Toyota 3S-GE Operating instructions

@ TOYOTA
REPAIR MANUAL
Oct 1993
-1
M39

@1994 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
iuced or copied, in whole or in part, without the
/vritten permission of Toyota Motor Corporation.
FOREWORD
This repair manual has been prepared to provide information
covering general service repairs for the 3S-GE engine
equipped in the TOYOTA CELICA and MR2.
Applicable models: ST202 series
SW20 series
Please note that the publications below have also been pre-
pared as relevant service manuals for the components and
system in this engine.
Manual Name l Pub. No.
0 3S-GE Engine Emission Control Repair ERM107E
Manual (For CELICA)
0 3S-GE Engine Emission Control Repair ERM102E
Manual (For MR2)
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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IGNITION SYSTEM
STARTING SYSTEM
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IN-2 INTRODUCTION -— HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist you in finding your way through the manual, the Section Title and major heading are
given at the top of every page.
GENERAL DESCRIPTION
At the beginning of each section, a General Description (Precautions) is given that pertains to all
repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause. _
PREPARATION
IIIOOF -01
IIDOII —0I
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and
SSM (Special Service Materials) which should be prepared before beginning the operation and
explains the purpose of each one.
IIOOK—0G
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
Oil Pump Body
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O O Ring
Oil Pump Body Cover
shows how the parts fit together.
Example:
Driven Rotor
Drive Rotor ®
/~\
® 0 Crankshaft Front Oil Seal
Oil Pump Oil Seal
N-m (kgf~cm, ft-lbf) : Specified torque
Q Non-reusable part
Pl5684

INTRODUCTION — HOW TO USE THIS MANUAL IN-3
The procedures are presented in a step—by—step format:
0 The illustration shows what to do and Where to do it.
0 The task heading tells what to do.
0 The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Exapmle:
iii Task heading: what to do
In ' ‘ ’
. I6. CRANKSHAFT PULLEY I
I‘ .
(la) Using SST, install the bolt.
2 ssr 09211354015 (90119-Q3126) .
Illustration, Set part No. Component part No.
W/18? T0 d0 and W’-7?” Detaileqitext: how to do task
I I I ' 1" E '\ "9 Q A; ,
{ I 2- A / - /- ;,,
I " , (b) Install the bolt. W»: W »- ,.
Torque so N-rh"'(§1(I”iqjI‘-ciii, 22 ft"-lb?)
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It ll‘, ii‘ \ , ‘ .
5;: ' Specrfrcataon
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This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.
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 at the end of each section,
for quick reference.
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‘N4 INTRODUCTION —— IDENTIFICATION INFORMATION
CAUTIONS. NOTICES. HINTS:
IIOOI -01
O CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
0 NOTICES are also presented in bold type, and indicate the possibility of damage to the compo-
nents being repaired.
O HINTS are separated from the text but do not appear in bold. They provide additional information
to help you efficiently perform the repair.
lllO0P—°l
SI UNIT
The UNIT given in this manual are primarily expressed with the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the yard/pound system.
Example:
Torque: 30 N-m (310 kgf-cm. 22 ft-lbf)
IDENTIFICATION INFORMATION MW.
ENGINE SERIAL NUMBER
)/ \ C The engine serial number is stamped on the engine
W "'
block as shown.
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INTRODUCTION —
GENERAL REPAIR INSTRUCTIONS IN-5
Negative (—) Terminal Cable
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P1357?
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Seal Lock Adhesive
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GENERAL REPAIR INSTRUCTIONS
|N04A—OI
Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
During disassembly, keep parts in the appropriate
order to facilitate reassembly.
Observe the following:
Before performing electrical work, disconnect the
negative (—) terminal cable from the battery.
If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (—) terminal which is grounded to the vehicle
body.
To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it. I
Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive objects.
Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do not
use a hammer to tap the terminal onto the post.
Be sure the cover for the positive(+) terminal is prop-
erly in place. .
Check hose and wiring connectors to make sure that
they are secure and correct.
Non—reusable parts.
Always replace cotter pins, gaskets, O—rings and oil
seals etc. with new ones.
Non—reusable parts are indicated in the component
illustrations by the ‘O’ symbol.
Precoated parts.
Precoated parts are bolts and nuts, etc. that are
coated with a seal lock adhesive at the factory.
If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.
When reusing precoated parts, clean off the old adhe-
sive and dry with compressed air. Then apply the
specified seal lock adhesive to the bolt, nut or threads.
Precoated parts are indicated in the component illus-
trations by the "*' symbol.
When necessary, use a sealer on gaskets to prevent
leaks.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
I.
2.
3.
(a)
lb)
(C)
(d)
(6)
(fl
4.
5.
la)
lb)
6.
(6)
(b)
(C)
7.
8.

INTRODUCTION — GENERAL REPAIR INSTRUCTIONS
Equal Amperage Rating
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9. Use of special service tools (SST) and special service
materials (SSM) may be required, depending on the
nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found in the
preparation part at the front of each section in this
manual.
IO. When replacing fuses, be sure the new fuse has the
correct amperage rating . DO NOT exceed the rating
or use one with a lower rating.
Illustration
Symbol Part Name Abbreviation
, é
——<>~/~<>—— FUSE
lNO365
FUSE
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BE5595
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MEDIUM CURRENT FUSE M-FUSE
IN0366
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HIGH CURRENT FUSE H-FUSE
IN0367
Q1’/Z
—<@'<>——
FUSIBLE LINK FL
moss?
- CIRCUIT BREAKER CB
moses
V00076
I1. 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 at the opposite end in
order to ensure safety.

IN-7
INTRODUCTION — GENERAL REPAIR INSTRUCTIONS
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(b)
(C)
(d)
(e)
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(a)
(b)
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After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on a
vehicle raised on a jack alone, even for a small job that
can be finished quickly.
Observe the following precautions to avoid damage to
the parts:
Do not open the cover or case of the ECU unless
absolutely nnecessary. (If the IC terminals are tou-
ched, the IC may be destroyed by static electricity.)
To disconnect vacuum hoses, pull on the end, not the
middle of the hose.
To pull apart electrical connectors. pull on the connec-
tor itself. not the wires.
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.
When steam cleaning an engine. protect the distribu-
tor, air filter, and VCV from water.
Never use an impact wrench to remove or install
temperature switches or temperature sensors.
When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
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.
Tag hoses before disconnecting them:
When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
After completing a job, double check that the vacuum
hoses are properly connected. A label under the hood
shows the proper layout.
Unless otherwise stated, all resistance is measured at
an ambient temperature of 20°C (68° F). Because the
resistance may be outside specifications if measured
at high temperatures immediately after the vehicle
has been running, measurements should be made
when the engine has cooled down.

'N'8 INTRODUCTION — PRECAUTION
PRECAUTION
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 explain 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 spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
5. Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
6. Avoid coasting with ignition turned off and prolonged braking.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two—way radios and cellular tele-
phones, observe the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's
electronics systems. For details about ECU and sensors locations, refer to the section on the
applicable component.
(3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Confirm that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.