Toyota 3S-GE Istruzioni operative

TOYOTA

REPAIR

MANUAL

Oct

1993

-1

M39

@1994

TOYOTA

MOTOR

CORPORATION

All

rights

reserved.

This

book

may

not

repro-

iuced

copied,

whole

part,

without

the

/vritten

permission

Toyota

Motor

Corporation.

FOREWORD

This

repair

manual

has

been

prepared

provide

information

covering

general

service

repairs

for

the

3S-GE

engine

equipped

the

TOYOTA

CELICA

and

MR2.

Applicable

models:

ST202

series

SW20

series

Please

note

that

the

publications

below

have

also

been

pre-

pared

relevant

service

manuals

for

the

components

and

system

this

engine.

Manual

Name

Pub.

No.

3S-GE

Engine

Emission

Control

Repair

ERM107E

Manual

(For

CELICA)

3S-GE

Engine

Emission

Control

Repair

ERM102E

Manual

(For

MR2)

All

information

this

manual

based

the

latest

product

information

the

time

publication.

However,

specifica-

tions

and

procedures

are

subject

change

without

notice.

TOYOTA

MOTOR

CORPORATION

"‘{

6’

IGNITION

SYSTEM

STARTING

SYSTEM

>6_$>Y»/».-.»»

%§§§§€%€4ég

»$%»..

IN-2

INTRODUCTION

-—

HOW

USE

THIS

MANUAL

HOW

USE

THIS

MANUAL

INDEX

provided

the

first

page

each

section

guide

you

the

item

repaired.

assist

you

finding

your

way

through

the

manual,

the

Section

Title

and

major

heading

are

given

at the

top

every

page.

GENERAL

DESCRIPTION

the

beginning

each

section,

General

Description

(Precautions)

given

that

pertains

all

repair

operations

contained

that

section.

Read

these

precautions

before

starting

any

repair

task.

TROUBLESHOOTING

tables

are

included

for

each

system

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

prepared

before

beginning

the

operation

and

explains

the

purpose

each

one.

IIOOK—0G

REPAIR

PROCEDURES

Most

repair

operations

begin

with

overview

illustration.

identifies

the

components

and

Oil

Pump

Body

K‘/Q»

e%»,,@

Ring

Oil

Pump

Body

Cover

shows

how

the

parts

fit

together.

Example:

Driven

Rotor

Drive

Rotor

/~\

Crankshaft

Front

Oil

Seal

Oil

Pump

Oil

Seal

N-m

(kgf~cm,

ft-lbf)

Specified

torque

Non-reusable

part

Pl5684

INTRODUCTION

—

HOW

USE

THIS

MANUAL

IN-3

The

procedures

are

presented

step—by—step

format:

The

illustration

shows

what

and

Where

it.

The

task

heading

tells

what

do.

The

detailed

text

tells

how

perform

the

task

and

gives

other

information

such

specifications

and

warnings.

Exapmle:

iii

Task

heading:

what

‘

’

I6.

CRANKSHAFT

PULLEY

I‘

(la)

Using

SST,

install

the

bolt.

ssr

09211354015

(90119-Q3126)

Illustration,

Set

part

No.

Component

part

No.

W/18?

and

W’-7?”

Detaileqitext:

how

task

I I

{

;,,

(b)

Install

the

bolt.

W»:

»-

Torque

N-rh"'(§1(I”iqjI‘-ciii,

ft"-lb?)

ll‘,

ii‘

‘

5;:

Specrfrcataon

Ii‘:

it’

"‘

vceeor

This

format

provides

the

experienced

technician

with

FAST

TRACK

the

information

needed.

The

upper

case

task

heading

can

read

glance

when

necessary,

and

the

text

below

provides

detailed

information.

Important

specifications

and

warnings

always

stand

out

bold

type.

REFERENCES

References

have

been

kept

minimum.

However,

when

they

are

required

you

are

given

the

page

refer

to.

SPECIFICATIONS

Specifications

are

presented

bold

type

throughout

the

text

where

needed.

You

never

have

leave

the

procedure

look

your

specifications.

They

are

also

found

the

end

each

section,

for

quick

reference.

if:.=‘§z=2=%i===izf:i===izizi§:

‘N4

INTRODUCTION

——

IDENTIFICATION

INFORMATION

CAUTIONS.

NOTICES.

HINTS:

IIOOI

-01

CAUTIONS

are

presented

bold

type,

and

indicate

there

possibility

injury

you

other

people.

NOTICES

are

also

presented

bold

type,

and

indicate

the

possibility

damage

the

compo-

nents

being

repaired.

HINTS

are

separated

from

the

text

but

not

appear

bold.

They

provide

additional

information

help

you

efficiently

perform

the

repair.

lllO0P—°l

UNIT

The

UNIT

given

this

manual

are

primarily

expressed

with

the

UNIT

(International

System

Unit),

and

alternately

expressed

the

metric

system

and

the

yard/pound

system.

Example:

Torque:

N-m

(310

kgf-cm.

ft-lbf)

IDENTIFICATION

INFORMATION

MW.

ENGINE

SERIAL

NUMBER

The

engine

serial

number

stamped

the

engine

block

shown.

INTRODUCTION

—

GENERAL

REPAIR

INSTRUCTIONS

IN-5

Negative

(—)

Terminal

Cable

x47

ref

‘_L__

P1357?

@\1\ii\\i‘*¥§‘¥i‘i*‘*‘l‘?“”

Seal

Lock

Adhesive

lN0036

211554

GENERAL

REPAIR

INSTRUCTIONS

|N04A—OI

Use

fender,

seat

and

floor

covers

keep

the

vehicle

clean

and

prevent

damage.

During

disassembly,

keep

parts

the

appropriate

order

facilitate

reassembly.

Observe

the

following:

Before

performing

electrical

work,

disconnect

the

negative

(—)

terminal

cable

from

the

battery.

necessary

disconnect

the

battery

for

inspec-

tion

repair,

always

disconnect

the

cable

from

the

negative

(—)

terminal

which

grounded

the

vehicle

body.

prevent

damage

the

battery

terminal

post,

loosen

the

terminal

nut

and

raise

the

cable

straight

without

twisting

prying

it.

Clean

the

battery

terminal

posts

and

cable

terminals

with

shop

rag.

not

scrape

them

with

file

other

abrasive

objects.

Install

the

cable

terminal

the

battery

post

with

the

nut

loose,

and

tighten

the nut

after

installation.

not

use

hammer

tap the

terminal

onto

the

post.

sure

the

cover

for

the

positive(+)

terminal

prop-

erly

place.

Check

hose

and

wiring

connectors

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

the

component

illustrations

the

‘O’

symbol.

Precoated

parts.

Precoated

parts

are

bolts

and

nuts,

etc.

that

are

coated

with

seal

lock

adhesive

the

factory.

precoated

part

retightened,

loosened

caused

move

any

way,

must

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

the

bolt,

nut

threads.

Precoated

parts

are

indicated

the

component

illus-

trations

the

"*'

symbol.

When

necessary,

use

sealer

gaskets

prevent

leaks.

Carefully

observe

all

specifications

for

bolt

tightening

torques.

Always

use

torque

wrench.

(a)

lb)

(C)

(d)

(6)

(fl

la)

lb)

(6)

(b)

(C)

INTRODUCTION

—

GENERAL

REPAIR

INSTRUCTIONS

Equal

Amperage

Rating

€

BEIIJBB

Use

special

service

tools

(SST)

and

special

service

materials

(SSM)

may

required,

depending

the

nature

the

repair.

sure

use

SST

and

SSM

where

specified

and

the

proper

work

proce-

dure.

list

SST

and

SSM

can

found

the

preparation

part

the

front

each

section

this

manual.

IO.

When

replacing

fuses,

sure

the

new

fuse

has

the

correct

amperage

rating

NOT

exceed

the

rating

use

one

with

lower

rating.

Illustration

Symbol

Part

Name

Abbreviation

——<>~/~<>——

FUSE

lNO365

FUSE

.»

BE5595

__<,,§_-,__

MEDIUM

CURRENT

FUSE

M-FUSE

IN0366

HIGH

CURRENT

FUSE

H-FUSE

IN0367

Q1’/Z

—<@'<>——

FUSIBLE

LINK

moss?

CIRCUIT

BREAKER

moses

V00076

I1.

Care

must

taken

when

jacking

up and

supporting

the

vehicle.

sure

lift

and

support

the

vehicle

the

proper

locations.

(a)

the

vehicle

jacked

only

the

front

rear

end,

sure

block

the

wheels

the

opposite

end

order

ensure

safety.

IN-7

INTRODUCTION

—

GENERAL

REPAIR

INSTRUCTIONS

WRONG

CORRECT

-do

IN0253

WRONG

CORRECT

lNO252

VTV

for

While

Side

VTV

r.,,

Blutk

Side

Example

moooz

lb)

(a)

(b)

(C)

(d)

(e)

lf)

l9)

lfh)

(a)

(b)

After

the

vehicle

jacked

up,

sure

support

stands.

extremely

dangerous

any

work

vehicle

raised

jack

alone,

even

for

small

job

that

can

finished

quickly.

Observe

the

following

precautions

avoid

damage

the

parts:

not

open

the

cover

case

the

ECU

unless

absolutely

nnecessary.

(If

the

terminals

are

tou-

ched,

the

may

destroyed

static

electricity.)

disconnect

vacuum

hoses,

pull

the

end,

not the

middle

the

hose.

pull

apart

electrical

connectors.

pull

the

connec-

tor

itself.

not

the

wires.

careful

not

drop

electrical

components,

such

sensors

relays.

they

are

dropped

hard

floor.

they

should

replaced

and

not

reused.

When

steam

cleaning

engine.

protect

the

distribu-

tor,

air

filter,

and

VCV

from

water.

Never

use

impact

wrench

remove

install

temperature

switches

temperature

sensors.

When

checking

continuity

the

wire

connector,

insert

the

tester

probe

carefully

prevent

terminals

from

bending.

When

using

vacuum

gauge,

never

force

the

hose

onto

connector

that

too

large.

Use

step—down

adapter

instead.

Once

the

hose

has

been

stretched,

may

leak.

Tag

hoses

before

disconnecting

them:

When

disconnecting

vacuum

hoses,

use

tags

iden-

tify

how

they

should

reconnected.

After

completing

job,

double

check

that

the

vacuum

hoses

are

properly

connected.

label

under

the

hood

shows

the

proper

layout.

Unless

otherwise

stated,

all

resistance

measured

ambient

temperature

20°C

(68°

F).

Because

the

resistance

may

outside

specifications

measured

high

temperatures

immediately

after

the

vehicle

has

been

running,

measurements

should

made

when

the

engine

has

cooled

down.

'N'8

INTRODUCTION

—

PRECAUTION

FOR

VEHICLES

EQUIPPED

WITH

CATALYTIC

CONVERTER

CAUTION:

large

amounts

unburned

gasoline

flow

into

the

converter,

may

overheat

and

create

fire

hazard.

prevent

this,

observe

the

following

precautions

and

explain

them

your

customer.

Use

only

unleaded

gasoline.

Avoid

prolonged

idling.

Avoid

running

the

engine

idle

speed

for

than 20

minutes.

Avoid

spark

jump

test.

(a)

Perform

spark

jump

test

only

when

absolutely

necessary.

Perform

this

test

rapidly

possible.

(b)

While

testing,

never

race

the

engine.

Avoid

prolonged

engine

compression

measurement.

Engine

compression

tests

must

done

rapidly

possible.

not

run

engine

when

fuel

tank

nearly

empty.

This

may

cause

the

engine

misfire

and

create

extra

load

the

converter.

Avoid

coasting

with

ignition

turned

off

and

prolonged

braking.

not

dispose

used

catalyst

along

with

parts

contaminated

with

gasoline

oil.

VEHICLE

EQUIPPED

WITH

MOBILE

COMMUNICATION

SYSTEM

For

vehicles

with

mobile

communication

systems

such

two—way

radios

and

cellular

tele-

phones,

observe

the

following

precautions.

(1)

Install

the

antenna

far

possible

away

from

the

ECU

and

sensors

the

vehicle's

electronic

system.

(2)

Install

the

antenna

feeder

least

(7.87

in.)

away

from

the

ECU

and

sensors

the

vehicle's

electronics

systems.

For

details

about

ECU

and

sensors

locations,

refer

the

section

the

applicable

component.

(3)

not

wind

the

antenna

feeder

together

with

the

other

wiring.

much

possible,

also

avoid

running

the

antenna

feeder

parallel

with

other

wire

harnesses.

(4)

Confirm

that

the

antenna

and

feeder

are

correctly

adjusted.

(5)

not

install

powerful

mobile

communications

system.

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