Toyota 3F-E Operating instructions

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FOREWORD
This supplement has been prepared to provide information
covering general service repairs for the 3F-E engine equipped
on the TOYOTA LAND CRUISER.
Application models: FJ62 series
For basic engine service repair, refer to the following repair
manual
3F Engine Repair Manual (Pub. No. 36253E)
Please note that the publications below have also been pre-
pared as relevant service manuals to the components and
systems in this engine.
Manual Name
Pub. No.
•
3F-E Engine Emission Control
ERM045E
Repair Manual
All information in this manual is based on the latest product
information at the time of publication. However, specifica-
tions and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
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TOYOTA 3F-E ENGINE
REPAIR MANUAL
SUPPLEMENT
NOTE: The following screen toning letters sections refer to
the 3F Engine Repair Manual (Pub. No. 36253E)
I
NTRODUCTION
ENGINE MECHANICAL
EFI SYSTEM
COOLING SYSTEM
I
GNITION SYSTEM
CHARGING SYSTEM
SERVICE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
SST AND SSM
©1993 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
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I N-1
INTRODUCTION
Page
HOW TO USE THIS MANUAL
.................................................
IN-2
I
DENTIFICATION INFORMATION
.........................................
IN-4
GENERAL REPAIR INSTRUCTIONS
....................................
IN-4
PRECAUTIONS FOR VEHICLES EQUIPPED
WITH A CATALYTIC CONVERTER
..................................
IN-7
ABBREVIATIONS USED IN THIS MANUAL
...................
IN-8
I N
I
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^% Clip
Fuel Hose
F)
Fuel Pump
V
Fuel Pump Filter
♦
Clip
Rubber Cushion
FA0555
Fuel Hose
Fuel Pump Bracket
kg-cm (ft-lb, N•m)
: Specified torque
•
N
o
n-
reusable part
a,4
I N-2
I
NTRODUCTION — How to Use This Manual
HOW TO USE THIS MANUAL
To assist in finding your way through this manual, the section
title and major heading are given at the top of every page.
An INDEX is provided on the 1st page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain to all repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the problem and find the cause. The repair
for each possible cause is referenced in the remedy column to
quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit to-
gether.
Example:
35 (30 in- lb.
3.4)
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I NTRODUCTION —
How to Use This Manual
IN-3
Illustration:
what to do and where
The procedures are presented in a step-by-step format:
•
The illustration shows what to do and
where to do it.
•
The task heading tells
whatto do.
• The detailed text tells
how
to perform the task and gives
other information, such as specifications and warnings.
Example:
Task heading: what to do
3.
INSTALL FUEL PUMP BRACKET TO FUEL TANK
(a) Install a new gasket and the pump bracket with the
screws.
Torque: 35 kg-cm (30 in.-lb, 3.4 N•m)
Detailed text:
how to do task
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task head-
ing can be read at a glance when necessary, and the text
below it provides detailed information. Important specifica-
tions and warnings always stand out in bold type.
Torque Specification
1
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the page to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text
where needed. You never have to leave the procedure to look
up your specifications. They are also found in Appendix A, for
quick reference.
CAUTIONS, NOTICES, HINTS
•
CAUTIONS are presented in bold type, and indicate there is
a possibility of injury to you or other people.
•
NOTICES are also presented in bold type, and indicate
there is a possibility of damage to the components being
repaired.
•
HINTS are separated from the text but do not appear in
bold. They provide additional information to help you per-
form the repair more efficiently.
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I DENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
IN -4
INTRODUCTION —
Identification Information, General Repair Instructions
GENERAL REPAIR INSTRUCTIONS
1.
Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2.
During disassembly, keep parts in order to facilitate re-
assembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
cable from the battery terminal.
(b) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the cable from
the negative (—) terminal which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting or prying it.
(d) Clean the battery terminal posts and cable terminal
with a shop rag. Do not scrape them with a file or
such.
(e)
Install the cable terminal to the battery post with the
nut loose and tighten the nut after installation. Do
not use a hammer or such to tap the terminal onto
the post.
(f)
Be sure the cover for the positive (+) terminal is
properly in place.
4.
Check all hose and wiring connectors to make sure they
are securely and correctly connected.
5. Non-reusable Parts
(a)
Always replace cotter pins, gaskets, 0-ring and oil
seals, etc. with new ones.
(b)
Non-reusable parts are indicated in the component
illustrations by the "s" symbol.
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INTRODUCTION —
General Repair Instructions
IN-5
6. Precoated Parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adheasive at the factory.
(a) If a precoated part is tightened, loosened or caused
to move in any way, if must be recoated with the
specified adhesive.
(b) Recoating of Precoated Parts
(1)
Clean off the old adhesive from the bolts, nut or
installation part threads.
(2)
Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c) Precoated parts are indicated in the component il-
lustrations by the "*" symbol.
7.
When necessary, use a sealer on gaskets to prevent leaks.
8.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9.
Use of special service tools (SST) and special service
materials (SSM) may be required depending on the na-
ture of the repair. Be sure to use SST and SSM where
specified and follow the proper work procedure. A list of
SST and SSM can be found at the back of this manual.
1
0. When replacing fuses, be sure the new fuse is the correct
amperage rating. DO NOT exceed the rating or use one
of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations.
(a)
If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b)
After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on the vehicle raised on one jack alone, even for a
small job that can be finished quickly.
1
2. Observe the following precautions to avoid damage to
parts:
(a)
To disconnect vacuum hoses, pull on the end, not
the middle of the hose.
(b)
To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(c)
Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
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I
N-6
I NTRODUCTION — General Repair Instructions
Example
VTV far TP
White Side
IN000J
VTV for TP
Black Side
(d)
When steam cleaning an engine, protect the distrib-
utor, coil, air filter, and VCV from water.
(e)
Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(f)
When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
(g)
When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched,
it may leak.
1 3. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(b) After completing a job, double check that the vac-
uum hoses are properly connected. A label under
the hood shows the proper layout.
is
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INTRODUCTION -
Precautions for Vehicles Equipped with a Catalytic Converter
IN -7
PRECAUTIONS FOR VEHICLES EQUIPPED
WITH A CATALYTIC CONVERTER
CAUTION: If large amounts of unburned gasoline flow
into the converter, it may overheat and create a fire hazard.
To prevent this, observe the following precautions and ex-
plain them to your customer.
1.
Use only unleaded gasoline.
2.
Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20
minutes.
3.
Avoid spark jump test.
(a)
Perform a spark jump test only when absolutely
necessary and as quickly as possible.
(b)
Never race the engine, while testing.
4.
Avoid prolonged engine compression measurement.
Engine compression tests must be made as quickly as
possible.
5.
Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra
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IN-8
INTRODUCTION —
Abbreviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL
Al
Air Injection
ASV
Air Switching Valve
BTDC
Before Top Dead Center
DP
Dash Pot
ECU
Electronic Controlled Unit
EFI
Electronic Fuel Injection
EGR
Exhaust Gas Recirculation
ESA
Electronic Spark Advance
EX
Exhaust (manifold, valve)
iG
Ignition
IN
Intake (manifold, valve)
ISC
Idle Speed Control
OHV
Over Head Valve
0/S
Oversize
PCV
Positive Crankcase Ventilation
PS
Power Steering
SSM
Special Service Materials
SST
Special Service Tools
STD
Standard
SW
Switch
TCCS
TOYOTA Computer Controlled System
TDC
Top Dead Center
U/S
Undersize
VCV
Vacuum Control Valve
VSV
Vacuum Switching Valve
VTV
Vacuum Transmitting Valve
w/
With
w/o
Without
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Page
EM-2
EM-4
EM-8
EM-13
EM-15
EM-16
EM-17
EM-32
EM-40
EM-1
ENGINE MECHANICAL
REFER TO 3F ENGINE REPAIR MANUAL (Pub. No. 36253E)
NOTE: The following pages contain only the points which
differ from the above listed manual.
DESCRIPTION
............................................................
TROUBLESHOOTING
................................................
ENGINETUNE-UP
.....................................................
I
DLE HC/CO CONCENTRATION CHECK
METHOD
.................................................................
I NSPECTION AND ADJUSTMENT OF DASH POT
(
DP) SETTING SPEED
..........................................
COMPRESSIONCHECK
..........................................
CYLINDERHEAD
........................................................
TIMINGGEARS AND CAMSHAFT
.........................
CYLINDERBLOCK
......................................................
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ENGINE MECHANICAL –
Description
EM-2
DESCRIPTION
The 3F-E engine is an in-line 6-cylinder 4.0 liter OHV 12-valve engine.
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ENGINE MECHANICAL —
Description
EM-3
The 3F-E engines are an in-line 6-cylinder engine
with the cylinders numbered 1 -2-3-4-5-6 from the
front. The crankshaft is supported by 4 bearings
specified by the inside of the crankcase.
The crankshaft is integrated with 9 weights which
are cast along with it for balance. Oil holes are built
into the center of the crankshaft for supplying oil to
the connecting rods, pistons and other components.
These engine's ignition order is 1 -5-3-6-2-4. The
cylinder head is made of case iron, with a counter-
flow type intake and exhaust layout and with wedge
type combustion chambers. The spark plugs are lo-
cated in the right side of the combustion chambers.
Exhaust and intake valves are equipped with ir-
regular pitch springs which are capable of following
the valves even at high engine speeds.
Each valve lifter is lifted up by the rotation of the
camshaft so that valve is driven via a push rod and
rocker arm.
The camshaft is located in the cylinder block. The
camshaft is turned by the crankshaft by means of the
ti
ming gears. To rotate the camshaft once, the
crankshaft must rotate twice because the camshaft
ti ming gear has twice as many teeth as the
crankshaft timing gear.
Pistons are made of high temperature-resistant
aluminum alloy.
Piston pins are the full-floating type, with the pins
fastened to neither the piston boss nor the connect-
ing rods. Instead, snap rings are fitted on both ends
of the pins, preventing the pins from falling out.
The No. 1 compression ring is made of steel and
the No. 2 compression ring is made of cast iron. The
oil ring is made of a combination of steel and stain-
less steel. The outer diameter of each piston ring is
slightly larger than the diameter of the piston and
the flexibility of the rings allows them to hug the
cylinder walls when they are mounted on the piston.
Compression rings No. 1 and No. 2 work to prevent
the leakage of gas from the cylinder and the oil ring
works to scrape oil off the cylinder walls to prevent
it from entering the combustion chamber.
The cylinder block is made of cast iron. It has 6
cylinders which are approximately 1.6 times the
length of the piston stroke. The top of the cylinders
is closed off by the cylinder head and the lower end
of the cylinders becomes the crankcase, in which
the crankshaft is installed. In addition, the cylinder
block contains a water jacket, through which
coolant is pumped to cool the cylinders.
The oil pan is bolted onto the bottom of the cylin-
der block. The oil pan is an oil reservoir made of
pressed steel sheet. A dividing plate is included in-
side the oil pan to keep sufficient oil in the bottom
of the pan even when the vehicle is tilted. This di-
viding plate also prevents the oil from making waves
when the vehicle is stopped suddenly and thus
shifting the oil away from the oil pump suction pipe.
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EM-4
ENGINE MECHANICAL —
Troubleshooting
TROUBLESHOOTING
ENGINE OVERHEATING
Problem
Possible cause
Remedy
Page
Engine overheats
Cooling system faulty
Troubleshoot cooling system
Incorrect ignition timing
Reset timing
EM-11
HARD STARTING
Problem Possible cause Remedy
Page
Engine will not crank
or cranks slowly
Starting system faulty
Troubleshoot starting system
Engine will not start/
hard to start
No fuel supply to injector
• No fuel in tank
Troubleshoot EFI system FI-9
(cranks OK) • Fuel pump no working
• Fuel filter clogged
•
Fuel line clogged or leaking
EFI system problems Repair as necessary
Ignition problems
Perform spark test
IG-5
• Ignition coil
•
Igniter
• Distributor
Spark plug faulty Inspect plugs
IG-6
High-tension cords disconnected broken Inspect cords
IG-6
Vacuum leaks Repair as necessary
• PCV line
•
EGR line
•
Intake manifold
• Air intake chamber
• Throttle body
•
ISC valve
•
Brake booster line
Pulling in air between air flow meter and
throttle body
Repair as necessary
Low compression
Check compression
EM-16
ROUGH IDLING
Problem Possible cause
Remedy Page
Rough idle, stalls or
Spark plug faulty
Inspect plugs
IG-6
misses
High-tension cord faulty
Inspect cords
IG-6
Ignition problems
• Ignition coil
Inspect coil
IG-7
•
Igniter
Inspect igniter
IG-5
• Distributor Inspect distributor
IG-7
Incorrect ignition timing
Reset timing
EM-11
Vacuum leaks
Repair as necessary
• PCV line
• EGR line
•
Intake manifold
•
Air intake chamber
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ENGINE MECHANICAL — Troubleshooting EM-5
ROUGH IDLING (Cont'd)
Problem
Possible cause
Remedy
Page
Rough idle, stalls or
•
Throttle body
misses (Cont'd)
• ISC valve
•
Brake booster line
Pulling in air between air flow meter and
throttle body
Incorrect idle speed
Check ISC system
FI-40,67
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ENGINE MECHANICAL —
Troubleshooting
EM-6
ENGINE DIESELING
Problem
Possible cause
Remedy
Page
Engine diesels
(runs after ignition
switch turned off)
EFI system problems
Repair as necessary
AFTER FIRE, BACKFIRE
Problem
Possible cause
Remedy
Page
Muffler explosion
(after fire) on
deceleration only
Deceleration fuel cut system always off
Check EFI (fuel cut) system
Muffler explosion
Air cleaner clogged
Check air cleaner
EM-8
(after fire) all the
ti
me
EFI system problem
Incorrect ignition timing
Repair as necessary
Reset timing
EM-11
Engine backfires
EFI system problem
Repair as necessary
Vacuum leak
•
PCV line
e EGR line
Check hoses and repair as
necessary
•
Intake manifold
•
Air intake chamber
•
Throttle body
•
ISC valve
•
Brake booster line
Pulling in air between air flow meter
and throttle body
Repair as necessary
Insufficient fuel flow
Troubleshoot fuel system
FI-9
Incorrect ignition timing
Reset timing
EM -11
Incorrect valve clearance
Adjust valve clearance
EM-10
Carbon deposits in combustion chambers
Inspect cylinder head
EXCESSIVE OIL CONSUMPTION
Problem
Possible cause
Remedy
Page
Excessive oil
Oil leak
Repair as necessary
consumption
PCV line clogged
Check PCV system
Piston ring worn or damaged
Check rings
EM-45
Valve stem and guide bushing worn
Check valves and guide
bushing
Valve stem oil seal worn
Check seals
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ENGINE MECHANICAL —Troubleshooting
EM-7
POOR GASOLINE MILEAGE
Problem
Possible cause
Remedy
Page
Poor gasoline
Fuel leak
Repair as necessary
mileage
Air cleaner clogged
Check air cleaner
EM-8
Incorrect ignition timing
Reset timing
EM-11
EFI system problems
Repair as necessary
• Injector faulty
•
Deceleration fuel cut system faulty
Idle speed too high
Check ISC system
FI-40,67
Spark plug faulty
Inspect plugs
IG-6
EGR system always on
Check EGR system
Low compression
Check compression
EM-16
Tires improperly inflated Inflate tires to proper pressure
Brakes drag
Troubleshoot brakes
UNPLEASANT ODOR
Problem
Possible cause
Remedy
Page
Unpleasant odor
Incorrect idle speed
Check ISC system
FI-40,67
Incorrect ignition timing
Reset timing
EM-11
Vacuum leaks
Repair as necessary
•
PCV line
•
EGR line
•
Intake manifold
• Air intake chamber
•
Throttle body
• ISC valve
•
Brake booster line
EFI system problems
Repair as necessary
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Recommended Viscosity (SAE):
20W-40
20W-503
10W-40 10W-50
5W-30
°F -20 0 20 40 60 80
1 00
°C -29 -18
-7
4
1
6 27 38
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
LUO311
15W-40
10W-30
ENGINE MECHANICAL — Engine Tune-up
EM-8
ENGINE TUNE-UP
I
NSPECTION OF ENGINE COOLANT
1.
CHECK ENGINE COOLANT LEVEL AT RESERVE
TANK
The coolant level should be between the "LOW" and
"FULL" lines.
If low, check for leaks and add coolant up to the "FULL"
li
ne.
2.
CHECK ENGINE COOLANT QUALITY
There should not be any excessive rust deposits or scales
around the radiator cap or radiator filler hole, and the
coolant should be free from oil.
If excessively dirty, replace the coolant.
I NSPECTION OF ENGINE OIL
1.
CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring
or thinning.
If the quality is poor, replace the oil.
Use API grade SC, SD, SE, SF or better and recom-
mended viscosity oil.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the
"L" and "F" marks on
the dipstick.
If low, check for leakage and add oil up to the "F" mark.
I
NSPECTION OF AIR FILTER
I NSPECT AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
If necessary, replace the air cleaner element.
(b)
Clean the element with compressed air.
First blow from inside thoroughly, then blow off the out-
side of the element.
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1.26
Upper Level
Lower Level
CH0551
it
ENGINE MECHANICAL —
Engine Tune-up
EM-9
I
NSPECTION OF BATTERY
1.
CHECK BATTERY SPECIFIC GRAVITY
(a)
Check the specific gravity of each cell.
Standard specific gravity
When fully charged at 20°C (68°F): 1 .25 — 1.27
If not within specification, charge the battery.
(b)
Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
2.
CHECK BATTERY TERMINALS, FUSIBLE LINKS
AND FUSES
(a)
Check that the battery terminals are not loose or
corroded.
(b)
Check the fusible links and fuses for continuity.
I
NSPECTION OF HIGH
-
TENSION CORDS
1.
CAREFULLY REMOVE HIGH-TENSION CORDS BY
THEIR RUBBER BOOTS FROM SPARK PLUGS
NOTICE: Pulling on or bending the cords may damage
the conductor inside.
2.
INSPECT HIGH-TENSION CORD RESISTANCE
Using an ohmmeter, measure the resistance without dis-
connecting the distributor cap.
Maximum resistance: 25 kQ per cord
If resistance is greater than maximum, check the termi-
nals. If necessary, replace the high-tension cord and/or
distributor cap.
I
NSPECTION OF SPARK PLUGS
(
See page IG-6)
Recommended spark plug: ND
W16EXR-U
NGK BPR5EY
Correct electrode gap: 0.8 mm (0.031 in.)
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