Toyota 3S-GTE Operating instructions

® TOYOTA
FIEPMR MANUAL SUPPLEMENT
Feb 1994 | I _

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35-GE Engine RupaIr Mlrlual (Pub, N0.RM3QBE) ,
INTRODUCTION
ENGINE
STARTING SYSTEM
CHARGING SYSTEM
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INTRODUCTION
HOW TC USE THIS MANUAL ---------------- -- IN
IDENTIFICATION INFORMATION IN
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GENERAL REPAIR INSTRUCTIONS
ABE-REVIATICN5 USED IN THIS
MAHUM_
STANDARD BOLT TDRCIUE
SPECIFICATIONS
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"H 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.
G EN ERAL D ESC R I PT I O N
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. mm
PREPARATION
|I|en¢—\7l
lIO0N—flI
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.
REPAIR PROCEDURES
moo: —M
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
Oil Pump Body
Driven Rotor
Drive Rotor
‘ -
OOR| ,‘\>
Hg
A
gg
\§%<,
P
/,.\ La
® '- 0 Crankshaft Front Oil Seal
Oil Pump Oil Seal
N-m (kgf-cm, ft-lbf) 1 Specified torque
O Non-reusable part
P156-t‘-1

INTRODUCTION — HOW TO USE THIS MANUAL IN-3
The procedures are presented in a step—by—step format:
O 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:
Task heading: what to do
. 5. INSTALL CRANKSHAFT PULLEY
(8) USIFIQ SST, install the IJOII.
SST 092113254015 (90119-Q2126)
”Ius”an.on._ Set pan No. Component part No.
what I0 G/0 arid Where Detailed text: how to do task
(b) Install the b6l/t.
Torque: 30 N-m (310 kgf-cm.<2 ft-lbf)
Specification
‘IUDI
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.

"M INTRODUCTION - IDENTIFICATION INFORMATION
CAUTIONS. NOTICES. HINTS:
IIMI —fll
0 CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
I NOTICES are also presented in bold type, and indicate the possibility of damage to the compo-
nents being repaired.
I HINTS are separated from the text but do not appear in bold. They provide additional information
to help you efficiently perform the repair.
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
ENGINE SERIAL NUMBER
/ The engine serial number is stamped on the engine
block as shown.
IIWO-01‘
I PIBSII

INTRODUCTION —
IN-5
GENERAL REPAIR INSTRUCTIONS
Negative (—) Terminal Cable
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Seal Lock Adhesive
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GENERAL REPAIR INSTRUCTIONS
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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 the negative (—)
terminal cable from the battery which is grounded to
the vehicle body.
To prevent damage to the battery terminal, loosen the
cable nut and raise the cable straight up without
twisting or prying it.
Clean the battery terminals and cable ends with a
shop rag. Do not scrape them with a file or other
abrasive objects.
Install the cable ends to the battery terminals with the
nut loose, and tighten the nut after installation. Do not
use a hammer to tap the cable ends onto the termi-
nals.
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, 0—rings and oil
seals etc. with new ones.
Non—reusabIe parts are indicated in the component
illustrations by the ‘Q’ 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 "k" symbol.
When necessary, use a sealer on gaskets to prevent
leaks.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
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IN-6
INTRODUCTION — GENERAL REPAIR INSTRUCTIONS
Fuse
Equal Amperage Rating
fit
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9.
10.
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.
When replacing fuses, be sure the new fuse has the
correct amperage rating . D0 NOT exceed the rating
or use one with a lower rating.
Illustration Symbol Part Name
Abbreviation
1 we
‘ B55594
.-iQ_/-vi
FUSE FUSE
INO385
BE 5595
é%——
MEDIUM CURRENT FUSE M~FUSE
M0366
BE5596
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HIGH CURRENT FUSE H-FUSE
INOSB7
I
BE5597
Avie?
FUSIBLE LINK FL
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BE5598
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CIRCUIT BREAKER CB
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Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at
the proper locations.
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.

INTRODUCTION — GENERAL REPAIR INSTRUCTIONS ‘N-7
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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, igniter and air filter 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.
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N; :§;
"M INTRODUCTION - PRECAUTION
PRECAUTION MM
FOR VEHICLES EOUIPPED 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 EOUIPPED WITH MOBILE COMMUNICATION SYSTEM “H
For vehicles with mobile communication systems such as two—way radios and cellular tele-
phones. observe the following precautions.
Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
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.
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.
Confirm that the antenna and feeder are correctly adjusted.
Do not install powerful mobile communications system.
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INTRODUCTION — ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL mu
A/C
Air conditioner
BTDC
Before Top Dead Center
BVSV
CPU
Bimetallic Vacuum Switching Valve .46»
' ..-tr
Central Processing Unit
DOHC
Double Over Head Cam
ECU
Electronic Control Uinit
EFI
Electronic Fuel Injection
ESA
Electronic Spark Advance
EGR
Exhaust Gas Recirculation
FIPG
Formed in Place Gasket
FL
Fusible Link
H ~Fuse
High Current Fuse
IC
Integrated Circuit
IG
Ignition
ISC
ldle Speed Control
LH
Laft—Hand
M—Fuse
Medium Current Fuse
MP
Multipurpose
PCV
Positive Crankcase Ventilation
PS
Power Steering
RH
Right — Hand
SSM
Special Service Materials
SST
Special Service Tools
STD
Standard
SW
Switch
TCCS
TOYOTA Computer controlled System
TDC
Top Dead Center
TEMP.
Temperature
TWC
Three—Way Catalyst
U/S Undersize
VSV
Vacuum Switching Valve
W/
With
w/o
Without
éeaasw

IN-10
INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
STANDARD BOLT TORQUE SPECIFICATIONS
IIDOI "DI
\ Mark Class Mark Class
head bolt
Hexagon 4- 4T
-— ST
Bolt 6 -— 6T
head No. 7_ 71-
4
- 8T
9
10
— 9T
— 1 OT
11- 11T
©
No mark
4T
Hexagon
flange bolt
wl washer
hexagon bolt
No mark
4T
Hexagon
head bolt
G
2
protruding
lines
5T
Hexagon
flange bolt
wl washer
hexagon bolt
2
protruding
lines
6T
Stud bOII
((((£((IL(((((((((((((O
((((((
_,
No mark
{((((((((((((’l(((((((((((((’G
\_J
G roov ed
Hexagon
head bolt
3
protruding
lines
7T
Hexagon
head bolt
4
protruding
lines
3T
Welded bolt
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IN-1
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
T
SPECIFIED TORQUE FOR STANDARD BOLTS
Diameter Pitch
Class mm mm
Specified torque
Hexagon head bolt
Hexagon flange bolt
N-m kgf-cm ft-Ibf N-m kgf-cm
ft~Ibf
6 1
8 1.25
10 1.25
12 1.25
14 1.5
16 1.5
4T
5
12.5
26
47
74
115
55
130
260
480
760
1,1 50
48
9
19
35
55
83
in.'Ibf 6
14
29
53
84
60
145
290
540
850
52
10
21
39
61
|l'1. lbf ;- w
6 1
8 1.25
10 1.25
12 1.25
14 1.5
16 1.5
5T
6.5
15.5
32
59
91
140
65
160
330
600
930
1,400
56
12
24
43
67
101
in.-Ibf
7.5
17.5
36
65
100
75
175
360
670
1.050
65
13
26
48
76
in.-lbf
6 1
8 1.25
10 1.25
12 1.25
14 1.5
16 1.5
6T
8
19
39
71
110
170
80
195
400
730
1,100
1,750
69
14
29
53
80
27
in.-Ibf 9
21
44
80
125
90
210
440
810
1,250
78
15
32
59
90
in.-Ibf
6 1
8 1.25
10 1.25
12 1.25
14 1.5
16 1.5
7T
10.5
25
52
95
145
230
1 10
260
530
970
1,500
2,300
8
19
38
70
108
166
12
28
58
105
165
120
290
590
1,050
1,700
9
21
43
76
23
8 1.25
8T 10 1.25
12 1.25
29
61
110
300
620
1.100
22
45
80
33
68
120
330
690
1,250
24
50
90
a 1.25
er 10 1.25
‘ 12 1.25
34
70
125
340
710
1,300
25
51
94
37
78
140
380
790
1,450
27
57
105
, a 1.25
1OT 1o 1.25
12 1.25
38
78
140
390
800
1,450
28
58
105
42
88
155
430
890
1 .600
31
64
116
8 1.25
11T 10 1.25
12 1.25
42
87
155
430
890
1 .600
31
64
116
47
97
175
480
990
1,800
35
72
130

EG-1
ENGINE
EG —
EG -
EG —
EG—
EG -
EG —
EG—
EG—
EG—
EG—
EG—
EG-
EG -
EG—
EG—
EG-
EG—
EG—
EG— 96
EG— 104
EG—1II5
EG—1l1B
EG— I09
EG— 110
EG— I10
EG— 1 12
11111‘-il%|<l%.l_.IUJOJ¢a.l LI'I(Alf\3—*Zl-DIXUJ-‘CDC?-in-G5-h-l'\Jf\JhJ
ENG|NE MECHAN|CA|_ ......................... ..
. . . - . - . . . . . . ... . . . ......... . . . . . . . . . . . . . ..
. . . . . . . . . . . . ... . - . . - . . - - - . - . . . . . . . . . . . . . .-
. . . . . . . . . . - . . . . . . . . . . . . . . .... . . . . . . . . ..
... . . . . . . . - ..... . . . . . . . . . . . . . . . . . . . . . . . . ... ..
......... . . . . - . . - . . - . . - . . . . . ... .-
- . . . . . - - . . - . . - - - - - - - - - - . - ..
. . . . . . . . . . . . . . . . . . . - . . . . ... - . - . . - - -.
... . - . . . .... . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . ........ . . ..
TURBOCHARGER SYSTEM ................... ..
. . - . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . - . . . . . - . .... . . . . . . ..
. . - . - . --- . . . . ..
PRECAU-|-|QN ................ ..
TROUBLESHOOTING ---- --
. . . . . . . . . . . . . . . . ..
. . . - . - . - . . . . . . . .... ..
|N-|-ERCQOLER RELAY ............................ ..
TURBO PRESSURE SENSOR ------------------- --
VSV [For Turbocharging Pressure) ---------- --
SERWCE spEC|F|cAT|QNS ...................... ..
EF| SYSTEM ........................................... ..
» . ~ . - . - ¢ - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
0PERAT|QN ........................................ ..
. . - - . - . - ... . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . - ..
TROUBLESHOOTING w/ VOLT.
. . . . . . . . . . . . . . . . . . . . . . . . - . . - . . . . . . . . . . . . .-
. . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
. . . . . - - - . . - . - - - - - . - - - - .- EG-
. . . ... - . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . ..
......... . . . .... . . . . . - - . . . . . - . . . - - .-
INTAKE AIR TEMPERATURE SENSOR ---- -- EG—I68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
FUEL PUMP RELAY AND RESISTOR ------- -- EG—1TU
SERVICE SPECIFICATIONS ---- EG~IT2
COOUNG SYSTEM ............................... .. EG_115
OpERA‘|'|0N ........................................ .. EG_115
. - . - . - . - - . - . - . . . - - . - . - - . . . . - . . - . - . - . . -.
SERVICE SPECIFICATIONS ---------------------- -- EG—IT3
. . . . . . . . . . . . . . . - . . . . . . . . . ..
. ... ........ ... . . . . . . . . . . ... .. .......
. . . . . . . . . . . . . . . ..... . - - . . ---- . . . . . ... ........
. . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . ..
SERVICE SPECIFICATIONS ---------------------- '- EG— I83
REFER TO 3S-GE ENGINE REPAIR MANUAL
(Pub. No. RM396EI
NOTE: The above pages contain only the points
which differ from the above listed manual.
2- .-'2

it
EG-2
ENGINE - ENGINE MECHANICAL
ENGINE MECHANICAL
DESCRIPTION
The 3S—GTE engine is an in—|ine, 4 cylinder, 2.0 liter DOHC 16—vaIve engine
OPERATION
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ENGINE — ENGINE MECHANICAL EG-3
The 3S—GTE engine is an in—line. 4 cylinder engine with the cylinders numbered 1 — 2 — 3 —
4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearings
are made of aluminum alloy.
The crankshaft is integrated with 8 weights for balance. Oil holes are placed in the center of the
crankshaft to supply oil to the connecting rods, bearing, pistons and other components.
The ignition order is 1 — 3 — 4 — 2. The cylinder head is made of of aluminum alloy, with a cross
flow type intake and exhaust layout and with pent—roof type combustion chambers. The spark
plugs are located in the center of the combustion chambers.
The intake manifold has 4 independent long ports and utilizes the inertial supercharging effect to
improve engine torque at low and medium speeds.
Both the intake camshaft and the exhaust camshaft are driven by a single timing belt. The cam
journal is supported at 5 places between the valve lifters of each cylinder and on the front end of
the cylinder head. Lubrication of the cam journals and cams is accomplished by oil being supplied
through the oiler port in the center of the camshaft.
Adjustment of the valve clearance is done by means of an inner shim type system. in which valve
adjusting shims are located below the valve lifters. To replace the shims, the camshafts must be
removed.
Pistons are made of high temperature—resistant aluminum alloy, and a depression is built into the
piston head to prevent interference with the valves.
Piston pins are the fu|l—f|oating type, with the pins fastened to neither the piston boss nor the
connecting 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 stainless steel and the No.2 compression ring is made of
cast iron. The oil ring is made of stainless 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 gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to
prevent it from entering the combustion chambers.
The top of each cylinder 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 contains a
water jacket, through which coolant is pumped to cool the cylinders.
The No.1 and No.2 oil pans are bolted onto the bottom the cylinder block. The No.1 oil pan is
made of alumimum alloy. The No.2 oil pan is an oil reservoir made of pressed sheet steel. The
dividing plate also prevents the oil from shifting away from the oil pump suction pipe when the
vehicle is stopped suddenly.
<