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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