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3VZ–FE
Toyota 3VZ–FE User Manual
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OIL COOLER
OIL COOLER REMOV
AL
EG0AL–02
1.
REMOVE UPPER RADIA
TOR SEAL
Remove the ten clips and radiator seal.
2.
REMOVE RH HEADLIGHT ASSEMBL
Y
(a)
Remove the three bolts.
(b)
Disconnect the three connectors and remove the
headlight
assembly
.
–
ENGINE TROUBLESHOOTING
COOLING SYSTEM
EG–277
279
281
Table of Contents
Engine Mechanical
2
Preparation
4
Sst (Special Service Tools)
4
Ssm (Service Special Materials)
7
Troubleshooting
8
Tune–Up
11
Engine Coolant Inspection
11
Check Engine Coolant Level at Reservoir Tank
11
Check Engine Coolant Quality
11
Clean Air Filter
12
Inspect Air Filter
12
High–Tension Cords Inspection
12
Air Filter Inspection
12
Generator Drive Belt Inspection
13
Valve Clearance Inspection and Adjustment
13
Remove Emission Control Valve Set
14
Disconnect Hoses
14
Disconnect Ground Straps
14
Disconnect Lh Engine Wire Harness
15
Disconnect Rh Engine Wire Harness
15
Adjust Valve Clearance
16
Set No.1 Cylinder to Tdc/Compression
16
Remove Cylinder Head Covers
16
Reinstall Cylinder Head Covers
18
Reconnect Rh Engine Wire Harness
18
Reconnect Lh Engine Wire Harness
19
Reinstall Air Intake Chamber
19
Reconnect Hydraulic Motor Pressure Pipe
20
Reinstall Egr Pipe
20
Reconnect Ground Straps
20
Reconnect Hoses
20
Reinstall Emission Control Valve Set
21
Reinstall V–Bank Cover
21
Idle And/Or 2,500 Rpm Co/Hc Check
25
Start Engine
25
Check Co/Hc Concentration at Idle
25
Compression Check
27
Remove V–Bank Cover
27
Remove Spark Plugs
27
Check Cylinder Compression Pressure
27
Reinstall Spark Plugs
28
Timing Belt Components
29
Remove Washer Tank
30
Disconnect Cable from Negative Terminal of Battery
30
Disconnect Engine Coolant Reservoir Hose
30
Timing Belt Removal
30
Remove Generator Drive Belt
31
Remove Ps Drive Belt
31
Slightly Jack up Engine
31
Timing Belt Inspection
37
Inspect Idler Pulleys
38
Inspect Timing Belt Tensioner
38
Temporarily Install Timing Belt
39
Install No.1 Idler Pulley
39
Install Crankshaft Timing Pulley
39
Timing Belt Installation
39
Install Crankshaft Pulley
40
Install No.2 Idler Pulley
40
Install Lh Camshaft Timing Pulley
40
Set Timing Belt Tensioner
43
Install Timing Belt Tensioner
43
Check Valve Timing
43
Install Engine Rh Mounting Bracket
44
Install No.2 Timing Belt Cover
44
Install Generator Drive Belt
45
Install and Adjust Ps Drive Belt
45
Install Rh Engine Mounting Stay
45
Install No.2 and No.3 Rh Engine Mounting Stays
46
Install Engine Coolant Reservoir Tank
46
Cylinder Heads
47
Cylinder Heads Removal
49
Remove Front Exhaust Pipe
49
Remove Iac Valve
50
Remove Throttle Body
50
Remove Egr Valve and Vacuum Modulator
50
Remove Egr Pipe
50
Remove Valves
60
Cylinder Heads Disassembly
60
Remove Valve Lifters and Shims
60
Cylinder Head Components Inspection, Cleaning and Repair
61
Clean Top of Pistons and Top of Block
61
Remove Gasket Material
61
Clean Valve Guide Bushings
61
Inspect Cylinder Heads for Flatness
62
Inspect Cylinder Head for Cracks
62
Clean Valves
62
Inspect Valve Stems and Guide Bushings
62
Install Valves
71
Cylinder Heads Assembly
71
Install Spark Plug Tubes
71
Install Valve Lifters and Shims
72
Cylinder Heads Installation
73
Install Lh Engine Hanger
74
Install Ps Pump Bracket
74
Assembly Exhaust Camshafts
74
Install Camshafts
75
Install Intake Camshaft of RH Cylinder Head
75
Install Exhaust Camshaft of RH Cylinder Head
76
Install Intake Camshaft of LH Cylinder Head
77
Install Camshaft Oil Seals
78
Check and Adjust Valve Clearance
78
Install Exhaust Camshaft of LH Cylinder Head
78
Install Cylinder Head Covers
79
Install No.3 Timing Belt Cover
79
Install Rh Exhaust Manifold
80
Install Oil Dipstick
80
Install Lh Exhaust Manifold
80
Install Intake Manifold
81
Install Water By–Pass Outlet
81
Install Rh Delivery Pipe and Injectors
81
Install Lh Delivery Pipe and Injectors
82
Install Air Pipe
82
Connect Rh Engine Wire Harness
83
Install No.1 Egr Cooler
83
Install Air Intake Chamber
83
Install No.2 Fuel Pipe
84
Connect Hoses
84
Install Water Outlet
84
Install Cylinder Head Rear Plate
84
Install Egr Pipe
85
Install Egr Valve and Vacuum Modulator
85
Install Emission Control Valve Set
85
Connect Lh Engine Wire Harness
85
Install Iac Valve
86
Install V–Bank Cover
86
Connect Front Exhaust Pipe
86
Cylinder Block
88
Engine Removal
88
Remove Cruise Control Actuator
90
Disconnect Ps Acv
95
Remove Ps Pump Without Disconnecting Hoses
95
Disconnect Lh Engine Mounting Insulator
95
Disconnect Fr Engine Mounting Insulator
96
Disconnect Rr Engine Mounting Insulator
96
Remove Engine Mounting Absorber
96
Remove No.2 Rh Engine Mounting Bracket
97
Remove Fr Engine Mounting Insulator
97
Remove Rr Engine Mounting Insulator
97
Remove Engine and Transaxle Assembly from Vehicle
97
Components
98
Preparation for Disassembly
99
Remove Oil Pressure Switch
99
Remove Engine Coolant Drain Cock
99
Remove No.2 Idler Pulley Bracket
100
Remove Water By–Pass Pipe
100
Remove Knock Sensors
100
Cylinder Block Disassembly
101
Remove Rear Oil Seal Retainer
101
Check Connecting Rod Thrust Clearance
101
Remove Connecting Rod Caps and Check Oil Clearance
101
Check Crankshaft Thrust Clearance
104
Remove Main Bearing Cap and Check Oil Clearance
104
Inspect Top Surfaces of Cylinder Block for Flatness
107
Clean Cylinder Block
107
Remove Crankshaft
107
Cylinder Block Inspection
107
Inspect Cylinder for Vertical Scratches
108
Inspect Cylinder Bore Diameter
108
Remove Cylinder Ridge
108
Piston and Connecting Rod Assy Disassembly
109
Check Fit between Piston and Piston Pin
109
Remove Piston Rings
109
Disconnect Connecting Rod from Piston
109
Clean Piston
110
Piston and Connecting Rod Inspection
110
Inspect Piston
111
Inspect Piston Oil Clearance
111
Inspect Piston Ring Groove Clearance
112
Inspect Piston Ring End Gap
112
Inspect Connecting Rod
113
Inspect Piston Pin Fit
113
Inspect Connecting Rod Alignment
113
Inspect Piston Pin Oil Clearance
113
Inspect Connecting Rod Bolts
115
Bore and Hone Cylinders to Calculated Dimensions
116
Keep Oversized Pistons
116
Calculate Amount to Bore Cylinder
116
Boring of Cylinder
116
Crankshaft Inspection and Repair
117
Inspect Crankshaft for Runout
117
Inspect Main Journals and Crank Pins
117
Crankshaft Oil Seals Replacement
118
Replace Crankshaft Front Oil Seal
118
Replace Crankshaft Rear Oil Seal
119
Piston and Connecting Rod Assembly
120
Assemble Piston and Connecting Rod
120
Install Piston Rings
120
Install Bearings
121
Cylinder Block Assembly
122
Install Main Bearings
122
Install Upper Thrust Washers
122
Install Main Bearing Cap and Lower Thrust Washers
122
Install Piston and Connecting Rod Assemblies
123
Install Connecting Rod Caps
124
Install Rear Oil Seal Retainer
125
Install Knock Sensors
126
Install Water By–Pass Pipe
126
Install No.2 Idler Pulley Bracket
126
Post Assembly
126
Install Engine Coolant Drain Cock
127
Install Oil Pressure Switch
127
Install Rear End Plate
128
Install Flywheel
128
Engine Installation
129
Install Rr Engine Mounting Insulator
129
Install Fr Engine Mounting Insulator
129
Assemble Engine and Transaxle
129
Connect Fr Engine Mounting Insulator
130
Install Engine Mounting Absorber
130
Connect Rr Engine Mounting Insulator
131
Connect Lh Engine Mounting Insulator
131
Install Ps Pump
131
Connect Hydraulic Cooling Fan Pressure Hose
131
Connect Ps Acv
132
Install Front Exhaust Pipe
132
Install A/C Compressor
132
Connect Engine Wire to Cabin
132
Connect Vacuum Hoses
133
Connect Wires and Connectors
134
Install Starter
134
Connect Fuel Inlet Hose
134
Install Clutch Release Cylinder
134
Exhaust System Components
138
Service Specifications
139
Service Data
139
Torque Specifications
141
Emission Control Systems
144
System Purpose
144
Recommended Tools
144
Equipment
144
Layout and Schematic Drawing
146
Positive Crankcase Ventilation (Pcv) System
147
Pcv Valve Inspection
148
Pcv Hoses and Connections Inspection
148
Evaporative (Evap) Emission Control System
149
Fuel Vapor Lines, Fuel Tank and Tank Cap Inspection
150
Charcoal Canister Inspection
150
Visually Inspect Lines and Connections
150
Visually Inspect Fuel Tank
150
Inspect Check Valve
151
Check Valve Inspection
151
Check Tvv by Blowing Air into Pipe
151
Tvv Inspection
151
Exhaust Gas Recirculation(Egr) System
152
Egr System Inspection
153
Check and Clean Filter in Egr Vacuum Modulator
153
Check Tvv with Cold Engine
153
Check Tvv and Egr Vacuum Modulator with Hot Engine
153
Egr Vacuum Modulator Inspection
154
Egr Valve Inspection
154
Check Egr Valve
154
Check Egr Vacuum Modulator Operation
154
Exhaust Pipe Assembly Inspection
156
Three–Way Catalytic Converter (Twc) System
156
Three–Way Catalytic Converter Inspection
157
Heat Insulator Inspection
157
Three–Way Catalytic Converter Replacement
157
Check for Dents or Damage
157
Sfi System
159
Fuel System
160
Air Induction System
160
Electronic Control System
160
Operation Fuel System
161
Precautions When Handling Oxygen Sensor
166
Maintenance Precautions
166
In Event of Engine Misfire
166
Precautions When Connecting Gauge
166
If Vehicle Is Equipped with Mobile Radio System (Ham, Cb, Etc.)
167
Fuel Pump System Circuit
171
On–Vehicle Inspection
171
Check Fuel Pump Operation
171
Check Fuel Pressure
172
Fuel Pump Removal and Inspection
175
Inspect Fuel Pump Resistance
175
Remove Fuel Pump Lead Wire
176
Inspect Fuel Pump Operation
176
Remove Floor Service Hole Cover
176
Fuel Pump Disassembly
177
Remove Fuel Pump from Fuel Pump Bracket
177
Remove Fuel Sender Gauge from Fuel Pump Bracket
177
Remove Fuel Pump Filter from Fuel Pump
178
Remove Connector
178
Install Connector
178
Install Fuel Pump Filter to Fuel Pump
178
Install Floor Service Hole Cover
179
Install Fuel Pump Bracket Assembly to Fuel Tank
179
Fuel Pump Installation
179
Cold Start Injector On–Vehicle Inspection
180
Cold Start Injector Removal
180
Inspect Resistance of Cold Start Injector
180
Cold Start Injector Inspection
182
Inspect Injection of Cold Start Injector
182
Cold Start Injector Installation
183
Inspect Leakage
183
Install Cold Start Injector
183
Connect Cold Start Injector Pipe
183
Fuel Pressure Regulator On–Vehicle Inspection
184
Fuel Pressure Regulator Removal
184
Fuel Pressure Regulator Installation
185
Disconnect Vacuum Sensing Hose
185
Remove Fuel Pressure Regulator
185
Install Fuel Pressure Regulator
185
Injectors
187
Inspect Injector Operation
187
Inspect Injector Resistance
187
Injectors Removal
188
Inspect Injector Injection
192
Remove Rh Delivery Pipe and Injectors
192
Remove Air Pipe with Hoses
192
Injectors Inspection
192
Injectors Installation
194
Install Injectors to Delivery Pipes
194
Install Air Pipe with Hoses
195
Connect Fuel Inlet and Return Hoses
196
Connect Hydraulic Motor Pressure Pipe
197
Connect Ground Straps
197
Fuel Tank and Lines Components
199
Fuel Lines and Connections Inspection
200
Precautions
200
Volume Air Flow Meter On–Vehicle Inspection
201
Volume Air Flow Meter Removal
201
Inspect Resistance of Volume Air Flow Meter
201
Volume Air Flow Meter Inspection
202
Volume Air Flow Meter Installation
203
Throttle Body On–Vehicle Inspection
204
Inspect Throttle Body
204
Inspect Throttle Position Sensor
204
Terminals
204
Idl-E2
204
Vta-E2
204
VC-E2
204
Inspect and Adjust Dash Pot (Dp)
205
Inspect Throttle Opener
206
Throttle Body Removal
207
Throttle Body Inspection
208
Clean Throttle Body
208
Inspect Throttle Valve
208
Throttle Body Installation
210
Install Throttle Body
210
Connect Hoses to Throttle Body
210
Inspect Iac Valve Resistance
211
Iac Valve
211
Check for Operating Sound from Iac Valve
211
Inspect Air Assist System
212
Iac Valve Removal
212
Iac Valve Inspection
213
Inspect Iac Valve Operation
213
Iac Valve Installation
214
Intake Air Control Valve (Iacv) On–Vehicle Inspection
215
Inspect Iacv
215
Iacv Removal
215
Iacv and Components Inspection
217
Iacv Installation
218
Connect Hoses to Iacv
218
Connect Cold Start Injector (No.2 Fuel Pipe)
219
Electronic Parts Location
220
Sfi Main Relay
221
Sfi Main Relay Inspection
221
Inspect Relay Continuity
221
Inspect Relay Operation
221
Circuit Opening Relay
222
Circuit Opening Relay Removal and Installation
222
Circuit Opening Relay Inspection
223
Inspect Resistance of Cold Start Injector Time Switch
224
Cold Start Injector Time Switch Inspection
224
Cold Start Injector Time Switch
224
Engine Coolant Temperature Sensor
225
Engine Coolant Temperature Sensor Inspection
225
Inspect Resistance of Engine Coolant Temperature Sensor
225
Fuel Pressure Vsv
226
Fuel Pressure Vsv Inspection
226
Check Vsv for Open Circuit
226
Check Vsv for Ground
226
Check Vsv Operation
227
Inspect Egr Gas Temperature Sensor
228
Egr Gas Temperature Sensor
228
Egr Gas Temperature Sensor Inspection
228
Oxygen Sensor Inspection
230
Warm up Engine
230
Inspect Feedback Voltage
230
Sub–Oxygen Sensor Inspection
232
Inspect Sub–Oxygen Sensor
232
Inspect Heater Resistance of Sub–Oxygen Sensor
232
Engine Control Module (ECM) Terminals
234
Ecm Inspection
235
Ecm Removal and Installation
235
Inspect Voltage of Ecm
236
ECM Wiring Connectors Voltage
237
ECM Wiring Connectors Resistance
238
Inspect Resistance of Ecm
238
Fuel Cut Rpm
239
Fuel Cut Rpm Inspection
239
Connect Tachometer to Engine
239
Inspect Fuel Cut Prm
239
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
240
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
240
Vs-E2
240
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
241
Ñ Ñ Ñ Ñ Ñ Ñ
241
Thw-E2
241
0.5 or Less
241
Table of Contents
242
Radiator
244
Radiator Cap
244
Reservoir Tank
244
Water Pump
244
Replace Engine Coolant
247
Check Engine Coolant Level at Reserve Tank
247
Coolant Check and Replacement
247
Water Pump Removal
249
Water Pump Inspection
250
Remove Water Inlet and Thermostat
250
Remove Water Pump
250
Inspect Water Pump
250
Water Pump Installation
251
Install Water Pump
251
Install Water Inlet and Thermostat
251
Install Water Inlet Pipe
252
Thermostat Removal
253
Remove Water Inlet Pipe
254
Remove Water Inlet
254
Inspect Thermostat
254
Thermostat Installation
255
Place Thermostat in Water Pump
255
Install Water Inlet
255
Radiator Cleaning
256
Radiator Inspection
256
Inspect Cooling System for Leaks
257
Radiator Removal
258
Uncaulk Lock Plates
260
Assembly of Sst
260
Radiator Disassembly
260
Radiator Assembly
261
Remove Tanks and O–Rings
261
Remove Oil Cooler from Lower Tank
261
Install Oil Coolant to Lower Tank
261
Install New O–Rings and Tanks
262
Caulk Lock Plate
262
Inspect for Water Leaks
263
Install Radiator and Hydraulic Cooling Fan
264
Radiator Installation
264
Install Hydraulic Cooling Fan to Radiator
264
Paint Lock Plates
264
Electronically Controlled Hydraulic Cooling Fan System
266
Fluid Level Inspection
267
Inspect Fluid Level
267
Hydraulic Cooling Fan System Bleeding
268
Check Fluid Level in Reservoir Tank
268
Bleed Cooling System
268
Inspect Oil Pressure
269
Connect Pressure Gauge
269
Oil Pressure Inspection
269
Hydraulic Motor
271
Hydraulic Motor Removal
271
Hydraulic Motor Disassembly
273
Mount Motor Housing
273
Hydraulic Motor Inspection
274
Inspect Drive and Driven Rotors
274
Inspect Oil Clearance of Drive Shaft
275
Install Oil Seal
276
Remove Oil Seal
276
Oil Seal Replacement
276
Hydraulic Motor Assembly
277
Hydraulic Motor Installation
278
Inspect Drive Shaft Preload
278
Install Hydraulic Motor to Fan Shroud
278
Install Cooling Fan to Hydraulic Motor
278
Oil Cooler Removal
280
Remove Upper Radiator Seal
280
Remove Rh Headlight Assembly
280
Remove Oil Cooler
281
Remove under Cover
281
Remove Rh Fog Lamp Assembly
281
Disconnect Hoses from Oil Cooler
281
Oil Cooler Inspection
282
Oil Cooler Installation
282
Inspect Oil Cooler
282
Install Oil Cooler
282
Connect Hoses to Oil Cooler
283
Install Rh Headlight Assembly
283
Install Upper Radiator Support Seal
283
Electronic Control Parts System Circuit
284
Inspect Cooling Fan Ecu
285
Cooling Fan Ecu Inspection
285
Cooling Fan Ecu Removal and Installation
285
Engine Coolant Water Temperature Sensor
286
Engine Coolant Temperature Sensor Removal and Installation
286
Inspect Engine Coolant Temperature Sensor
286
Solenoid Valve Inspection
287
Ñ Ñ Ñ Ñ Ñ Ñ Ñ
288
Lubrication System Description
289
Oil Pump
290
Oil Pressure Regulator
290
Oil Filter
290
Check Engine Oil Level
293
Oil Pressure Check
293
Check Engine Oil Quality
293
Oil and Filter Replacement
295
Drain Engine Oil
295
Replace Oil Filter
295
Fill with Engine Oil
296
Oil Pump Removal
297
Remove Stiffener Plate
298
Remove Oil Pan
298
Remove Oil Strainer
298
Remove Oil Pan Baffle Plate
299
Remove Generator Bracket
299
Remove A/C Compressor Bracket
300
Remove No.1 Idler Pulley
300
Remove Crankshaft Timing Pulley
300
Remove Oil Pump
300
Oil Pump Disassembly
301
Remove Relief Valve
301
Remove Drive and Driven Rotors
301
Inspect Rotor Body Clearance
302
Inspect Rotor Side Clearance
302
Inspect Relief Valve
302
Oil Pump Inspection
302
Crankshaft Front Oil Seal Replacement
303
Inspect Rotor Tip Clearance
303
Oil Pump Assembly
304
Install Drive and Driven Rotors
304
Install Relief Valve
304
Oil Pump Installation
305
Install Generator Bracket
307
Install Washer Tank
307
Install Oil Pan
308
Install Oil Strainer
308
Install Oil Pan Baffle Plate
308
Install Stiffener Plate
309
Oil Filter Bracket Removal
310
Remove Oil Filter
310
Remove Oil Filter Bracket
310
Oil Filter Bracket Installation
311
Install Oil Filter Bracket
311
Install Oil Filter
311
Ñ Ñ Ñ Ñ Ñ Ñ
312
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
312
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
312
Kgf CM Ft Lbf
312
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ft Lbf
312
65 In. Lbf
312
How to Proceed with Troubleshooting
315
Customer Problem Analysis
315
Check and Clear Diagnostic Trouble Code (Precheck)
315
Diagnostic Trouble Code Check in Test Mode
315
Check for Momentary Interruption
317
Circuit Inspection by Checker
319
Customer Problem Analysis Check Sheet
321
Diagnosis System
323
Diagnostic Trouble Code Check
324
Malfunction Indicator Lamp Check
324
Diagnostic Trouble Code Clearance
326
Diagnostic Trouble Code Chart
327
Fail–Safe Chart
335
Back–Up Function
335
Perform a Simulation Test
336
Set Test Mode
336
Basic Inspection
337
Parts Location
340
Wiring Diagram
341
Terminals of Ecm
343
Standard Value of Ecm Terminals
345
Matrix Chart of Problem Symptoms
347
Location of Connectors in Engine Compartment
349
Location of Connectors in Body
352
Location of Connectors in Instrument Panel
353
Circuit Inspection
357
Diagnostic Chart
358
Inspection Procedure
359
RPM Signal Circuit (No. 2)
360
Ignition Signal Circuit
361
Control Signal Malfunction
367
Main Oxygen Sensor Circuit
369
Diagnostic Trouble Code Detection Driving Pattern
370
Engine Coolant Temp. Sensor Circuit
373
Intake Air Temp. Sensor Circuit
377
Air–Fuel Ratio Lean Malfunction
379
Air–Fuel Ratio Rich Malfunction
379
Sub–Oxygen Sensor Circuit
385
Check Voltage between Terminal HT of ECM Connector and Body Ground
388
Check Sub–Oxygen Sensor Heater
388
Volume Air Flow Meter Circuit
391
Check Voltage between Terminals VC and E2 of ECM
392
Check Voltage between Terminals VS and E2 of ECM
394
Check Resistance between Terminals VS and E2 of Volume Air Flow Meter
394
Throttle Position Sensor Circuit
395
Vehicle Speed Sensor Signal Circuit
399
Starter Signal Circuit
403
Knock Sensor Circuit
405
EGR System Malfunction
411
Switch Condition Signal Circuit
415
Park/Neutral Position Switch Circuit
419
ECM Power Source Circuit
423
Back up Power Source Circuit
429
Cold Start Injector Circuit
435
IAC Valve Circuit
439
Fuel System Circuit
443
Fuel Pressure Control VSV Circuit
449
Air Conditioning Cut Control Circuit
453
IACV Control VSV Circuit
455
TE1, TE2 Terminal Circuit
459
Ignition System
461
Pickup Coils
462
Distributor
462
Ignition Coil
462
Igniter
462
Spark Test
467
Check that Spark Occurs
467
Spark Plugs Inspection
470
Inspect Electrode
470
Visually Inspect Spark Plugs
471
Inspect Electrode Gap
471
Clean Spark Plugs
471
Install Spark Plugs
471
Inspect Secondary Coil Resistance
472
Ignition Coil Inspection
472
Inspect Primary Coil Resistance
472
Distributor Inspection
472
Inspect Signal Generator (Pickup Coil) Resistance
473
Distributor Removal
474
Distributor Disassembly
476
Remove Wire Harness Clamp Clip
476
Remove Distributor Cap
476
Install Wire Harness Clamp Clip
477
Install Distributor Cap
477
Remove Rotor
477
Distributor Assembly
477
Distributor Installation
478
Set No. 1 Cylinder to Tdc/Compression
478
Adjust Ignition Timing
480
Starter Removal
487
Remove Starter
488
Starter Disassembly
488
Remove Field Frame and Armature
488
Remove Brush Holder
489
Remove Steel Ball
489
Remove Starter Housing, Clutch Assembly and Gear
489
Starter Inspection and Repair
490
Inspect Commutator for Open Circuit
490
Inspect Commutator for Ground
490
Inspect Commutator Circle Runout
490
Inspect Commutator Diameter
491
Inspect Undercut Depth
491
Inspect Field Coil for Open Circuit
491
Inspect Field Coil for Ground
491
Inspect Clutch Pinion Gear
492
Inspect Brush Holder Insulation
492
Inspect Gear Teeth
492
Inspect Brush Spring Load
492
Inspect Bearings
495
Magnetic Switch
496
Starter Assembly
496
Install Brush Holder
496
Insert Steel Ball into Clutch Shaft Hole
497
Install Starter Housing, Clutch Assembly and Gear
497
Install Field Frame and Armature Assembly
498
Inspect Clutch Pinion Gear Return
499
Perform Hold–In Test
499
Perform Pull–In Test
499
Starter Performance Test
499
Starter Installation
500
Install Cruise Control Actuator
500
Starter Relay Inspection
501
Inspection Relay Continuity
501
Check Battery Terminals, Fusible Link and Fuses
511
Inspect Drive Belt
511
Visually Check Generator Wiring and Listen for Abnormal Noises
512
Inspect Discharge Warning Light Circuit
512
Inspect Charging Circuit Without Load
513
Inspect Charging Circuit with Load
513
Generator Removal
515
Remove No.2 and No.3 Rh Engine Mounting Stays
515
Remove Drive Belt
516
Remove Generator
516
Generator Disassembly
517
Remove Rear End Cover
517
Remove Brush Holder and IC Regulator
517
Remove Rectifier Holder
517
Remove Rectifier End Frame
518
Remove Pulley
518
Inspect Rotor for Open Circuit
519
Inspect Rotor for Ground
519
Generator Inspection and Repair
519
Stator (Drive End Frame)
520
Inspect Slip Rings
520
Inspect Stator for Open Circuit
520
Inspect Stator for Ground
520
Inspect Negative Rectifier
521
Inspect Front Bearing
521
Inspect Positive Rectifier
521
Rectifiers (Rectifier Holder)
521
Inspect Rear Bearing
522
Generator Assembly
523
Install Rotor to Drive End Frame
523
Install Rectifier End Frame
523
Install Pulley
524
Install Rectifier Holder
524
Install IC Regulator and Brush Holder
525
Install Rear End Cover
525
Generator Installation
526
Install Drive Belt
526
5
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Toyota 3VZ–FE Specifications
General
Brand
Toyota
Model
3VZ–FE
Category
Engine
Language
English
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