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Subject: Toyota 4A-F, 5A-5F, 7A-FE-Guide to repair and maintenance.


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    Toyota 4A-F, 5A-5F, 7A-FE-Guide to repair and maintenance.    




    ENGINES Toyota 4A-F, 5A-5F, 7A-FE-user guide/instruction on repair, maintenance and operation.
    Repair manual carburetor engines Toyota 4A-F (1.6 l); 5A-F (1.5 l) and 4A-FE engines (1.6 l), 16-and 20-valve 4A-GE (1.6 l), 5A-FE (1.5 l), 7A-FE (1.8 l) with fuel injection.
    The amount of information this book allows you to use a guide when servicing other engine modifications 4A and 5A: 4A-G, 4A-GZE, 4A-GELU, 4A-ELU, 4A-GEU, 4A-FHE and 5A-FHE. Publication contains detailed information on repair and adjustment of carburettors and fuel injection system components, ignition systems, charging and starting systems, how to use the self-diagnostic system, as well as possible faults and remedies, matched the size of the main components and their allowable wear.
    The book is designed for car owners, staff stations and repair shops.


    Content:

    Abbreviations and symbols 6
    6 identification
    General repair manual TOYOTA ENGINE 6
    Engine-mechanical part
    Description engines TOYOTA 4A-F, 4A-FE, 4A-GE, 5A-F, SA-FE, 7A-FE 7
    Check the level and quality of the coolant 8
    Check the engine oil level and quality 8
    Checking and cleaning the air filter 8
    Check the status of the battery 8
    Check high-voltage wires 8
    Check spark plugs 8
    Check drive belts mounted units 8
    Check and adjust thermal gaps in valves 9
    Check and adjust ignition timing 15
    Preliminary observations 15
    Check and adjust ignition timing 16
    Check and adjust the rotational speed and the whole mixture at normal idle mode 17
    Additional adjustment of fuel injection systems 20 items
    Check the intake system with a choke valve for engines designed to run on depleted line-ups mix 21
    Check valve system WT only (4A-GE (AE101, AE111) 22
    Check the engine 22
    Check the operation of the valve 22
    Check compression 22
    The timing belt 22
    Removing the timing belt 22
    Checking the status of your items, timing 26
    Timing belt installation 26
    Cylinder head ENGINES TOIOTA 29
    General information 29
    Removing the cylinder head 4A-F and 5A-F 29
    Removing the cylinder head 4A-FE, 5A-FE-FEH7A-33
    Removing the cylinder head 4A-GE (ae92, AW11 iat160) 41
    Removing the cylinder head 4A-GE (AE101, AE111) 45
    Disassembling the cylinder head 47
    Checking, cleaning and repair of parts of the cylinder head 47
    Cylinder head Assembly 53
    Install the cylinder head 4A-F and 5A-F 54
    Install the cylinder head 4A-FE, 5A-FE FEH7A-57
    Install the cylinder head 4A-GE (ae92, AW11 iat160) 65
    Install the cylinder head 4A-GE (AE101, AE111) 69
    The cylinder block 69
    69 General information
    Preparation for disassembly of the cylinder block 69
    Disassembling the cylinder block 72
    Check the cylinder block 75
    Disassembly site piston-connecting rod 75 "
    Check the status of the piston and connecting rod 76
    Boring cylinder 78
    Inspection and maintenance of the crankshaft 78
    Check valves and nozzles for cooling the piston (4A-GE) 79
    Replacing the crankshaft oil seals 79
    Replace nozzle (4A-GE) 79
    Building site piston-connecting rod 79 "
    Assembling the cylinder block 80
    Final Assembly of the engine 81
    Troubleshooting 84
    Engine overheats 84
    Difficulty starting the engine 84
    Unstable idling 84
    " " Dips in the engine/sluggish 84
    Hot surface ignition engine 85
    Additional combustion in the suppressor, Flash in the carburetor 85
    Increased oil consumption 85
    Increased fuel consumption 85
    Engine cooling system TOYOTA
    Description of cooling system 86
    Petrol tank cooling system 87
    Check the level and quality of the coolant 87
    Replacing the coolant 87
    Pump coolant 88
    Thermostat 90
    Radiator 90
    The fan of the refrigerating system with electric 91
    Check the cooling fan on a 91 car
    Verification of thermal switch (thermostat) 92
    Check the main relay engine (ENGINE MAIN) (for models AE and AT) or the main electric fan relay cooling system (FAN MAIN RELAY) (for model AW) 92
    Check cooling fan relay or relay # 1 fan cooling system (FAN # " 1 ") (for Ae110, Ae101 Iat190, as well as for model AW) 93
    Check the electric fan motor 93
    Check the electric fan sites and an electric fan control system components (AW) 94
    Possible problems, their causes and methods of eliminating 94
    Lubrication system
    A description of lubrication system 95
    Oil pump 95
    Oil pressure regulator (pressure reducing valve) 95
    Oil filter 95
    Check oil pressure 96
    Change oil and filter 96
    Oil pump 96
    Replace front oil seal crankshaft 97
    Oil cooler and pressure regulating valve 97
    Removing and replacing the oil cooler 97
    Removing the pressure reducing valve 97
    Checking the pressure reducing valve 97
    Assembly of pressure reducing valve 98
    Possible problems, their causes and remedies 98
    Fuel injection system General provisions 99
    Description fuel injection systems 99
    Fuel system 99
    Air supply system 99
    An electronic management system 100
    Location of components of fuel injection systems 105
    Precautions 109
    Precautions for maintenance of 109
    Precautions in the presence of a car mobile radio communication systems (US, SW, etc.) 109
    Precautions when working with a system of air supply 110
    Precautions when working with electronic control system 110
    Precautions when working with fuel system 110
    System Diagnostics 111
    111 description
    " Lamp CHECK 112
    The output of diagnostic codes in the current mode of self 112
    The output of diagnostic codes in test mode 113
    Erasing a diagnostic code 114
    Indication of diagnosis 114
    Diagnostic codes for the electronic control unit 115
    4A-GE without air flow (At160 and Ae92 release since 1987) 115
    4A-GE with a flow of air (At160 and Ae92 release since 1987), 4A-GE (Ae92 release since 1989), 4A-FE (ae92, ae95, At171 and At180) 115
    the serial version of the 4A-FE (Ae101, At190), 4A-FE with the system burning dining mixes (Ae101, At190), 5A-FE (Ae110) release in 1995 and 7A-FE (AE93, AE102, Ae103) 117
    4A-FE (Ae111), 5A-FE (Ae110) release in the year 1997, 7A-FE (AE115) 120
    4A-GE (AE111) 121
    Fault diagnostics using driving test 122
    Code No. 21-oxygen sensor 122
    Code # 25-poor air-fuel mixture 123
    Code No. 52-knock sensor 123
    Troubleshooting Volt/ohmmeter 123
    Procedure for verifying the electronic fuel injection system 123
    Conclusions the electronic control unit 125
    Conclusions the electronic control unit (s) 127
    Voltage and resistance between the electronic control unit 130
    Check the individual chains of electronic fuel injection system with a voltmeter 134
    Conclusions: + in +, B1-E1-E1 135
    Conclusions: WATT-E1 135
    Conclusions: IDL-E2, VTA-E2, VCC-E2 135
    Conclusions: IGT-E1 136
    Conclusions: STA-E1 137
    Conclusions: № 10-E01, E02, № 20-E01, E02 138
    4A-GE (fuel injection system with additional resistance nozzles) 138
    Conclusions: W-E1 139
    Conclusions: PIM-VCC-E2 and E2 (VC-E2 engine-5A-FE and 7A-FE) 139
    Conclusions: VC-E2 and VS-E2 (engines with air mass meter) 139
    Conclusions: TNA-E2 140
    Conclusions: THW-E2 140
    Conclusions: a/s-E1 (models with air conditioning) 140
    Conclusions: RSC-E1, RSO-E1 141
    Check the oxygen sensor and/or sensor depleted composition of the mixture 141
    An electronic management system 143
    Main relay fuel injection systems 143
    Relay-switch fuel pump 144
    Additional resistance and relay nozzles 144
    Termovremennoe relay injector cold start 145
    Coolant temperature sensor and temperature sensor of the inlet air (engines without air flow) 145
    Absolute pressure sensor in the intake manifold (engines without air flow) 145
    Variable resistor (engines without air flow and/or catalytic converter) 146
    Switch ban start (models with automatic transmission) (4A-FE (ae111), 5A-FE (ae110), 7A-FE (Ae115)) 147
    Knock sensor 147
    Electromagnetic valve increase idle speed when you turn on the air conditioner (model with air conditioning) 147
    EPV systems forced air (4A-FE (Ae101 and A190)) 148
    Oxygen sensor (models with catalytic converter exhaust gases) 148
    Exhaust gas temperature sensor 149
    Check the oxygen sensor 150
    Sensor depleted composition of the mixture (4A-FE system may appear in the combustion) 151
    System off the fuel supply to the modes of forced idling 152
    Pressure control system of fuel depending on the temperature of the motor (4A-GE (Ae92 models At160 and for Europe) 152
    Increase system speed idle (4A-GE (Ae92 and At160) with a flow of air) 153
    The valve control system speed at idling (4A-FE (ae92, ae95, At171 and At180)) 153
    The air supply control valve (4A-GE (Ae92) without air flow, release in 1989) 154
    Stop operation system (4A-FE (ae111), 5A-FE (AE110), 7A-FE (AE115)) 154
    Fuel pump 154
    Check the engine 155
    Check fuel pump 157
    Removing and installing fuel pump (4A-GE (Ae92 and At160) and 4A-FE (ae92, ae95 and At171)) 157
    Removing and installing fuel pump (4A-FE (Ae101, At180 and At190), 5A-FE (ae110), 7A-FE (AE93, AE102)) 158
    Removing and installing fuel pump (4A-GE (AE111)) 159
    Assembly and disassembly of the fuel pump (4A-FE (Ae101, At190), 5A-FE (ae110), 7A-FE (Ae93, Ae102)) 159
    Assembly and disassembly of the fuel pump (4A-FE (AT180)) 160
    Injector cold start 161
    Check the engine 161
    Removing injector cold start 161
    Check injector cold start 161
    Install injector cold start 162
    Differential pressure fuel 162
    Check the engine 162
    Injector 163
    Checking nozzles on the engine 163
    Removing the nozzle 164
    Checking nozzles 166
    Install injectors 166
    The air flow 169
    Check the engine 169
    Removing the air flow 169
    Check the air flow 169
    Setting the air flow 169
    Throttle body (4A-GE (Ae92, AW11 and At160)) 169
    Check the engine 170
    Body throttle valve 4A-GE (Ae101, ae111) 171
    Removing and installing 171
    Adjustment of 171
    Check the throttle body number 1171
    Check the throttle body number 2172
    Check the throttle body number 3173
    Check the throttle body number 4173
    Throttle body (4A-FE, 5A-FE, 7A-FE) 173
    Check the engine 173
    Removing the throttle body 175
    Check the throttle body 175
    Install the throttle body 176
    The valve control system speed idling 177
    Check the engine 177
    Removing the valve control system speed idling 178
    Check the valve control system speed idling 178
    Installing the valve control system speed idling 179
    Notes on the troubleshooting procedures 179
    The troubleshooting ENGINE TOIOTA 179
    The engine does not start, or starts with difficulty (the crankshaft is rotated or rotated slowly) 179
    Engine will not start or starts with difficulty (the crankshaft is rotated easily) 179
    The engine is often muffled 180
    Engine sometimes deaf 180
    Erratic idle and/or misfiring 180
    High speed idle 180
    Flash into the intake system (lean mixture) 181
    Afterburning in the exhaust pipe (rich mixture, misfiring) 181
    Engine runs erratically and/or poor dispersal 181
    Fuel injection system with a carburetor
    Description carburetor and some elements of food 182
    Precautions 185
    Checks on the car 185
    Cold engine 185
    Hot engine 186
    The constructive design of the carburetor 187
    Removing the carburetor 188
    Disassembling the carburetor 189
    Technology of cleaning of the carburetor 191
    Check carburetor 191
    Assembling carburetor 191
    Adjusting the carburetor 194
    Install the carburetor 196
    Fuel pump 196
    Removing fuel pump 196
    Check the pump (leak test) 197
    Troubleshooting 197
    Installing the fuel pump 197
    Ignition system
    198 description
    Check for sparking 198
    Check high-voltage wires 200
    Check spark plugs 200
    Standard spark plugs 200
    Spark plugs with Platinum electrodes 201
    Verification of components of the ignition system or elements of the combined unit plugs 201
    Check the ignition coil 201
    Check distributor 202
    Check with an oscilloscope 203
    The joint unit plugs 204
    Removal of 204
    Demolition of the combined unit plugs (4A-F (ae92) and 5A-F) 204
    Checking the combined unit plugs (4A-F (ae92) and 5A-F) 206
    Assembling the combined unit plugs (4A-F (ae92) and 5A-F) 206
    Installing the combined unit plugs (4A-F (ae92) and 5A-F) 207
    Demolition of the combined unit plugs (4A-FE, 5A-FE, 7A-FE) 207
    Checking the combined unit plugs (4A-FE, 5A-FE, 7A-FE) 208
    Assembling the combined unit plugs (4A-FE, 5A-FE, 7A-FE) 208
    Installing the combined unit plugs (4A-FE, 5A-FE, 7A-FE) 208
    The Distributor ignition system 209
    Removal of 209
    Disassembly of 209
    Verification of 209
    Replacement of valve gear driven 209
    Build 210
    Installation of 210
    Possible problems, their causes and methods of their elimination 211
    Starting system
    Connection diagrams Starter 212
    Location on the engine 212
    Starter without gear 212
    Starter with conventional gear 213
    Starter with planetary gear 214
    Replacing the findings traction relay (7A-FE (Ae103)) 216
    Checking the Starter 217
    Check the anchor 217
    Check the reservoir 217
    Check the stator 217
    Check brushes 217
    Check brush Springs 218
    Check the brush holder 218
    Check the freewheel and gears 218
    Test drove and bearings (for a starter with planetary gear) 218
    Check bearings (for a starter with the usual gear) 218
    Check traction relay 219
    Check Starter 219
    Relay Starter 220
    Troubleshooting 220
    The charging system
    Precautions 221
    Checks on the car 221
    Generator-disassembly, inspection and Assembly 222
    Disassembly of 222
    Check the rotor 223
    Check the stator 223
    Check brushes 224
    Checking rectifier unit 225
    Check bearings 225
    Build 225
    Main relay engine (4A-F, 4A-GE (AE92)) 226
    Diagram vacuum lines 227
    Wiring (electrical circuits)
    Instruction manual
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