Toyota 4a-fe Operating instructions

TOYOTA

4A-FE, 4A-GE

NGINE REPAIR

MANUAL

TOYOTA MOTOR CORPORATION

not

be

reproduced or copied, in

whole

or

in part.

without the

written

permission

of

Toyota

Motor Corporation.

INTRODUCTION _

ENGINE

MECHANICAL

om

EFI

SYSTEM

COOLING

SYSTEM

m

LUBRICATION

SYSTEM

m

IGNITION

SYSTEM

STARTING

SYSTEM

Eli

CHARGING

SYSTEM

m

SERVICE SPECIFICA,"IONS

..

STANDARD BOLT TORQUE SPECIFICATIONS

..

SSTANDSSM

_

Tune-up data

Valve Clearance

Ignition Timing

Idle Speed

Compression Check

Timing Belt

IN-1

INTRODUCTION Page

HOW

TO USE

THIS

MANUAL

................................

IN-2

IDENTIFICATION

INFORMATION

..........................

IN-4

GENERAL REPAIR INSTRUCTIONS ..

.. ..

...........

.......

IN-4

PRECAUTIONS

FOR

VEHICLES EQUIPPED

WtTH

A

CATALYTIC

CONVERTER

...............................

IN-7

ABBREVIATIONS

USED

IN

THIS

MANUAL

..........

..

.

IN-8

\1-2

Pulley

Seat

I

Water

Pulmp

Pulley

• : Non-reusable part

INTRODUCTION -

How

to

Use This Manual

+Bearing

'

HOW

TO USE THIS

MANUAL

To

assist you

in

finding

your

way

through this manual, the Sec-

tion 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 system problem and find the cause. The

repair

for

each possible cause is referenced in the remedy col-

umn

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

together.

Example:

Water

Pump Suction Cover

+

0-Ring

•Seal

I

+Rotor

•Gasket

Water

Pump Body

C00499

INTRODUCTION -

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

what

to

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. DISCONNECT CONNECTING ROD FROM PISTON

Using SST, press

out

the pin

from

the piston.

SST

09221-25022

/

(09221-00050,

09221-0~1-00140)

Set

part

No.

Component

part

No.

Detail text:

how

to

do

it

/

(d)

Install and alternately tighten the cap nuts

in

several

passes.

Torque:

500

kg-cm

(36

ft-lb.

49

N·m)

~

Specification

This

format

provides the experienced technician

with

a FAST

TRACK

to

the information needed.

He

can read the task head-

ings and only refer to the detailed

text

when

he

needs it. Impor-

tant 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 go to.

SPECIFICATIONS

Specifications are presented in bold type

throughout

the

text

in

the applicable step. You never have

to

leave the procedure

to

look

up your specifications. All specifications are also found in

Appendix A,

for

quick reference.

CAUTIONS, NOTICES,

HINTS:

• CAUTIONS are presented

in

bold type, and indicate the

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

type. They provide additional information

to

help you

effi-

ciently perform the repair.

\1-4

4A-FE Engine

INTRODUCTION

-

Identification

Information, General Repair Instructions

4A-GE Engine

INOl

16

IN0035

IDENTIFICATION

INFORMATION

ENGINE SERIAL NUMBER

The engine serial

number

is stamped

on

the

left

side

of

the

cylinder block.

GENE_RAL

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

reassembly.

3. Observe

the

following:

{a)

Before performing electrical work,

disconnect

the

negative cable

from

the

battery terminal.

(b)

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 vehi-

cle 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 terminals

with

a

shop

rag. Do

not

scrape

them

with

a file

or

other

abrasive object.

(e)

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.

(f)

Be

sure the cover

for

the

positive(+)

terminal is pro-

perly in place.

4. Check hose and wiring connectors to make sure

that

they

are secure and correct.

5. Non-reusable parts

(a)

Always

replace

cotter

pins gaskets,

0-rings,

oil seals,

etc.

with

new

ones.

(b)

Non-reusable parts are indicated in

the

component

illustrations by

the

symbol

"+".

WRONG

INTRODUCTION

-General Repair Instructions IN-5

Seal Lock Adhesive

IN00:16

CORRECT

IN0001

6. Precoated Parts

Precoated parts are the bolts, nuts, etc. which are coated

with

a seal lock adhesive

at

the factory.

(a)

If

a precoated part is tightened, loosened or caused

to

move

in

any way,

it

must

be recoated

with

the

specified adhesive.

(b)

Recoating

of

Precoated Parts

(c)

(1) Clean

off

the

old adhesive

from

the part's

threads.

(2) Dry

with

compressed air.

(3)

Apply

the specified seal lock adhesive

to

the

part's threads.

Precoated parts are indicated

in

the

component

mustrations by the symbol "*

".

7.

When

necessary, use a sealer on gaskets to prevent leaks.

8. Carefully observe all specifications

for

bolt

torques.

Always

use a torque wrench.

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

procedure. A list

of

SST and

SSM

can be found

at

the back

of

this manual.

10.

When

replacing fuses, be sure the new fuse is the

correct

amperage.

DO

NOT exceed the fuse

amp

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

chock

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 ajack alone. even

for

a small

job

that

can be finished quickly.

12. Observe the

following

precautions to avoid damaging the

parts:

(a)

Do

not

open the cover

or

the case

of

the

ECU

unless

absolutely necessary.

{If

the

IC

terminals

are

touched,

the

IC

may be destroyed by static electricity.}

(b)

To

disconnect vacuum hoses, pull on the end

of

the

hose,

not

the middle.

(c)

To

pull apart electrical connectors, pull on the con-

nector itself,

not

the wires.

~-6

INTRODUCTION

-General Repair Instructions

Example

IN0002

(d)

When

steam cleaning an engine/

protect

the distribu-

tor, coil, air filter, and VCV

from

water.

(e)

Never use

an

impact

wrench

to

remove

or

install ther-

mo

switches

or

thermo

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.

13. Tag hoses before disconnecting them:

(a)

When

disconnecting vacuum hoses, use tags to iden-

tify

how

they should be reconnected.

(b)

After

completing a job, double check

that

the

vacuum hoses are properly connected. A label under

the

hood

shows

the

proper layout.

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

explain

them

to

your

customer.

1.

Use

only

unleaded

gasoline.

2.

Avoid

prolonged

idling.

Avoid

running

the

engine

at

fast

idle speed

for

more

than

10

minutes

and

at

idle speed

for

more

than

20

minutes.

3.

Avoid

spark

jump

test.

{a)

Perform

spark

jump

test

only

when

absolutely

necessary and as

quickly

as possible.

(b)

While

testing, never race

the

engine.

4.

Avoid

prolonged

engine

compression

measurement.

Engine

compression

tests

must

be

made

as

quickly

as

possible.

6.

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

con-

taminated

with

gasoline

or

oil.

-8

INTRODUCTION

--

Abbreviations

Used in

This

Manual

ABBREVIATIONS USED IN THIS

MANUAL

A/C

ACV

Approx.

A/T

BTDC

BVSV

DP

ECU

EFI

EGR

ESA

EX

Ex.

FIPG

FL

IG

llA

IN

ISC

LH

LHD

LLC

MP

M/T

0/5

PCV

RH

RHD

SSM

SST

STD

SW

TDC

TEMPO

TWC

UIS

VSV

w/

w/o

2WD

4WD

Air

Conditioner

Air

Control

Valve

Approximately

Automatic

Transmission

Before

Top

Dead Center

Bi-metal

V8cuum

Switching

Valve

Dash

Pot

Electronic Controlled

Unit

Electronic Fuel Injection

Exhaust

Gas Recirculation

Electronic Spark

Advance

Exhaust (manifold. valve)

Except

Formed in Place Gasket

Fusible Link

Ignition

Integrated Ignition

Assembly

Intake (manifold, valve)

Idle Speed Contro.

left-Hand

Left-Hand Drive

Long Life

Coolant

(Year Around Coolant)

Multipurpose

Manual Transmiss!on

Oversized

Positive Crankcase Ventilation

Right-Hand

Right-Hand Drive

Special Service Materials

Special Service

Tools

Standard

Switch

Top

Dead Center

Temperature

Three-Way

Catalyst

Undersized

Vacuum

Switching

Valve

With

Without

Two

Wheel

Drive

Four

Wheel

Drive

EM-2

DESCRIPTION

4A-FE ENGINE

ENGINE

MECHANICAL

-Description (4A-FE)

The

4A-FE engine is

an

in-line

4-cylinder

1.6 liter DOHC 16 valve engine.

EM7830

EM7831

ENGINE

MECHANICAL

-Description (4A-FE) EM-3

The 4A-FE 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 specified

bearings inside

the

crankcase. These bearing are

made

of

aluminum alloy.

The

crankshaft

is

integrated

with

8

weights

which

are cast

with

it

for

balane_

Oil holes are

made 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

aluminum alloy,

with

a cross

flow

type

intake and exhaust layout

with

pent

roof

type

combustion

chambers.

The

spark

plugs

are

located in the center

of

the

combustion

chamber.

The

intake

manifold

has 4 independent long

ports

and utilizes

the

inertial supercharging

effect

to

improve

engine torque at

low

and medium

speeds.

Exhaust and intake valves are equipped

with

irregular

pitch

springs made

of

special carbon steel

which

are capable

of

functioning

no

matter

what

the engine speed.

The

exhaust

side cam

shaft

is

driven by a

timing

belt, and a gear

on

the

exhaust side cam

shaft

engages

with

a

gear

on the intake side cam

shaft

to

drive it.

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 journal gear 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

outer

shim type system, in

which

valve adjusting shims are located above

the

valve

lifters.

This

permits

replacement

of

the shims

without

removal

of

the camshafts.

The

resin

timing

belt

cover

is made

of

3 pieces.

A service hole is provided

in

the No.1

belt

cover

for

adjusting

the

timing

belt

tension.

Pistons are made

of

highly temperature-resis-

tant

aluminum alloy, and a depression is

built

into

the

piston head

to

prevent interference

with

valves.

Piston pins are

the

semi-floating

type,

with

the

pins fastened

to

the

connecting rods by pressure

fitting,

allowing

the

pistons

and pins

to

float.

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

a

combination

of

steel and 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

the

leakage

of

gas

from

the

cylinder and oil ring

works

to

scrape oil

off

the

cylinder walls

to

prevent

it

from

entering the

combustion

chambers

.

The cylinder block

is

made

of

cast iron.

It

has 4

cylinders

which

are approximately 2 times the

length

of

the

piston stroke.

The

top

of

the cylin-

ders

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

to

the

bottom

of

the

cylinder block.

The

oil pan

is

an

oil reservoir made

of

pressed steel sheet. A dividing plate

i~

included

inside the oil pan

to

keep.

sufficient

oil at

the

bot-

tom

of

the pan even when

the

vehicle

is

tilted. This

dividing plate also prevents the oil

from

making

waves

when

the vehicle is

stopped

suddenly and

thus

shifting

the

oil away

from

the oil

pump

suc-

tion pipe.

•

EM-14

ENGINE

MECHANICAL

-Troubleshooting (4A-GE)

EXCESSIVE FUEL

CONSUMPTION

Problem

I

Possible

cause

'

Remedy

Page

I -

Poor gasoline mileage Fuel leak Repair

as

necessary

Air

cleaner clogged Check air cleaner

EM-25

Incorrect

ignition

timing

Reset

timing

EM-28

EFI

system

problems

Repair

as

necessary

• Injector

faulty

• Deceleration fuel

cut

system

faulty

Idle speed

to

high

Adjust

idle speed EM-30,

31

Spark plug

faulty

Inspect plugs

IG-11,

12

I

EGR

system always on (w/

EGR

system) Check

EGR

system

Low

compression Check compression

EM-38

Tires improperly

inflated

Inflate tires

to

proper

pressure

Clutch

slips

Troubleshoot

clutch

Brakes drag

Troubleshoot

brakes

UNPLEASANT

ODOR

Problem

Possible

cause

Remedy

Page

Unpleasant

odor

i Incorrect idle speed

Adjust

idle speed EM-30,

31

Incorrect ignition

timing

Reset timing

EM-28

Vacuum

leaks Repair as necessary

• PCV line

•

EGR

line

(w/

EGR

system)

• Intake

manifold

•

Throttle

body

• Brake

booster

line

EFI

system problems i Repair as necessary

ENGINE

MECHANICAL

-Engine

Tune-up

(4A-FE)

EM-15

Front

Back

'------------~'"\~~061

ENGINE TUl\IE-UP (4A-FE)

INSPECTION OF ENGINE

COOLANT

(See

steps

1

and

2

on

page

C0-5)

INSPECTION

OF

ENGINE

OIL

(See

steps

1

and

2

on

page

LU-6)

INSPECTION

OF

BATTERY

(See

page

1

and

2

on

page

CH-3)

Standard

specific

gravity:

1.25

-

1.27

when

fully

charged

at

20°C

(68°F}

INSPECTION

OF

AIR FILTEA

1.

INSPECT

AIR

FILTER

Visually

check

that

the

element

is

not

excessively

dirty,

damaged

or

oily.

2.

CLEAN

AIR

FILTER

Clean

the

element

with

compressed

air.

First

blow

from

the

back

thoroughly.

Then

blow

off

the

front

of

the

element.

INSPECTION

OF

HIGH-TENSION CORDS

(See

page

IG-5)

Maximum

resistance:

25

fl

per

cord

INSPECTION OF SPARK PLUGS

(See

page

IG-6)

Correct

electrode

gap:

0.8

mm

(0.031 in.)

Recommended

spark

plugs:

ND

Q16R-U

NGK

BCPR5EY

INSPECTION

OF

ALTERNATOR DRIVE BELT

(See

page

3

on

page

CH-3}

Drive

belt

deflection:

Used

belt

10.0

-

12.0

mm

(0.394

-

0.4

72

in.)

New

belt

8.5

-

10.5

mm

(0.335

-

0.413

in.)

Drive

belt

tension

(Reference):

Used

belt

40

-

55

kg

New

belt

60

-

70

kg

EM-16

1 1

ENGINE

MECHANICAL

-Engine

Tune-up

(4A-FE)

EM7820

3 3 4 4

EM7821

INSPECTION

AND

ADJUSTMENT

OF

VALVE

CLEARANCE

HINT:

Inspect

and

adjust

the

valve clearance

when

the

engine is cold.

1.

DISCONNECT

HIGH-TENSION

CORDS

FROM

SPARK

PLUGS

2.

REMOVE

CYLINDER

HEAD

COVER (See

page

EM-62)

3.

SET

N0.1

CYLINDER

TO

TDC/COMPRESSION

(a)

Turn

the

crankshaft

pulley

and align

its

groove

with

the

timing

mark

"O"

of

the No.1

timing

belt cover.

{b)

Check

that

the

valve

lifters

on

the

No.1 cylinder are

loose and valve

lifters

on

the

No.4

cylinder

are

tight.

If

not,

turn

the

crankshaft

one revolution

(360°)

and

align

the

mark

as

above.

4.

INSPECT

VALVE

CLEARANCE

(a)

Check

only

those

valves indicated in the illustration.

• Using a

thickness

gauge, measure

the

clearance

between

the

valve

lifter

and

camshaft.

• Record

the

valve clearance measurements

which

are

out

of

specification.

They

will

be used later

to

determine

the

required replacement adjusting

shim

.

Valve

clearance

(Cold):

Intake

0.15

-

0.25

mm

(0.006

-

0.010

in.)

Exhaust

0.20

-

0.30

mm

(0.008

-

0.012

in.)

(b)

Turn

the

crankshaft

one

revolution

(360°)

and align

the

mark as above. (See procedure step

3)

(c)

Check

only

the

valves indicated as shown.

Measure the valve clearance.

(See

procedure

step

(a)).

5.

ADJUST

VALVE

CLEARANCE

(a)

Remove

the

adjusting shim.

• Turn the

crankshaft

to

position

the

cam

lobe

of

the

camshaft

on

the

adjusting valve upward.

• Using

SST

(A). press

down

the

valve

lifter

and

ptace

SST

(8)

between

the

camshaft

and valve

lifter. Remove

SST

(A).

SST

09248-55010

ENGINE

MECHANICAL

-Engine Tune-up (4A-FE)

EM-17

EM4252

• Remove the adjusting shim

with

small screwdriver

and magnetic finger.

(b) Determine the replacement adjusting shim size

by

using the following Formula

or

Charts.

• Using a micrometer, measure the thickness

of

the

shim

which

was removed.

• Calculate the thickness

of

the new shim so the

valve clearance comes

within

specified value.

T Thickness

of

shim used

A

.....

Valve clearance measured

N

.....

Thickness

of

new shim

Intake:

N =T +

(A

-

0.20

mm

(0.008

in.})

Exhaust:

N = T +

(A

-

0.25

mm

(0.010

in.))

• Select a shim

with

a thickness

as

close

as

possible

to the calculated values.

HINT: Shims are available

in

seventeen sizes

of

0.05

mm

(0.0020

in.),

from

2.50

mm

(0.0984

in.)

to

3.30

mm

(0.1299

in.).

(c) Install a new adjusting shim.

• Place a new adjusting shim on the valve lifter.

• Using SST (A), press

down

the valve

lifter

and

remove SST (8).

SST

09248-55010

(d)

Recheck the valve clearance.

6.

INSTALL

CYLINDER

HEAD

COVER (See

page

EM-86)

7. CONNECT

HIGH-TENSION

CORDS TO SPARK

PLUGS

EM-18

ENGINE

MECHANICAL

-Engine

Tune-up

(4A-FE)

Adjusting

Shim

Selection

Chart

INTAKE

tnatalted

Shim

fhicknHa

(rnml

MllHLmtd

0"'

o,o

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o·g

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11118

Imm)

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IO

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~.~

~ ~

~

~!~

~ ~;g

q

~;~

~

~-~ ~;~

~~~~·~~~~~I~

"'

"'It\

'°

IO

N N N

N:l'il

....

"'

N;N

N

~

~~~

~ N ~

NIN

N N

N:N

N!N

~

N

~.N

~

N N N

N~~:N.~

~ M

~~Mi~

M

~ ~ ~

~:M

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1

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:

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000

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1001 -1.025

34

Intake

valve

clearance

(cold):

0.15

-

0.25

mm

(0.006

-

0.010

in.)

Example:

A

2.800

mm

shim

is

installed

and

the

measured

clearance is

0.450

mm.

Replace

the

2.800

mm

shim

with

shim

No.

24

(3.050

mm).

34.

Shim thicknesses

mm

(in.)

Shim Shim

No. Thickness No. Thickness

02

2.500

(0.0984)

20

2.950

(0.1161)

04

2.550

(0.1004)

22

3.000

(0.

1181)

06

2.600

(0.,

024)

24

3.050

(0.1201)

08

2.650

(0.1043) 26

3.100

(0.1220)

10

2.700

(0.1063)

28

3.150

(0.1240)

12

2.

750

(0.1083)

30

3.200

(0.1260)

14

2.800

(0.

1102)

32

3.250

(0.

1280)

16

2.850

(0.

11

22)

34

3.300

(0.1299)

18

2.900

(0.1 ,

42)

M.esured

Ci.&r1nce

lmml

ENGINE

MECHANICAL

-Engine Tune-up (4A-FE)

Adjusting

Shim

Selection

Chart

EXHAUST

lnattlkld

Shim

Thiekneu

Imm)

EM-19

Shim thicknesses

mm

(in,)

Exhaust

valve

clearance

fcold):

0.20

-

0.30

mm

(0.008 -

0.012

in.J

Example:

A

2.800

mm

shim

is

installed

and

the

measured

clearance

is

0.450

mm.

Replace

the

2.800

mm

shim

with

shim No.

22

(3.000

mmL

Shim

No.

02

04

06

08

10

12

14

16

18

Thickness Shim

No. Thickness

2.500

(0.0984)

20

2.950

(0.1161)

2.550

(0.,

004)

22

2.600

(0.1024)

24

2.650

(0.1043~

26

2.

700

(0.1

063)

28

2.

750

(0,

1083)

30

.800

(0.11

02)

!

32

2.850

(0.11

22}

34

2.900

(0.,

142)

1181)

3.050

(0.1201)

3.100

(0.,

220)

3.1

50

(0.1

240)

3.200

(0.1

260)

3.250

(0.1280)

3.300

(0.1

EM-20

Check Connector

/

Connector

ENGINE

MECHANICAL

-Engine Tune-up (4A-FE)

EM7500

INSPECTION

AND

ADJUSTMENT

OF

IGNITION

TIMING

1.

WARM

UP ENGINE

2.

Allow

the engine

to

reach normal operating temperature.

CONNECT

TACHOMETER

Connect

the

test probe

of

a tachometer

to

terminal

IG 8

of

the check connector.

LOCATION: See page Fl-1

33

NOTICE:

• NEVER

allow

the

tachometer

terminal

to

touch

ground

as

it

could

result

in

damage

to

the

igniter

and/or

ignition

coil.

•

As

some

tachometers

are

not

compatible

with

this

ignition

system,

we

recommend

that

you

confirm

the

compatibility

of

your

unit

before

use.

3.

INSPECT

AND

ADJUST

IGNITION

TIMING

(a)

Using SST, connect terminals

TE1

and

E1

of

the

SST check connector.

EM7502

IG1266

EM7515

SST

09843-18020

(b) Using a timing light, check the Ignition timing.

Ignition

timing:

10°

BTDC @

idle

(Transmission

in

neutral

range)

If

necessary# loosen the

distributor

bolts

and turn the dis-

tributor. Recheck the timing aftertightening the distributor

bolts.

Torque:

200

kg-cm

(14

ft-lb,

20

N·m)

ENGINE MECHANICAL -Engine Tune-up (4A-FE) EM-21

EM7503

IG1266

4.

FURTHER CHECK IGNITION TIMING

{a)

Remove SST from the check connector.

SST

09843-18020

(b)

Check

the

ignition timing.

Ignition

timing:

5 -

15°

BTDC @

idle

(Transmission in

neutral

range)

HINT: The timing mark move

in

a range between 5° to

15°.

5. DISCONNECT TACHOMETER AND TIMING

LIGHT

FROM ENGINE

ENGINE

MECHANICAL

-Engine

Tune-up

{4A-FE)

\ Idle Speed

\~Adjusting

Screw

~

EM6886

INSPECTION

AND

ADJUSTMENT

OF

IDLE SPEED

(w/

TWC)

1.

INITIAL

CONDITIONS

{a)

Air

clearance installed

(b)

Normal

engine

operating

temperature

(c)

All

pipes and hoses

of

air

induction

system

con-

nected

{d)

All

vacuum

lines

connected

HINT:

All

vacuum

hoses

for

EGR

systems, etc.

should

be

properly

connected.

(e)

All

accessories

switched

off

(f)

EFI

system

wiring

connectors

fully

plugged

{g)

Ignition

timing

set

correctly

(h)

Transmission

in

"neutral"

range

2.

WARM

UP

ENGINE

Allow

the

engine

to

reach

normal

operating

temperature.

3.

CONNECT

TACHOMETER

(See

page

EM-20)

4.

CHECK

AIR

VALVE

OPERATION

{See

page

Fl-131)

5.

INSPECT

AND

ADJUST

IDLE

SPEED

Idle

speed:

800

rpm

(w/

Cooling

fan

OFF)

If

not

as

specified,

adjust

the idie speed by turning the

IDLE SPEED

ADJUSTING

SCREW.

Toyota 4A-FE Operating instructions

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