @raw rubber gacket, proscirg f evenly info the groove around the Incarside ofthe cylinder head ower. Ifthere's tw AED ‘58 Afterremoving the centre bol, remove ‘the crankshaft pulley 7 oa Tes O°" 69 18 litre engine timing bett cover tails. There are only two covers on the “13 ire engine ‘cover gasket is ited te the spark plug ‘tube grooves - VVTS engines ‘osiduo or all onthe meting surtaess when the condor head cover is installa, el leaks may velop. Note: Mako cave tha te sean ptig Ibe gaskels are i place on the undersie of the vaws cover hater siting Jt (S08 lustrations), 8 On VST engines, apply sealant (Tayeta ‘No 08826-00080 or equivalent) to the area where the timing chain cover abuts the evinder head On al engines, raft the cylinder head ‘evar and tighten the nutshoots evenly to te spacited torque 10 eft the remaining parts, nn the engine ‘and check foral aks 5 Timing belt and sprockets + temoval, inspection x and refiting 8 Note: The folowing ercoasuro applies ony t0 he FE-PE and 4a-reNon.v¥Tvengines. The SZL-FE ana S2ZFE WT engines ere fied tiara tng chase (e0e Section 6) Removal + Black the handbrale 2 Loasen the nits on the right front wheel tnd rase te vehicle. Support ine front ofthe vehicle securely on axle stands (sae Jecing ‘and vehicle syppar). Remove the nghtnend front radwheel 3 Remove the auxliary drivebelt{s) as ear wheals and sat the 5.128 Retighten the bolt to keep the tension off the belt for removalinetallation Undo the screws and remove the right-hand) fengne undarsrield fhe ited) 4 Set the engne to TOC on No 1 cylinder €s desorbed in Section 3 16 litre engines '5 Suppor the engine fom undemeth with @ Jack (usa a wood block on the jack, but dont labs fe blcolcundar i ol sump dean plus Note: #youse planning on removing the a sump in adaiten to the fing elt support ite engine vit a hoist rom above 6 Undo the four batts and romove the coolant pup pulsy Allengines 7 Topreventthe crankshaat rom rotating hilt the erankshat puley central bat is slackened, ‘engage top gear anc have an aesistant pros the Brale pedal tirly Slacken the pulley balt, On autortic transmission models, i wll be necessary to remave the stator motor (Chapter 54) and have an assistant Wedge 2 large Tet-laded screndriver between the dhiveplate teeth and the transmission casing ergire ine sereverver doesnt sip 8 Check the timing mars are stl aligned a5 deseribedin Section 3, then side the crankshat pulley trom tho crankshaft eee iltustration}, 5 Remove the two (1.8 lire engne) oF tras (165 ire engine) timing belt covers (se0 ustration). 10 Remove the timing bell guide from the cranks, notng that the cupped side Taoas fut and the smocth side is next to the bot. {1 Htyou plan to reuse the ming bel, apply match’ marks on tha sprocket and ba and an arrow indicating direction of rotation cr the belt Nete: Lie recommend that he ball Js venewed wnenevor it has noen removed, regardess of mioage, 12 Logeen the bet tensioner adustmert bot, fy the Tensioner ta tha reer ane’ raigrten the bol inthis postion (86 Mlustration). Sip te ming bait ottthe sprocket. it youre remoang the batt for camshatt sea renoxal or ovinder heed removal, fiat necessery te detach the bolt fom te crankshatt sprocket cr, on 18 Ite fengnss, 10 unbolt tne ngnt engne mount. On 18 lire engines, if you 9 remiowna the belt eompletely, suppor tha ght engine mount with a jack, then remove the two nuts from the engine mount (fam underneath) and the 6.12 With the engine mounting supported by ajack, remove the two nuts (arrowed) from the right-hand engine mountingEngine in-car repair procedures 2A+7 6.14 Paint marks (arrowed) on the ‘.12¢ ... and remove the upper engine ‘mounting bolt arrowed) bolt from above (see illustrations). Lower the ‘engine, then pul the upper part ofthe mounting up {fre ruther will law rovamart) unl the bat canbe sipped out between he upper and lower sections of the mounting - this saves, removing the meunting completely 18 IF the camshaft sprocket 1s worn or hole! the front (exhaust) camnshait vain a large wrench and remove tne bat, then detach the sprocket (998 Section 10) 14 Slip the timing belt off the crankshaft eprocket and ramove it. the sprocket is ‘ern ar damaged, of "you need to renee the crankshatt oll seal, remove the sprocket ‘tom the crenkshat. Betore removing t, paint matching marks on the erankshat sprocket and the oil pump case, so that yeu ean find the TOC postion witout the erankehar puloy 11 olace (608 ilustration} Inspection Caution: Do not bend, twist or tum the timing belt inside-out Do not afew It 10 ‘come n contact with ol, cofant or uel. D0 bot uthize timing belt tension to keep the Camshaft of erankshat from tung when Instaing the sprocket bolts. Do net turn the crankshattor camshaft more than afew degrees (i necessary for tooth alignment) while te tring belts removed 18 I the timing bat broke during engine operation, the bet may nave been Conlaminaed of overtigtened Caution: If the ming belt broke during engine operation, the valves may have ome In contact with the pistons, causing damage. Check the valve clearances (se Chopter 1) bert valves usually wl have excessive clearance, indieabg damage thet wil require cylinder heed removal repatr “Ihe belt teth ate cracked or missing {see Illustration), the. disrbuter ppicable, ol pump oF camshats may have Seed 17 era nteseble wearer creeks on th foce ofthe bel check to see ee are nds Sours on he ier ples (eee Mustation) 18 il there f war or damage en only ane sige oft bat, hci te eR gulde este sigrmert ofthe soroctets (ge illustration). 49 Renew the bing belt frebwcus weer crankshaft sprocket and the oil pump case ‘$0 you canfind TDC. uthout mista them up (See tlustrations). 42 Position the inteke camshaft in a vice, clamping iton the heeagenal secon. Using a lesen spanner, rotate the sub-gear docks and remavo the service Dat fern he threaded hole, then allow the sub-gsar to rotata back Uti al tension isralieod (be illustration). Engine in-car repair procedures 2A+13 40.118 Mark the followers/shims and remove them with a magnetic ool 13 Remove the sub-gear circa. The wave ‘washer, sub-gear and camshaft gear sprin fn nov oo remaved from the camsnatt (ee iluatrations} Inspection 14 Inspect each follower for soufing end soore marks (gee tlustration}. 48 Visually examine the cam lobes. and bearing Joumals for score marks, pitting, galing and evidence of overheating (blue, discoloured areas). Lock for fishing away of 18 It in any doubt es ta the condition of the vamshafts/gears, have them examined ane measured by an automotive engiesring workshop. Reftting 17 Reassemble the intake camshell sub- {gear Instal the eamshait goar spring, sub- ‘ear an weve washer Secure them win Ts 10.12 Use a spannerto relieve the tension ‘on the service bolt 70.13b Remove the wave washer (1), then ‘camshaft sub-gear 2) andthe gear spring (3) . © Me 8 SS 10.11» Mark up a cardboard boxto store the followersishime and bearing caps cirlip (gee Mustrations 10-138 and 10.136) 48 Referto paragreph 6 and installa service bat 19 Apply moly-tase grease or engine assembly lube to the inlake" camshatl followers, then install them in their orginal looetlons Make sure the valve equstmant shims a9 in place on the flowers 20 Apply moly-bave grease or engine fassembiy lune to the intake camsnatt labas ‘and bearing joumals 21 Pesition the intake cemshaft 0 that the service bolt Pole in the cemshat gear is Uppermost then place the camshaft in positon {see ilustration 10.4), 22 Install the intake camshat bearing caps {excopt the righthand cap) n numerical erde ‘eth the arrows pointing towarcithe timing belt and of ha engine 28 Tighion the bearing cap bots uniformly land alematay, in severe stages, url he caps 40.134 Remove the circlip with a pal of cirelip pliers 10.14 Wipe off the ol and inspect each Tollower for wear and seuing2A*14 Engine in-car repair procedures 10.26 Align the exhaust camshaft gear with the intake camshaft gear by matching Up the timing marks an the gears Tring Mark 10% Enaing) ~ 10.26b DO NOT use the timing marks for the S engines when installing the ‘camshafts and gears 10.33 Intake camshaft bearing cap bolt tightening sequence - 13 litre ‘are soug withthe cylinder head. Do nat ghten the bots to the Rl torque seting atthis stage. 24 Apply moly-baso grease ar angina assembly lube to tho exhaust camshatt Falewers, thee install tnam in their onginal locations. Make sure the valve adustment shims er in place onthe folowers 25 Apply moly-base grease or onging assembly be 1 the exraust camshelt lobes ‘and beering joumals, 25 ign the evmaust eamshan gear with Be intake camshait geen by matching uo the ‘ming marss on the gear: (see Mustration), On some 1 Ire engines there are two sets or iming merks - OO NOT use the Umirg marks for the $ engines whon installing the bamshats en goars (gee Mustration). FT Rall the exhaust camshatt down into position. Tum the intake camshet back-and forth a ile unl the exhaust camshat sts in tne beeangs even 10.36 Exhaust camshaft bearing emp tightening sequence -13 lire 26 Install the exhaust camshat bearing caps (except the nght-hand cap) n numerical order ih a arta pointing toward the ming batt fond ofthe engine 28 Tighten the Dearing cap bolts uniformly ‘and alernately,in severa stages, nb the caps ‘ae snug wit the osinder head. Do not tighten the bolts tothe fulltorque seting atts stag. 30) Remove tne service bolt Fem ine intake camshell gear 31 Apply a thin coat of RTY seslart to Inteke carishatt nohthand bearing-cap-to- cyinder-head mating surtace, Nate: The cap rust de ssl mmediataly ortho Saale wh ‘ry premature. instal the cap and tighten the by bearing cap bolts uniformly and ‘altemately, in several stages, ui the cap Is Snug with the evinder head. Bo notighten the bolts to the fll torque seting at this stage. 32 Ital the housing plug to its location in Front ofthe take cash 88 Following the recommendod sequence {see illustration), tighten all the intake ‘camshaft beanng cap bolts urvfarmly to the torque sted in hls Chapters Speciteations 34 Lubricate the ins of a new exhaust camshat oll seal witn enone ol! or mult purpose grease and instal the seal in the Cylinder head Push the sxel fully into the recess inthe head. 35 Apply a thin coat of RTV sealant to the exhaust carrshatt righthand beaning-cap-to- ‘ytinder-head mating surface. Note: The cap fnustbe insaled imrediatay of tho saater wit Oy prematurely. instal the cap and tghlen the two bearing cap bolts unifarmly and atomatsly, in several stages, untl tne cap is snug ith te cinder head. Do ncthhten the Dolls tothe ful torque settng atts stage. 38 Following the recommended sequence (See illustration), tighten’ al the exneust ‘camsheft beanng cap bolls uniformly to the torgus listed inthis Chapter’s Specicatons, 37 Install the timing bek sprocket on the ‘exhaust camshaft and tightan the bot to the torque Usted in thls Chapters Specifications Prevent the camshaft rom tuning by holding Itwih a sparnee an the hexagonal section, 38 Install the timing bel (sse Section 5). 438. The remainder of refting fs the reverse of ‘ho removal pracodare 1.6 litre 44-FE engine Note: Before beginning this procedure, oan {ho Sx1.0 mm, Bol 18 fo 20 mm Jong. They bl be voter 29 sarven Beto i th text Removal 40. Remove the distnbutor (see Chepler 5B) Remeve the timing belt and camshet sprocket 600 Sections $ and 9) 41 Measure the camehat thrust clearance (endfloat) with @ diel indicator Hlustration} Ifthe clearance is greater the service limit, renew the camshaft andor the cyinder heed 42 Position the knock pin in the exhaust fcamefa just above the tap of the oylindsr hheod (eee illustration). This will postion the Intake camshaft labes so the camshat wil be pushed up evenly by val spring prassura Caution: This positioning is. important 10 avoid damaging the cylinder head or ‘camshaft as the camshaft is removed. 10.81 With the dial zeroed, lever the ‘camshaft forward ang back, then read the ‘endfioat on the dial 1042 Place the exhaust camshaft Knock pin between the 9 o'clock and 10 o'clock positions 4103 Remove the two bolts and the right- hand camshaft bearing cap from the intake ‘camshatt43. Remove the two bats and the right-hand bosring cap trom the intake camshlt (S00 ‘lustration) 44, Secure the intake camshatt sub-geor to ‘he main gear by inetaling ene ef the sence bolts ita tne thraaced Nelo (gee tustraten), 45 Following the reverse of tha tightening sequence (see illustration 40.70), loosen f= remaining intake camshet beating cap bots in Vaturn increments unti the bolts can be removed by hand. Lif the besring caps straight up and oft Caution: As the centre bearing cep bolts are being loosened, make sure ihe ‘camshoftis moving up evenly. rane end or the other stoos moving and the camshaft gets jammed, start over by refitting the bearing caps. DO NOT try © lever or force the camshaft out 46 Lin the camshat straight up and out ot tne coinder head 47 Position the knock pin tn the exhaust camshaft st approximately the 6 o'dlack postion (see illustration). 48 Remove the right-hand exhaust camshett bbeering cap bots and detach the beating cop and ol see Caution: Do not fever the cao off. It it dosen't come loose easily, leave tin place without bolts. 49: Fallon the reverse of the tightening sequence (eee Mlustration 10.60}, lnosen the remaining exhaust camshaft beanna cag bolts in tum mnerements unt the bolts can be removed by hand. Lit effine bearing caps. Caution: As the centre bearing cap bolts are being feosened, make sure the camshaft is ‘moving up evenly. If one end or the other Stops moving and the camshaft gets Jammed, start over by reftting the bearing ‘caps and resetting the knock pin. DO NOT tty fo lever or force the camshaft out 50. Lin the camshat strat up and out of ‘he eyinder head 51 Clean the oll off the camshaft follower shims, mark them with 2 felctip marker arc famova the foliowers, weeping the shane ouith their followers (eee iustration 10.11. Store ine camshett bearing caps, tallowors and shims s0 they oan be reinstalled without Imising them up (see Mlustration 10115) 52 Position the intake camshaft in a vice, Engine in-car repair procedures 2A+15 10.44 Install a service bol through the sub-gear and thread It into the main gear (arrowed) damping it on the hexagen section. Using 2 two-pin spanner, rolate the sub-gear Glaclwise and ramove the sarvice Balt tram the threaded hole, then allan the subegear to rotate back urt all tension Is relaved (eee Illustration 10.12) 53 Remave the sut-pear circip (see Mus tration 19.432). Tho wave washer, sub-goa" ‘ant camshat gear spring can now bs removed from the camshert (8¢e Mlustation 10.136), . 54 Folaw tha instructions given in para graphs Ito 16 Refitting 55 Apply moly-tase grease or engine assomtly luoe to the exhaust camshat fellewers, than iestall them in thar orginal localions Meke sure the vale edustm ent shims ae on place on te flloners 58 Anply moly-bass grease or engine fssembly lube to the exhaust camshaft lobes {and bestng journals 57 Position the exhaust camshaft in the oylinder head auith the knock pin at approximately tne 5 o'clock postion (see Ilastration 10.47), 58 Apply a thin coat of RTV sealant to the outer edge of the nght-nand beanng cap-to-cylindarhead mating surface (see llustration). Note: The cop mst te istoled mediately or te caaler wil ay armature 58 Install the exhaust camshatt beanng caps in numerical order with the arrows painting {oward the timing bet end ofthe engine 60 Following the recommended tightening 40.47 Tum the exhaust camshaft until the knock pin is pointed at aboutthe § o'clock position sequence (eee illustration), tighten te. beanng cap bolts in Uteumn increments tothe torque listed inthis Chapters Specifications 81 Refer to Section 9 and instal a now ‘amsnat al sa) 82 Reassombla the inlake camshaft cub- gear Install the camshaft gear spring, sub- eer end wave vention Secure them withthe ‘eg (See llustatons 10.138 and 10.136), 158. Relertoperagreph 44 and instal a Serica bat 1 Apply maly-base grease or engine assembly lube te the inteke comshet followers, then instal nem in their cnanal lecations’ Make sure the vaWe aductment shims are in place an the followers 88 Apply moly-base grease or engine assem lube to the intake camshatt lobes {and bearing jeurals ‘86 Rotate the exhaust camshatt until tha snack pr is pastioned bebuesn the 9 o'dack and 10 otoekposiion (gee Mustration 1047). 87 Align the intake camshaft gear with tho exhaust camshan gear by matening Up the instalition merks on the geors (6 ustration} Caution: There are two sets of marks. Do not use the timing marks. The camshatt Installation marke are the only marke that fare duplicated on both sides of the ‘wo ccamshart gears 68 Roll tho intako camchat down inte postion. Tum the exhaust camshamt beck anc-orth @ ite until the intake carshat sts inthe beanngs evenly {8 Install the intake camshaft bearing caps seal Packing 1058. Apply sealant to the shaded areas of ‘the exhaust camshaft bearing cap 10.60 Exhaust camshaft bering cap bolt tightening sequence «16 litre Installation Mark talon ar 10.67 Use the instalation marks, NOT te timing marks,2A+16 Engine in-car repair procedures 10,70 Intake camshaft besring eap bolt tightening sequence - 16 lite 1083 Position the No 1 cylinder camshaft lobes away from the followers Jn numerical orgar wth the arrews painting toward the timing bet end ofthe ensine 70 Following the recommended sequence (see illustration), tighten the bearing cap alts in iM-tum increments to the torque listed n ths Chaptor's Specifications. 71 Remove the sarvice batt from the intake camsnen geet 72 Install the timing belt spracket on the exhaust camshaft and tighten the boltto the torque listed in this Chaptor’s Spocifcators Prevert the camshaft fram tuming by haldng hnvath a spannar on tha hexagonal section 78. Iretal the timing bat (a88 Section 5). 74 The remander of reiting is the reverse of the removal procedure WF-i engines Removal 75 Romove the timing chain as desent in Seetion 8, There is na reed to remeve the Camshaft sprockets unless you are rareing the camshans, Te Rotate tho crankshaft 80° ent-codavise to eliminate ary possbiity of acacertal valve to-pistan contact during the camshat removal procedure TT Working from the ends of the camshats, (gradually and wenly lackan and remave the Bearing cops trom the intake and exhaust camshafts. Lit ofthe beating cans Caution: As the centre bearing cap bolts are ‘being loosened, make sure the camshafts {are moving up evenly, If one end or the ‘other steps moving and the camshaft gets Jammed, start over by refiting the bearing 10.84 The camahsft bearing caps are marked (Geromed) £ for exhaust, and Iforintake aps, DO NOT try to lever or force the camshatts out 7a Lit the camshatt straight up and cut of the eyinder head 19 Clean the oll off the camshatt folowers, mark therm uth fat-ip maker end remove thom (see illustration}. Store the camshatt bearing caps and followers so they can be renstaled without ming them up {e0e lustration 10.116}. Inspection 0 Follae the Instructions given in para orarhs Mito 16, Refitting 81 Appiya ile dean enaine ol to the esheust ‘camshaft followers, than instal them in thar Snginal locabors. Repeat this procedure for the intake camshat 82. Apply ate ciaan encine al to the avnaust camshaft labas and bearng journals. Repeal this procedure forthe intake cemshert '83. Posifon the exhaust end irtake camshaft vith the lebes for No 1 cinder painting Upwerds, away from the followers (see iuswation), 24 Rell the camshaft pearng caps to thelr ‘nghal postions. Note that he exha.st bean aps ate meiked E and the intdee caps are marked |, 2s well as being numbered 2 1 S fromthe timing chain end. No t bearing oep Is tho ‘double’ cap fitted adjacent to the ming enain. Apply alitie clean engin ail to the threads and underside ofthe heads, then install the retaining bols and fghten them gradualy, ‘and evenly rom the middle of the camshats ‘oulwards (eee lustration). 85 Algn the comshat sprocket timing marks (see Mlustration 3.7b), then rotate the crankshatt 90° dacavise, back to TDC paiton (withthe evanksht key upnght in the 12 o'clock postion) 88 Refit the timing chain as desenbod in Sectan 6 11 Cylinder head- & removal and refitting x & Note: The angie must be completely coot before hepinaing tis procedure Removal 1 Drain the coolant om the engine block and Fatiator(se0 Chapter {). 2 Drain he engne ol and remeve tne ot ter (see Chapter 1) 3 Remove the throttle cody, fuel injectors, fusl ral, intake and exhaust maniflds (see Chapter aa) Non-WT4 engines 4 Remove the timing belt and camshaft sprocket (9s Soctons 5 and 9} 5 emeve the aermalo an dct (18 ie engi cnly)-see Chapter 54 end 5B. 5 Urbane pewar staering pump and set tha pump aside witout disconnecting the hases 7 Remove the coclart junctions from each end ofthe evinder nead. WTi engines: 8 Remave the timing chain 6s descrbed in Section 6. 9 Undo the bolt and witheraw the WTS oll control valve from the cylinder head (see Iustration 7.3), All engines 40 _Remave the camshatts and followers (see Section 10) 41 Labol and ramave any remairing items, such 3s coolant fitings, tites, cables, noses 12 Using an & mn allen Key bit (NOnAT engines) or an 12 bihexagon bit (VVT-i angines), loosen the cyindsr nead bolts In ‘sd-tum increments until they can be removed by hand. Loosen the cider ead bolts in the reverse af the recommended tightening soquonca (see Hlustrations 11.26a, 11.25b oF 11.27) fo evoid warping oF orscking the felindar head. Recover the washers, 13 Lif, the oylinder head off the engine look. tits stuck, vary earetully pry up atthe transmission end, beyor fs gasiet surface (ee ilustration): ‘4 Reve al extemal oompcnerts from the evince head 19 alovs for tharough olsaring ‘and inspection. See Chapter 2B, for elinder head servicing procedures, Refitting 18 The mating surfaces of the evinder head and block must be parfeciy clean when the ylinder head is installed411.18 Lever only a the overhang, not between the mating surfaces 16 Use @ gasket soraper to remove all traces of carbon and old gasket material (see ilustration}, then clean the rating surtaces vith broke cieener there's oll an the mating surtacos when the cinder head is installed the gasiet may not seal correctly and leaks could develop. Yen working an the block suf the cylinders with cleen rags to keep fut dabris, Use a vacuum cleaner to remove ‘materia thet falls inlo the exlincers, 17 Check the black and einer head meting surfaces for nicks, deep scretches and other damage. lfdamag® ssi, an be removed witha fle, FS excessive, machining may be tne ony alternate 18 Use a tap of ha comect size to chase the threads in the cinder head bolt holes, then een the heles with compressed air make sure that nefhing remairs the holes Warning: Wear eye protection when using compressed air, 419 Mount each bolt in a view and run @ de ‘aon the threads to remove corresion and reslere he treads. Dit, comasion, sealat and damaged threads wil afec torque readings 20 On VT engines, measure the overal Tength of the ovinder head bolls. i any ff the balls lengths exceeds that given in the Specitcations (indicating excessive ssretching}, renew all the cvinder head bolts {see lustraton) 21-Gn all engines, install eny components that were removed from the eylinder ree. 22 Postion the new gasket over the dowel pins in the biock (gee tustration). On VVTs Reef, ¢ 61a 2 Engine in-car repair procedures 2A+17 14228 Note the markings for UP on the ‘gasket - NonsVVT+ engines engines, the ‘Lot number must be facing Uonards (see Mlustration). 23 Cefotuly sot the oyinder heed on the block without disturbing the gasket 24 Before instaling the ovlnder head bots, 2pely asmall amcunt af clean engine al fa the threads ere uncer the bot heads Non-WT4 engines 25. Insta ho lls and tghten them fngertight instal tne snorer bots alona te rtske sce of the oyinsar haed and the longer bolls along the exhaust side Folewing the recormended saquanoa, tghtan the balls in thrae steps to ‘he torque sted in this Chapters Specifestons (see Mlustrations). Some ofthe Stages afte lightening sequence require the belts to be angistightened. you dont have an angle lerque attachment Yor your torque wrench, simply apply @ pant mats at ono edge of each cyinder head bot and bghlen the bot url that atk i680 degrees fom where you sari 11.20 Measure the overall length of the ‘dlinder head bolts - VVT-i engines 14.22 OnVVT. engines, the ‘Lot number (arrowed) must face upwards 26 Theremsining reiting stepsare he reverse of removal. Note! ifthe oumrcveuar mbbor uy haa been retmaves rom tn oyinder hed instal twa some RT sealant WT engines, 27 Install the ofinder head bolts and ‘washers, then tighten tnem in sequence tothe i391 torque seltng (gee Mlustration), 28 Angla lighten the bolts. futher 90° in sequence All engines 2B Check and aqust tha vake clearances as nscossary (999 Chapter 1) 30. The remainder of rafting is @ reversal of removal, rcting the fallowing points 9) Petite cooing syste, insta row ifiter ana ado of to the engine (see napier 1) 1) Fun the engine and check fos feats ©) Foad tos the wanes 11.28a Cylinder head bot tightening ‘Sequence -13 litre 11.25b Cylinder head bolt tightening sequence = 16 litre non VVTs engines 11.27 cylinder head bolts tightening sequence - VVT-I engines,2Ae18. Engine in-car repair procedures 127 Remove the front bolts ofthe chassis brace (arrowed) ‘rom the block 120i sump- removal and refitting WS Removal 4 Set the parking brake and block the rear wheels 2 Raise the front of the vehicle and supper of LSet AB 428 On 16 litre Non-VVT4 engines, unbolt the block-oransmission brace 12.9 On WWT4 engines, pull down the plastic cover slotted Into the engine block Ie securely on axle stanes (eee Jacking anc veticie sunpon 3 Remave the two splash shields under tha ne. 4 Dra the engin oll and remove the ol fter (see Chapter 1] Remove the ol dipstick Non-VVT- engines 5 Disconnect the electrioa connector fo the oxygen sensor [see Chapter 45} GLE Bias |: 12.46a Sealant application detalls Non-WT4 engines 6mm a A-A me BAB 12450 Sealant application details ‘WWT4 engines 6 Remove the two nuts retaining the font ‘exheust pipe tthe exhaust manifold, then the tio baltgnuts connecting the pipe to the rear ofthe exhaust system T Remove the two front bolts of the longitudinal chassis brace and the to nuts sectring the radiator sca angina meunting {see istration}. For batter asess fr sump removal, youll have to irset a large lever bar between the brace end the chassis to lever the tree down 8 On 18 lire gngines, unbolt and remove the black-to-transmission brace (gee ilustration). All engines: 8 Remove the bolts and detach the ol sump. TFs stuck, pry loose very carefully with 3 putty Ine (Gee lMustration). Dorit damage the mating surfaces of the sump and block for oil bakes could develop. Note: On UVT engines, aul) down the plestc cover sine’ inio the ‘either’ end oF the enpins book fo access the vafthand sume ‘ota (see sustration) 10 Uniolt the pick-up tubs/oil strainer assembly and remave f for cleaning. Discard the pick-up pipe gasket, @ new one must be Fitee Refitting 41 Use a scraper to remove all traces of le Gaskel material and sealant om the block and cl sump. Tale great care nc o gouge te matng curaces, Clean the malig surtaooe ‘hn brake econ “2 bao trp Ie threaded bok ales inthe Blocker dean, 13. Check the ol! sump fange fr distortion paculaty ardund the bot Noles. On too Sumps, i nevsstay, place he ol sump on a wwo0e black ang use 9 hammer te fatten and fectre the gach suracs 1 tnepect the ofl pump pickup. tube assonly tor crake anda Moceed san. the poleup was removed, dean i theroughly and instal t pew, using a new O-nng [rere WVT- engines) or gasket (WTA angnas) Tighen the r/o o he torque std in {ne Chapters Specifeabone, 48 Apply © 5 mm [approximately] wide bead of RIV zedlrt (ate sumps) of Taye Sealact No 08628-00080 [auminum sump) ‘phe sump flange (eee tlustrations). Note Fefitro rue te completed whe 8 ales nce fe sao hes tear aealad 18 Carataly postion tha a sump an the engine tock and instal the bots Working {fom tho corre ot. Tighton the bos tothe terguo listed nthe Chasters Speciteatone mn ths of ur steps 17 The remainder of refiting fs the reverse of removal be sure to ad ol and ene ol ferUse now geskelseais an the rent trast ipa Non VWTengras) 18. Run hw engine and chack for ol presatra and leneEngine in-car repair procedures 2A+19 13 Ol pump- removal, inspection S and rfiting 8 Removal Non-WVT4 engines 1 Rerave the ol aipstick, oll sump ah of pickuplsrainer assembly (see Section 12) 2 Remove the timing belt, ier pulley and benng, erankshat puloy, crankshat sprocket il pump body-to-black (202 Secon 5) and, on 1 ltr anignas, undo (arrowed) the nul end remove the ol pure sprocket. 3. Where fitted, remove te orankshatt postion 433 Remove the bol (errowed) ang withdraw the crankshaft postion sensor ‘rom the oll pump body sensor (see illustration). Unoot and remove 8 Presse Rugulator the ail pstick pipe. On 13 Ite engines, Vaan Tomoye the oil pressure retet vale from the B— Prison engine black. ‘Sing 4 Remove the bots and detach the oll pump ‘Tension Spring Bracket riven Rotor Ai Reaver 'bosy tram the engine (see illustration), You aa ore one =e may have to pry caretully between tha main Soap ing bearng cap end the pump body with 2 serewahiver, of tap behind the ell pump wath 2 safieaoed hammer On 1 Irs engines remave the O-ring, 5 Use 9 scraper to remove all traces of Sadat and old gaskot material arn the pump body and engine block, then clean the mating surfaces wth lacquer thinner or acetone. © Remave the twe Tar soreve (18 litre fengne] and separate the pump caver ram the body. Lit out the anve ancl diven rotnes (eee iMustraions), 7 Remove the oll pressure relist valve Grp (i Pump Body retsner, spring end pstan, Waring: The spring is tightly compressed - be careful and wear i Pen eee 1362 Oil pump components - 13 litre WTi engines, 8 Remove the timing chain as described in Sedtien 6 8 Undo the five bats and remove the oll pump trom the engina tleck (gee Mlustation}. 10 Uno the plug and remeve the pressure rele spring end piston (Se illustration) 11 Undo the3 scree remove the pump cover Lit out the pump olor (see illustration). Inspection 12 Clean all componsnts wth solent, inspect 13.9 Oil pump bots (errowed) 41366 Oil pump components = 16 litre ‘WTA engines2:20 Engine in-car repair procedures 1810 Oil pressure relief valve plug (arrowed) 48:11 Undo the three screws (arrowed) and remove the pump cover 13.44b Use a straightedge and fester gauges to measure the rtorto-cover clearance ‘hem for wear and damage. Use compressed arto blow through the cilways in the pump body. 13. Check the ol pressure rele valve piston sliding surface and vaive spring I eiher the spring or the piston is damaged, they must be renened as a set. The piston must Foe to ‘lida up and down the bore inthe pump body ‘thou binaing at ery pot 1 Check the driven rotorto-body clearance, fotor-lo-cover dearance and drive rotor tip clearance with a feoler gauge (eee lustrations) anc compere the resus to this Chaptor’s Specifcauons. if any clearance IG areasve, renew he rotors as a set IT necessary, renew the oll pump body. Refitting Non-WVT4 engines 15 Lubneate all rotors wth elaen engine ol Seal Diameter 2— 3mm (0.08 — 0.12 in.) 13:18 Apply a bead of sealant as shown “3 titre 1B.Ade Measure the roter tip clearance witha eer gauge - rotor marks (arowed) ‘and place them in the pump body with the marks facing in (1.3 lire engine) or cut (1.8 Ire fora} (S00 illustration 13.14), 18. Pack he pup cauity with poroboum jelly, attach the pump cover and tgrten tne screws: (18 ttre engine only. ‘7 Lubricate tno all prossure raat vave piston vat clean engine oll and reinstall the valve ‘amponents inthe pump body or enghs black 48 On 13 live engines, apply a bead of RTY sealant to the pump body (see Mustration) ‘and lncate 9 neve Oving in the body groove (On 18 lire enanss, place 2 now gasket on the engine blods tthe dowel pins shoud held it in lace) 1B Position the pump assombly against the black ang instal the maurting Bets On 18 tre engines, mave sure bet the fas onthe of pump tive olor ain withthe Rats on the crankshait (ee illustration) 13.18 Align the lats in the pump rotor with ‘the fats on the crankshaft 78.144. Measure the driven rotor-to-body 20 Tighten tne bolts to me torque listed In this Chapters Specifications in three or four steps. Follow a criss-cross pattern to avoid warping the body 21 The remainder af reessembly isa reversal of removal WTi engines 22 Lubrioate the pump rotors with dean engine ol, ane! place them in the pump tody with the mates facing the purnp Bady cover sid 23. Rel the pump Dody eover end tighten tne fetainng serows to the spect torque. 26 Refit the oll pressure relief piston snd Spring, than tighten the plug to the specified tone 25 Position a new gasket on the engine biock, then reft the oll pump. Ensure the flats fon the eve rotor aig wth tho fats machined fn the crankshaft, and tian the batts to the spocited torus (Se llustration), 28 Rell the timing chain ap described in Seaion 6 44 Oil pressure witch - renewal 4 Tho oil prassure switch is locatad on the Tort face ofthe engine block, atthe let-iend fend (4E-FE engine), right-hand ond [4AFE fengite), of above the ol ter (422-FE and SZ2FE engines) 2 Disconnect the wiring plug from the switch (see lustrations) | eT 13:28 Algn fe fate on he caveat wh Iieaatelstite pump wc1428 On 13 litre Non-VVT4 engi oll pressure switeh is located atthe left- hand end ofthe eylinger Block (arrowed) 2 Linscrae the sivtch fre the engine block Ee propated for al spillage 4 Prorto rotting, apply 4 ito Loctite Three Bond 1244 (or similar) to the threads of the swteh 5 Refit the switch and tighten it to the specified torque 6 Reconnect the wiring plug. 15 Flywheel/driveplate - removal and refiting HY, Removal 1 Remove the transmission as desorbed in CChepler 7A or 7, 2 Romovs the pressure plate and clutch dsc (Cherter 6) [marual transmission vehicles). 3 Use @ contre punch of paint to. make alignment marks an tha fywneovarwepiato ne crarksnaft to ensure soract alignment suing retiting (see Mustration). 4 Remove the bolts that secure tha ywhesvdnveplate fo the crankshat. Ifthe rankshafttums, wedge a screwdhiver in the ring gear tosth to jam the flywnosl, or use 4 tool ta lock the fyhaal in position (see Iustration) 5 Remove the fywheolfariveplate jrom the Crankshaft Since the fywhee is faily heavy, be sure to support it while removing the last bolt. Some automatic transmission equipped vehicles nave spacers on both sides of the ‘riveplcte (see illustration}. een them wath the divealate A Waming: The ring gear teeth may be sharp, wear gloves to protect Refitting yourhands 6 Clean te tyeneel to remove grease and oll Inspect the surface far eracke, nvat grooves, bumed arses and score meri. Light sconng can be removed with emery cloth. Chexk for cracked and broken ng gear teeth. Lay the fyheol on a flat surface and use a straight edge to check for namsege. 7 Cheen end inspect the mating surfeces of the fywneelttveplate and the crankshat. It Engine in-car repair procedures 2A+21 14.2 On 16 litre Non-VVT4 engines, the oll pressure switeh is atthe right-hand end of the evlindar biock (arrowed) the crankshaft sea is leaking, renave it tore reingaling the fywheelirveplete (see Seo- tien 16), 8 Poston the fyheelidnvepleta against the cranks. Be sure to align the marks made {during removal Nete that some engies have an algnment dowel or staggored bolt hobs to ensure correct rafting. Before instsling the bolts, apply tnread-locking compcund to the trea 9 Wedge @ srendhiver inthe ring gear teeth to keep the Mywhestarveplate fern turing {and tighten the bolts to the lorque listed in this Chapters Specifications. Folow 3 enss- ‘ross paltern and wark Up to the fal torque In three oc our steps 1 The remainder of retirg is the reverse of the removal procedure 16.3 Mark the fywheelrivepiate and the crankshaft so they can be reassembled in the same relative positions 185 On vehicles equipped with a spacer Plate, note the position ofthe locating pin (arrowed) 44.2¢ On WT engines, the oll pressure ‘Switch Is above the oll iter location 16 Main oil sect - renewal 4 Remove the fywhesliarivepia tion 15) 2 The seal can be renewed without removing the all sump or seal retainer. Cereuly prise out the old seal with a screwdriver (see Mustration}, Take arest care not to damage the seal bore othe surface ofthe crankshatt 3 Apply mutpurese grease tothe crankshatt Seal Journal and the lp of the nev seal and carefully push the nav seal inte place. The lia 's Sif so carfully work itonko tha saa joural brtha crankshamt Wifi a smaotn etyect he Pe 15.4 Lock the flywheel in place using a too! bolted to the engine block 162 Carefully prise out the old seal -take ‘great care notto damage the crankshaft2A+22 Engine in-car repair procedures 16338 Tap the oll seal into place using block of wood ‘nd ofan extension. then tap into place using a bieck chwacd (Gee Mlustrations). Dont rush Iter you may damage the seal 4 The remainder of refing & the reverse of removal 47 Engine mountings - a check and renewal x 41 Engine mountings seldom require atention, but brokan of datanorated mountings shoul be renewed immediately or the added strain placed en the dhvaline components. may aise damage or wear luntl the outer edge ofthe seal ‘lush with the engine block Check 2 During the cheok, the engine must be Taced siohty to remove the weiant ftom to rourtings 8 Rese te vehicle end support it securely on tle sien (se Jacking and vehi sypoan), then postion jack underthe engine ol sump Place @ large wood black belwaen the jack hed an the of sumo, then caretuly rasa the angie just enough fo take tne weight of the mountings, Do nt postion the 990d black Ungar the dan lu, Warning: DO NOT ptaceany partof ‘your body under the engine when Ite supported only by ajack. the mountings to see ifthe rubber Is cracked, narsanea or separated mom the metal petes. Sometimes the rubber ill spit night down the canta, 5 Check for relative movemert between the maunting plates and the engine or body (use 2 large Scrovtriver or pry Barto attempt to ‘mova the mourtings). i movement is noted, lower the engine end tighten the mounting fasteners 8 Rubber preservative should be applied to ‘he mountings to sew dteroreion Renewal 7 Rae the vehicle and support it sectrsly on te stands it ct areedy dene). Support the engine 8s deserted In paragraph 2, 8 To remove the nght engine mounting, Famave tha bo rus Tom uncemeeth, ane bolt from above, and tho upner section wil separate fom the engine braclat 8 Rermeve the mourting-to-chassis muts and ‘ietach the mountne, 10 To remove the fear engne mourting, pull the nutoer plugs fom the longitudinal chassis brace to access the two nuts 11 To remove the Font engine mounting, emo tha twa ns retaining tha instr 1 the longitudinal chassis race, then the three nuts retaning the insutorio the chassis 12 Retiting Is he reverse of removal. Use thread-locking compound on the maurting beltsiuts and be sure to tareen them seaurelChapter 2 Part B: 1 Engine removal and overhaul procedures Contents ‘Section number Craniahat = nepedton.s oun Engipoerhasl=rentaebly_ kaon ‘e Crankenat > ‘refing Engne rebutdng atemetves 5 Crankshaft - removal. Ie removal - methods and precautions. 3 hinder raed -eaning and ribadlen Genera norman . ee i Glinder heed dsassembly iil statap ater over 2 Cine head ° reassembly 10. Man and connecting rod boatngs-ispecion 7 Enmecremovalard wt Pion ages ting ts Endre block dering 13. Pitonefeonnecting rds" epecion ‘6 Enane tack nepectan 14 Pensconnestng rede reiting n Engi ovemaul-dsassorbly soquance @ Pitonatermestng rods removed it Engre crete paren! tele: 2 Makes = Serving... oa 3 Degrees of difficulty Easy, suitable for Fairly easy, suitable ©. | Fairty dficutt, SA | Difficult, suitable | Very ditfoutt, $ novice with litle for beginner with S| sutablfor competent X | for experienced DIY 3 | sultabe for export experience some experience S| DYmecharic S| mechanic BJ] dv orprotessional LS Specifications General Tete (1822 co) Non:VVTs engin see 1 tte (1998 ce) WT onan ase ‘Bl (981 co] NonvvTa eng tare Bite (5a ec) Wis ange SEEEE Cylinder head vagpage ts Block surface, 0.05 mm Manifold surfaces. 0.10. mm. Engine block Bek werpage ime as ran Gunde ore dometer nina ‘Sinedere erare 74.000 7403 arm altro aazre | “ongmno. Taoot 78019 mm Vite are engine 21001681 03m lire aZzFe engine 500 o P2.0te mm Valves and related components ano stom diameter Non-V¥T-iengines Intoke Eshoust wwTiongnes Intaie Exhaust vous spring Freelengh 3 lire dE FE: 1a ire AZZFE 1B lire ANTE 16 ire AZZ FE nine engine orgie 5.970 tn 5985 mm 5.995 t0.5:980 mm 470 t06.4865 mm ‘56S to 5.400 mm 390mm 4340 mm 38.57 mm 4340 mm2B+2. Engine removal and overhaul procedures Crankshaft (Crankshaft endfoet ‘Standard 413 le 4E-FE engne, 14 ire 422-FE engine 16 livre 48-F= engine 16 lire 322-FE engine Service lim... “Thrust washer thickness 113 fire 4E-FE engine, 44 fe 422-FE engine, 18 tre 4A-FE engine 16 ive 222-FE engine. Pistons and rings Piston diameter: “13 le 4E-FE engine 14 ire 4Z2-FE engine (at 28.8 mn fam the Piston clown), 46 fire 4A.FE engine, 16 fire 3Z2-FE engine (ot 238 mm from the piston crown... Piston ring end gen 18 He 4E-FE engine No 1 (op) compression rina, No 2 (mie) compression ring ol ring “ 14 re 422°FE engine No 1 (op) compression ring Ne 2 ie) compression a. Olring:... 1Biitre 4&7 engine: No 1 (top) compression ring No 2 (mide) comeression rina. ol ring. ‘Bitre SZZ.FE engne: No 1 (tap) compression ring. No 2 (middle) compression ring. ol rng Torque wrench settings Refer to Part A for torque specifications. Information Included in his portion of Chapter 2 are the general overhaul procedures for the cyinder head and internal engine components ‘The Information ranges trom advice ‘concerning preparation for en overhaul and the purchase of new parts to detailed, ste by-step procedures covering removal and installation of internal engine components and the inspection of parts “ne following Sections have been writen ed on the assumption that the engine has been removed ftom the vehicle. For information concerning in-vehicle engne repair, 2s well as removal and instalation of the external components necessary forthe ‘overhaul, see Chapter 2A and Section 8 of this Chapter ‘The Specifications included in this Pat are ‘only those necessary forthe inspection and fvernaul procedures which fellow. Refer to Part A or addtional Specifications. 10.02 to.020 mm 1006 t0.024 mm 1002 to.022 mm 0.04 t0 0.24 men 0:30 mm 2.440 t0 2490 mm = 2430 to 2480 mm ‘2.440 10 2.490 mm 12420 to 2.480 mm 17386910 73.889 mm 78817 to 78.927 mem '30.805 to 80935 mm 78.955 10 78 865 mm Standard = 028 10 0.26 mm Dat to051 mm 1913 16 038 mm 902 t0.007 mm (908 to 007 tren 04 0.12 mm 9.25 0 045 mm 19.35 0 060 mn 0.40 10050mm 1002 to 0.07 mm £103 t0 0.07 mm 10.08 to 0.12 mm 2 Engine overhaul - general information it wath 4 Its not abvays easy to determine when, or 4. an engine shuld be completly overhauled, £285 a number of factors must be consicered 2 High mileage fs not necessatly an indication that an overhaul is needed, while low mileage does not preclude the need for an. overhaul Frequency of servicng is probably the most Important consideration. An engine which has had reauarand frequent oll and fiter changes, 28 wel as oter required maintenance, should ‘ive many thousands of kilometers of reliable ‘Service. Conversely, a neglected engine may require an overhaul very ear in sie. 23 Excessive oil consumption is an indlction that piston rings, valve seals andlor valve ‘guides are in need of attention, Make sure that Gl leaks are not responsible before decising thatthe rings andior guides are worn. Perfo 2 compression test, as described In Part A of this Chapter, to determine the Ikely cause of the problem, ‘Service limit 085 mm 440 mm 0.98 mm 4105 mmm 4120 mm 105 mm 195 mm 4120 mm 440 mm 4.05 mm 4120 mm 105 am 4 Check the ai pressure with @ gauge fitted in place ofthe ol pressure switen, and compare ‘Specified. If tis extremely tow, the main and big-end bearings, andlor the ol ump, are probably worn cut 5 Loss of power, rough running, knocking metalic engine noises, excessive valve gear nose, end high fuel consumption may also point to the need for an overhaul, especialy If they are all present at the seme time. If 4 complete service does not remedy the Situation, major mechanical work isthe only solution. 5 A full engte overhaul Involves restoring all intemal parts to the speciication of a New engine. During @ complete overhaul, the Pistons and the piston nngs are renewed, and the cylinder bores are reconditioned. New main and big-end beavings ae generally fite: if necessary, the crankshaR may be reground. to compensate for wear in the joumals. The valves ere also serviced as wel, since they are usually in lessthan-pertect condtlon a this point Always pay careful attention to the conation othe ol pump when overhauling he ‘engine, and renew itifthece is any doubt as toits sovioesbilty. The ond result should be an 2e-nav enanee that will give many troubia-e@ isiometers 7 Critical cooling system components such as the hoses, thermastat and water pump should be rengyed whan an engine is overhauled ‘The radiator should be checked caranly, 10 ensure that tis rot clogged orleaking. Also it Ia good idea o ranan tna. purrp xhanever the engine is overhavied 8 Before beainning the enaine overnaul, road through the entire procedure, to tamilarise yourself with the scope and requrements of ‘he oe. Overhauling an engi is not eel Ifyou follow caretlly al ofthe instructions, have the neoessary tools and equipment, and ay close attention to al epecicetions. I can, however, be time-consuming. Plan on the car being off the read for a minimum of twa ‘waeks, especialy if parts rmust be taken to er fengneenng werks for repair of reconcitioning Check on tho availabilty of parts and make sure that any necessary special tools ana ‘equipment are abtained in advance. Most work an be done with typieal hend tools, athouan {number of precision measuring tools are Fequited for inspecting parts to determine if they must be renewed. Often the enginesnng works wll handle the inspection of pats ants offer advice conceming reconditioning and renenal 9 Always walt Until tha engine nes been completely dismantled, and until all componerts [especialy tha cyinder block? frankcase and the crarkshatt} have been inspected, before deciding what service and ropait operations muct ba performed by an angnesnrg works. ‘The condition of these components wll te the major factor to eansidar whan determining whelher to ovethaul the original engine, o to. buy @ reconditioned uni. Do not, therefore, purcnase parts or have overhaul work done on other components until they have been thoroughly nspected. As 9 general rule, time isthe primary cost of an overhaul, so t does ret pay to ftSuom ar sub-standard parts 10 As @ final nole, to ensure maximum Wie ‘and mirimum trouble from @ recancitioned engine, everything must be assembled wath cafe, n a spotlassiyciean environment 3. Engine removal - methods and precautions 4 Ifyou have desidad thet the engine must be removed for overhaul er majr repair nor, several preliminary steps should be taken, 2 Locating a suitable place to work i6 ‘stemaly Important. Adequeta werk space along with storage space for the car, wil he niveded. If a workshop or gerage 1S not salable, al the very least, a fa, level, lean ‘work surtace is required 8 Cleaning the enane compariment and fenginefransmission before Beginning the Engine removal and overhaul procedures 28-3 removal procaaure vl help keep taols clan end organised An engine hoist or A-frame will aso. be necessary. Miaka sure the equprnent 6 rated In e102ss of he welgnt of he engine. Satety is of primary Importance, considering the potential hezares involved nh litingthe engine? Transmission out of he oar 5 Ifthis is the fist ume you have removed fan engina, en assistant should weally be avaiable, Advice and ald from someone more fexpenenoed would also be helptl, There are many instances when ane parson cannot simultaneously perferm all ofthe operations Fequired when liting the engine cut of the vehi 6 Plan the operation ahead of time, Before starting work, arange forthe fire of or tain ail ofthe tools anc equipment you will need Same ofthe equipment nooassary to perform enginetransmssion removal sha instaliston Safely and vith relabve ease gr adcibon to an engine hoist} is a Fellowes 2 heavy cy trelag Jack, complete sets of spanners and sockets (s00 Tools and working faoties), wooden blocks, and plenty ofrags and cleaning solvent for mogping-up spiled al, coolant and tue. If the heist must 2 ried, maka sura that you arrange fer it im aevenca, and perform all of the operations possible witut it beforenend. This wil save you money and time. 7 lan forthe car to be out of use for quite @ while, An engineering orks willbe required ta perform some of the wark which the do itryourselter eannet accomplish without ‘special equipment. Thase plaoas eten have f busy schedule, so twauld be a good idee to carsut them before removing the engine, in order to accurately estimate the amount of Ime raquited fa rebuild or rapar eemponanis, thal may need work, 8 Alveays ba edramaly caratulihen removing ‘and refting the enginefransmission. Serious injury can result fem careless actions. Plan ahead and take yourtime, and a job of this nature, athough majer, can be accomplished successfully Note: Such is the complexity of the power unit arrangement on these vehicles, and the variations that may be encountered according to model and optional equiament fitted, thet the following should be regarded as aguideto 4 Label both ends of each wire and hose before disconnecting it the work iweved, rotor tam 2 siao-ty-stm recede. Where differences are encourered, ‘or axiaions! component alaconnection or (removal necessary, make noes of te work Irvoled as an aid fo retftng. 4 Engine - x removal and refitting Note: Asad thowmh tie enire Secon zefore baginnng Bis procedure The factory recommends removing the engine and frarsmission form the top es a unit then separating the engine trom te vansmisson 00 the werkanap Noor ff the Wanamisaan Js not Doig seniced, it posailo to ave the ansmpoien in the vehioke and remove the fenane fom the feo by isle by removing the Crankshaft auley and ting ep te timing belt ‘hain and of tho engine for olearance Warning: These models are ‘equipped with airbags. The airbag 1s ermed and can deploy (nate) anytime the battery is connected, To prevent accidental deployment (ard possible injury), tum the ignition key to LOCK and disconnect the negative bettery cable whenever working near airbag components. After the battery is disconnected, wat at least two minutes before beginning work (the system hes @ backup capacitor that must fully ‘ischarge). For more information see Chopter 12, Removal || Relieve the fuel system pressure (see pier 4A) 2 Remove the ballay as described in Chap ter 54, ten lt out ihe plastic batry ray 3 Remove the bomnet as desenbac! in Chap. ters 4 Remove the air cleaner assembly (see Chepier 44) 5 Raise the vehicle ard support it securely fon ake ctands. Drain the cooling system ard engine ol! and remove the drivebelts (see Chepter 1) 8 early label, then disconnect, all vacuum lines, eealant and emissions hoses, wiring ames connectors, earth straps and fos! lines. Masking tepe endfor @ touch up paint applicator work well for marking toms (s lustration). Take photos or sisteh tne locations of components end brackets T Remove the vindsotoen washer tank and ‘aclant rasenvir tank 8 Remove the cooling Saris) and radiator (see Chapter} © Disconnect the neater noses. 10 Release the residual fuel pressure in the tank by removing the fuel tani cep, then Catach the ful lines connecting the engine the chassis. Plug or cap all open tings. 11 Disconnect the accelerator cable, trengmission Thratie Valva (7) linkege end2B+4 Engine removal and overhaul procedures speed control cable, if equipped, from the engi 12 Refer Chaptor 48 and remove the intako ‘and exhaust marifolds 13 On power stearing-equipped vehicle, Uunbolt me power steoring pump. It clearance allonis, te the pump aside ythout discomectng he hases. Hrecessary, remave the pump (see Chapter 10} 4 On air conditioned models, unbolt the compressor and set & aside. Do not Aisconnect ihe remigarent hoses. Note: Dov7t Jet the comaressor hang an the hoses 15 Attach a Ing sing tothe engine. Position a hoist and connect the sing toi Take up the Slade until there Is slight tension onthe heist 6 Reter to Chapter 8 and remove tt vesnans, 57 Remove the awilary divebet(s), overt pump pulley and crankshaft puley 48-On automatic. ransmission-equipped models, pry cut the plastic toroue converter ust shield from the lower eallhousing, Remove the torque cenverterto-arveplate fasteners (se Chapter 78) and push the ‘canverter back slightly int the belinousing 49 Ramovo tho engino-o-transmission bots and separate the engine trom tne transmission (cao Chapter 74 or 7B}. Tho torque convertor Should erain ta tha transmission Nate: if the transmission is tobe removed at the same time, the tse engine mounting shouts bo removed, along wll any weres, cables or fooes conected to the tranamisson. The ‘engine-to-vansmssion ots should remain #9 place atthe tine 20 Recheck to be sure nothing except the ‘maurtings are stil connecting the engine ta the vehiclaorta the transmission Disconnact ind label arying stil remeining 21. Support the transmission with 2 traley Jao Place a blook of woad on the jaok head to prevent damage to the tens ssion Remove tne balts Fam the engina mountings, leaving those attached fo the Iransmissicn in place Waming: Do not place any part fof your body under the engine/ transmission when its supported only by @ holst or otheriiting device. 22 Slowly lit the engine (er engine’ transmission) out of the vehicle (gee llustration). It may be necossary 10 lover the 422 LiNthe engine out ofthe vehicle mountings away trom the frame brackets Note: When removing the engine from a menial irensmissiomequipoed vehicle snd the transmesion &s ta romain f the vehice, you may have 10 use the Jack sypcoring the anamegan to ut ibe tensmesion arash fo alow te engine fo be angled cut of te etic. 28 Move the engine away from the vehicle {and carofuly lower the hoist unti the engine fn be sel on the oer arramave be fysheels stiveplate and mourt the engine on an engine Stand. Note: D4 aufomate ranameson- equipped models, mark the frat and rear spacer plates (where Blted) and becp ther ih ine drveoire Refitting 24 Checkthe enginefransmission mountings Ittheyre wom ardamaged, ren them 25 On manual. transmission-equipped models, inspect the cluten components (s9e Chapter 8) and on automatic madals inspect the converter seal and bushing 25 On aulomatle. transmissian-aquipped Tmades, apply 8 deb of gmese to the nese of the converter 27 Cersiuly guide the transmission into place, following the procedure outlined in (Chapter 7A 0 7B. Caution: Do not use the bolts to force the ‘engine and tranemiseion into alignment. They may crack or damage major components. 26 Install the engine-to-rensmission bolts ‘ana tighten inem fhe torque listed in the CChepter 7A or 78 Spociestors 28 Attach the hoistto the engine and carefuly lower the enginestransmission assembly into the engine compartment. Note: 1 fre engine vas rerraved with the varsrmssion remelting In the cay, sone the engine nie the car unt ‘an assistant oan tole you lie up the dowel ins.on the blockwith the Bansmssion Some twisting ant anging of te engine endor the trnamsion wil be necessary 1 Secure proper atignreant of the #90 20 Install the mounting bolts and tighten them securely 31 Reinstal the remaining components and {asterars inthe raverce order of removal 32 Add coclant, oll, pwersteenng snaitrans- mission ics as needed (see Charter 1) 33 Run the engine and check for proper ‘operation and leaks, Shut off he engine and recheck the fia lvls 5 Engine rebuilding alternatives The doit-yourselter Is faced with o number of options when. perlerming an engine ‘overhaul. The decision fo renew the engine black, piston/cannectina red assemblies and crankshelt depends on a number of factors, vith the rumber one consideration being the ‘condition of the block. Otrer considerations fara ost, aooass lo machine shop faaiiies parts availabilty, time requred to complete the project and the estar of prior mechanical ‘expenencs on the part ofthe dost-yourseler ‘Some ofthe rebuiling atemetves include: Individual parts IFthe inspection procedures reveal thatthe engine block end most engine components er= in re-usable condition, purcnasing indivicual parts may be the most economical atamatve. The boos, crankshaft and pistoniconnecting rad assemblies should al be inspected carefully. Even ifthe black shows Ile weer, the cyinder bores shoud be surtace honed ‘Short engine A short engine consists of en engine block with a crankshaft and pisteniconnactng rod assemblies shoady rstaled All rev bearings 210 Inoorporstect and all clearancas wil bo correct. The existing camshafts, velve tran components, ofinder head and exlemal pets, tan be bolted to the short engine with litle or ro machne shop work necessary Reconditioned engine A recenditioned engine usually consists of short engin plus a cil pup. ll pan, exinder head, valve cover, camshatl and valve train components, uming sprockets and timing Dot covers. All components are installed wth ray beenngs, sats aid gaskets incorporated throughout. The installation of maritoles ard ‘taal parts al that's necessary ‘Siva caretul tought to whieh altemative Is best for you and discuss the stuation wh local automotive mactine shops, auto parts dealers end experienced rebullders before fordenng or purchasing new parts. 6 Engine overhaul - disassembly sequence 4 It's much easier to disassemble and work tn the engine if it's mounted on @ portable engine stand. stand can often be rented Quite cheaply trom en equipment rental yara Bofore the engine is mounted on a stand, the ‘yheeliarveplate and ail sea retainer should be remavad from the engine 2 Ifa stand isnt avaiable, its possible to ‘isassemble the angina with it blocked up on the foor. Be extra care rot totip or drop the engine when working without a stand 2 It youre going to obtain a reconditioned engine, al extemal components rust come of fist, to bo transfered to the new enaine, Just 28 they will if youre doing a complete lenge overnau urself Those iniude ‘iterator and brachets Emiseers conral components Thermostat and housing cover Water euma and remaining cooing gystert componsnis55) components Infekotexnaust maniots, outer, Enyine mcuetiogs eres and Sywhecttinvepiae Enyine enipsie. Note: Wuhan mowing tre externalcomponents rom te engine, pay cbse atte elas that may be helatul oF i ‘uring instaleton Hote the instaled postion of gastels, sas, spacers, prs brackals wwadhers, bots and other smal tems. 4 If yau'te obtaining a short engine, which consists of the engine block, erankshat, pistons and connacting rods ail assembled, Then tne ewinder heed, oll sump and oll pum wall hava lo be removed a6 well from your enghe. 580 Engine rbuing afternatves for ‘deitional information reaercing the siferent possiaiities to be cansigeres 5 I'you'e planning a complete ovemaus, m3 ‘engine must ba eisassemblac and tho intemal amonents removed in ths following order Intaia and exhaust mantols Crrinder head cover. Tian belo covers Tieng nettichain and sevockets, Cysineler hood Ov sume, 8 pump Pistonteonsecting rod assembies Cranlonartoriovalrataner Cranthatt and main searings 7 Oylinder head - R disassembly x § 41 Cifnder head disassembly ineaives removal ofthe inlake and exhaust valves and related components. Es assumed thet the rockers! followers and camshats have already been removed (see Pata ss needed) 2 Botore the valves are removed, arrange to label and store them, along with ther related Components, 0 they can be kept separate fand reinstaléd inthe same valve guides they frsreraved tom (see illustration). $8 Compress the springs an the tet valve with @ spring eampressor ane remove the ealets (gee Mlustration). Cerotully release tho wave spring compressor and remove the retaner, the spnng and the spong seet (fuses) Cautlon: Be very caretul not 10 nick or otherwise damage the follower bores when ‘compressing the valve springs. 4 Pul ha vale out oftha had, han remove tne oi seal from the guide. lithe yale binds inthe guide (won't pul trough), push it back into the head and debur the araa around the beeper groove witha fine fle or whetstone. '5 Repeat the procedure for the remaining Valves, Remerter to Keep all the parts ter teach valve together sa they can be rainstaled Inthe sere locations 5 Ones tne yaives and related camponenis have been remaved ana steredin an organises Engine removal and overhaul procedures 2B-5 72 A small plastic bag, with an ‘appropriate label, can be usedto store the valve components manner, the head should be thoroughly teaned'and inspected. Ir complete enna ‘verhaul is being done, finish the engine Aisassembly procedures before begining the cylinder head cleaning and inspection process 8 Cylinder head - leening and inspection 8 1 Thorcugh eleaning ofthe evinder head ard releted vale ran components, follwied bya dolated inspecticn, will anatie you to decide how much valve service work must be dons sling he engine overhaul Nete: #zhe engine as seievely ovameata, the ein has Broth warped (eee paragraph 12) Cleaning 2 Serapa all tracas of old gasket material land sealing compound aff the head gasket, intake manifold and exhaust marvel seaing surlaces. Be very caren rit to gouge tne ‘liner head. Special gasket removal soivents that soften gaskets and make remaval much fsasor are avaiable al aLfamative acseasery parts retsiers 3 Remove all uilkup scale fom the exatant passages. 4 Run a stiff wire brush through the various holes to remove deposits that may have formad in tham. If there ara heavy aust ‘deposits in the water passages, the bare hese ‘should ba professional cloaned. '5 Run an appropnietste tap irta each othe threaded holesto remove corrasion and throsd sedentthat maybe present. Itcompressed ar |g avalabie, usa ito dear the helbe of debris produced by this operation Waming: Wear eye protection when using compressed ai. 6 Clean the exhaust end intake manifold stud ‘reeds wih awire brush, 7 Cloan tha eyinder head wth selvartand dry itthereughiy. Compressed airwill speed the fying process and ensure that all cies and recessed ereas are clean, Note: Decartomsing ctomeas are avaiable and may erove very Lsetutwton clearing oyinter heads and valve 7.3 Compress the spring untl the colletz ‘can be removed wth a small magnetic ‘screwdriver of thin-nosed pliers ain component. They are very cays and ‘should b2 weed with caution. Be Sure f follow the instuctons on the container 8 Cleon the falawers with solvent and ny them thoroughly, Camaressed air will speed the drying process and can be used to clean ‘outthe oll pesseges. Dont mix them up durng the clesnina process; keep them in 8 Box wth rhumbered compartments 9 Clean all the valve springs, spring sects, Colles nd retainers wth soWvert end drythem thorouahy. Work onthe companents irom one vale at ame to evale ming up tha pars 0 Serape of any heavy deposits that ray heve formed en the valves, then use a ‘rotonsed wire bruch to remove degosts from the valve heads snd stems. Again, make sure the valves centt got moced up Inspection Note: 82 sxe to pottorm al ofthe folowing Inspection procedures before conctuding thet machine shop workss 1oquied Mako 2 ft of the ems hat need aifenton. The inspection procedures for the folowers asd camshats (ca bm foun in Part (Cylinder head 11 Inspect tha had very caratuly for cracks, exidence of coolant Isakage and other ‘damage. If cracks are found, check with an fulomotive machine workshop ecneemng repair. I repr isnt posite, 3 nev eyinder head should be ottamnea 1D Using a straight-adge and flor gauge, check the head gesket meting surface for ‘warpege (see illustration). Ifthe warnage 8.12 Check the oylinder head gasket surface for werpage by tying to slip a Teeler gauge uncer the straight-edge2B+6 Engine removal and overhaul procedures ‘8.7 Measure the free length of each valve ‘spring ‘exooeds the limit found in this Chapters Specineations, it can be resurtaced st an futomotive machining workshop. 18 Examine the valve sects in each of the cambustian chambers. if they'ra iad, cracked er burned, the head vil require valve sevice thas beyond the scope ofthe home macnanie 14 I in any daubt as to the condition of the cvinder head, have it inspected by an automotive engine overhaul specialist Valves 15 Caretully inspect each valve face for Lnevan weer, deformation, cracks, pls and bumed areas. Check the valve ‘stem for scuffing and caling and the neck for cracks. Roles the valve and cheek for any obvious Indicaticn that ies bent Look fer pits and ‘excessive Wear on the end of the stem. The presence of any ofthese eonudions Indicates the reed for vale service by an automative rmacnine shop 46 fin any doubt asto the condtion of the valves, Fave them inspected by an automotive fergie overhaul specialist, Valve components {7 Check each vale spring for wear (on the ends} and pits. Measure the tee length and compare it to this Chapters Specifcations (see llustration), any springs that ere snorer than speciad have sagged and shauld ral be reused 18 Stand eech spring on eck it for squaronoss (et ‘it surface and 103 Tap the valve stem seals (arrowed) Into place with a deep socket and hammer {618 Check each valve spring for ‘squareness ary of the springs are distorted or sagged, anaes al atthe 418 Cheok the spring seets and oolets for obviaus Wear and cracks. Any questionable parts should ba renewed, as extensive damage will cccur if they fall during engine operation 20 Any damaged or 6 nut ba renews, 21 Irine inspection process indicates that the valve components are in generally poor Cendtion and worn beyondthe mis spectod, ‘ich is usually the case in an engine that's bong overnaulad, reassomrble tne vaivos in the oyinder head ‘ard refer to Section 9 for vale servicing recommendations sively wom pats 9 Valves - ‘ servicing ‘ 1 Because of he complex nature ofthe job and the spacial tools and equipment needed, Saving ofthe valves, te valva seats and te Yalve quces, commieniy known 26 vel should ba dene by a professional 2 The heme mechanic cen remove and ‘sasserile the head, do the ral ceering and inspaction, thon reassombia and deliver t a7 automotive engine evemaul spedaist for tre ‘ctual service work, Daing the inspection wil ‘alo yau to ses what condition tha hoad and vaive ain componerts ae in andvill rsure that sou kre inst werk nd nae pris are reared wen deaing wth the avernau! spacial, 406 The small valve stom collets are aslerto position when costed with grease 3 The engine overnaul specialist will remove tho vals and springs, tezondition or onan the valves and valve Seats, raconaition the valve guides, check and renew the vabe springs, spring retsiners and collets (as nacessaty), renew the valve seals, reassemble the valve components and mai sure the installed spring haigh is comect. Tho eyindor head gasket surtace wll so Ne resurTaced it itswerped 4 After ine valve job has been perfommed by 4 professional, the nead will be In Ike ne Condition. Ywhen the head is retumed, be sure to clean it again before installation on the enane fo remove any metal parties ani Abrasive grt thet may stil be present fram the vale service or head recurianng gperaiens Use compressed ai, if available, fo blow aut alte oll holes and passages, 1 Regardless of whether or not the head ‘yas Sent fer reconditioning, make sure it's loan before beginning reassembly. Note thf there ara several smal cara plugs in the head. These should be renewed nhenever the engine is overhauled or the cylinder head Is recondtioned (see Section 13 for renowal procedure). 2 Ifthe head was sent out forvava servicing, the valves and related components wil already bein place. 5 Insta new esate on aach ofthe vaive guides. Dn Non-¥VT4 engines (4=-FE and 4AFE) the Intake seat lp = grey ard ths exhaust seat io is black, whist on WT4 engines 422-FE and SZZ-FE} the intake coal tody is grey and the fexhaust seal hod is black Note: inte and exhaustvainesroquiediferentseats-D0 KOT ‘mux thera yp. Gerlly tap each irae valve sea into place untl ifs seated on the guide ( Tlustration), Cautfon: Don't hammer on the valve seals once they're seated or you may damage them. Don't twist or cack the eeals during installation or they won't seat properly on the vaive stems. 4 Boginning at ona and ofthe head, lubricate {and instal ihe trst valve. Apply dean engins Gil tothe valve stom 55 Crop the spring sect or shins) over the valve guide and se the valve spring and retanerin place 15 Compress the springs wih a valve spring ‘compressor and carefully instal the collets Inthe upper groove, than slowly rélaase tha comprasser and make sure the collets seat ptoperiy. Apply @ sal dab of greasoto each fall to hold Hw place if necessary (see IMustrtion). T Repeat the procedure for the remaining valves. Be sure to retum the components to their original locations - don't moc them up 410 Cylinder head reassembly‘111 Aridge reamer is required to remove the ridge from the top of each cylinder ‘11 Pistonsiconnectingrods + removal Note: Priar to removing tha pistor/connacting rod asembtes, remove the cylnder frat, the of sump and the of pump pickin tobe by refering © ie anoropnate Sections in Chapter 24 1 Use your ngsmal ofl edge has famed atthe upper limit of rng travel [about 8 mm ‘down fom the top of each cylinder) carbon lleposts or evineerwear nave produced ridges, they must be completely removed with a specel too (see lustraton}. Foi the mnucturers instnictons provided withthe tool. Fai to remove the ridges before stomping io remove the pstonvcomecting rod assembles mayresut inpiston damage 2atter the cylinder ridges have been Femoved, tur the engine upside-down so ine srankshat is facing up 3 Check the connecting rods and caps for idertifeation marke. 11 they arent plainly marked, Lee a small cenbe punch to make the ‘appropriate number of indentations on each rod and cap (1. 2, 3, ote, depending on the engine tyne and cylinder theyre associeted vith) (Gee llustration). 4 Logsen each of the connecting rod cap russteolls V2ium ef atime unt thay oan be removed by hand. Remove the number one Connecting rod cap and bearing shell Dent rep the bearing shell cut of the cap 5 Slip a shor lonath of plastic or rubber hose ‘over each connecting rod cap balt (where ‘epplicable) to grotect the crankshaft jeumal fad cylinder wall 95 the piston is removed (see illustration). © Remove the bearing shell ancl push the connecting rodipiston assernbly cut through the top ofthe engine, Use acooden hammer handle to push on the upper bearing surace inthe connecting red. It resistanca is fal ‘oubie-ohae to make sure that all of Ihe ridge wes removed from the cylinder. 7 Repeat the procedure for the. remaining cylinders. Note: Turn the rankanart as needed to put the sod fo be removed close to paral! th the cyinder hove, 1, don't ty fo ave cutwhie at large angie othe bore. Engine removal and overhaul procedures 2B+7 S 143 Donotconfuse these markings as rod numbers they re bearing size Identfieations 8 Alar removal, reassemble the connecting rod caps and bearing shells in their respactve Connecting rods and install the cap nufsibolts fingortont. Leaving tho old beanng shells in labs untt reassembly vel nelp prevent the connecting rod beenng surfaces from berg tccidentaly nicked or gouged 2 Dont seperate the pistons rom the ‘connecting rods [see Sacton 15 for econ information] 12 Crankshaft - removal x 8 Note: rhe orankanatioan ba rmavedeni ater the engine has been remaved rn the values (fs assuied nat the Sywheet or daveptete, crankehatt sprocket, ting belotain, al ump, olf ck-up tube, oi pump and oston/ onrecing rod acoemblies have abeady bean ‘emaved. The main ol seatand housing (where pplogble) mist be removed from tre hisok ‘before proceeding wi crankshaft removat 41 Before the crankshaft is removed, check the endfiost. Mount a dial incicater with the stem in ina with the crankshaft throws (see IMustration). 2 Push the cranishat fully ene way and zero the dial indicator. Next, ever the cranksha the other way as fer as possible and check the reading on the dal inccater. The distance that ft moves 1 the endfoet, if fs orecter than specifiad, check the crankshat thrust surfaces for weer. Ifno Weer is evident, naw thrustrashers should cerrect the endfost 116 Slip sections of hose over the rod bolts before removing the pistons. 3 Ifa dial indicator isn't available, feslor ‘Deuges can be used. Gently pry of push the Crankshatt fully one way. Slip feeler gouges between tho cranisha and the face of the ‘umber 3 qnnust} main bearing te datermina the elaerance (see ilustation). Non-WT-i engines 4 Chock the main bearing caps to see it they're marked to indicate their locations They should be numbered consecutively from tha night oftha angine to the lek It ‘ney areit, mark tem with a centre punch Main beating caps generally have a oast-in ‘arts, which paints tothe nat ofthe enaine. Loessn the main beanng cap bots 1-tumn at a time each, in the reverse order of the Fecammended tightening sequence (see Ilustration 20.9), ure thoy can be rameved byneng 5 Gently tap the caps with a sof-fave hammer, then separate them fram the engine Diack. Innecessary, use the bolts as levers to remove the caps. Try not to drop the bearing shels ifthey come outwith the caps. WF-i engines 8 Working is the reverse of the tightening sequence (see llustration 20.12), oradully fend evenly secksn and remove the bolts ‘securing the main beanng laderto the engine block 7 Uso a flatbladed scramctiver to gently prise ie man beeing ladger ftom the engine block, atthe castin lovarage parts, Encure the loner bearing shells slay in ther orignal poahions he bacnng leader dial indicator.2B+8 Engine removal and overhaul procedures the core pluge sideways in their bores All engines 28 Careful itthe crankshoft cut of he engine E may be a good! idoa to have an assistant valable, since the orankshert is que neck {With the beanng shells 1 place in the engine lock and main bearing caps or cap assembly, retum the cans to thei respecte locations on ‘he engine block and tighten the belts inger ‘ght 18. Engine block - desning WhE Caution: The core plugs may be dificult for impossible to retrieve if theyre driven completely into the block coolant passages. "| Usha the turk end of @ punch, tap in on the outer edge of the core plug to tum the plug sideways the bore. Then usr pls, pul the oore plug from the engine block (see Mustrations), 2 Using agashat sereper, remove all traces ot ‘eck materia rom the engine block. Be vory Careful not f nick ar gouge the geal secing suriaces, 2-Remove the main beeing caps er oap ‘assombly and separate the bearing shells from the caps and the engine block. Tag the bearings, indeating which oylinder they wera removed from and whether they ware in the tperthe block, then set them aside 4 Remove all ofthe threaded all galery lugs from the block. The plugs are usually very light - they may heve to be dnlled out and 188 All bolt holes inthe block should be cleaned and restored with atep, 419.1b Pul the core plugs from the block ‘with pliers the holes retapped. Use now plugs when the fenghe is reassembieg 5 Ifthe enane is extromely diy, should be steam cleaned B ater the block is retuned, clean all al heles arc ol galeries one mere me. Brushes spectically dasianed for this purpose aro valve a most aitometn accessory relates Fish the pesseges with ».am water unl the ‘watar runs clear, dy the block thorcughiy and vine all machred surfaces with a light, rust prevenivecol. Myouhave accessto compressed 2a, use it to speed the drying process and to law our el the al has ana gatieres Waming: Wear eye protection when using compressed air. 7 tthe block isnt extremely aity or sludges Up, you can do an adequate daring jab with hot Soapy water and a sif brush, Take plenty of time and de a thorough jab. Regardess of ‘he cleaning method used, be sure to cian allo heles and galeries very thoroughly, ory tne block completely and cost all machinect surfaoes‘uih ight al 8 The threaded holes in the block must be lean to ensure acourate torque readings fring reassembly. Run tha proper size tep ra ach ofthe holes fo remove rust, carrasion, thread secant or sludge and restore damaged treads (gee illustration) (7 possible. use compressed air ta clear the holes of debris procuced by this operation. Now is 2 good lime to clean the Gweads on the head bells and the mah bearing can bolts as well 8 Renstal the main beanng caps and tanten the bolts finger tight Aas 18.40 A large socket can be used to drive ‘the new core plugs into the bores 11 Atle coating the seating surfaces of the ‘new core plugs with sealant, instal them in tne angine block (gee Hlustration), Mako sure theyre ariven in straight and seated properly oF leakage cauld rasult Special taols are avaiable fortis purpose, but 2 large socket vith en outside diameter thet wil ust sip into the core plug, 2 122inch ctive extension and ‘a nemmer wil work st as wl 11 Apply ronhardening seslent to the now cil gallery plugs and thread them into the hales inthe block, Make sure heya boftaned securely 12. the ergine ist going to be reassembled nant avay, cover itwith ¢ large plastic 03g to aep itoloan ‘44 Engine block - x inspection x 8 1 Before the block ie inspected, it should be leaned as descrined in Section 13 2 Visually check the block for cracks, rust land oorrasian. Look for singed traces in the threaded oles. W's alsa a good idea to have the block checked for hidgen cracks by an engne ovemaul specialist that has ta equipment to do ths type of work, especially ifthe venice had a nistory of overheating or sing coolant. If dafects are found, have the block repaired, ifpossible, or renewed 3 It in any doubt as to fe conation of the ‘uinder block, have it inspected and measured by an angine reeandtening specalet It ihe bores are wom or damaged, they wll be able te carry out any necessary reboring, and supply appropiate oversized pistons, ete 45 Pistons/connecting rods = ingpection s 1 Botor® the inspection process canbe carned out, the pistonfconnecting rod ‘assemblies must be cleaned and tne ergial piston nnge removed Fom the pistons. Note: Always use new piston ngs when fre engine ‘sveascembted 2 Carefully expend the old rings over the lop of the pistons. The use of two oF thos 162 Use old feeler gauge blades to ‘carefully expand the plston rings