Sau khi học xong bài này người học có khả năng: Kiến thức: Trình bày đúng nhiệm vụ, cấu tạo chung, lực tác dụng lên thân máy, nắp máy và cơ cấu trục khuỷu thanh truyền. Kĩ năng: Tháo lắp bộ phận cố định và cơ cấu trục khuỷu thanh truyền đúng quy trình, quy phạm và đúng yêu cầu kỹ thuật Năng lực tự chủ và trách nhiệm: Chấp hành đúng quy trình, quy phạm trong nghề công nghệ ô tô, Rèn luyện tính kỷ luật, cẩn thận, tỉ mỉ của học viên.
IN–1 INTRODUCTION – INTRODUCTION 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 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 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 Most repair operations begin with an overview illustration It identifies the components and shows how the parts fit together Example: IN–3 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: Example: • The illustration shows what to and where to it • The task heading tells what to • The detailed text tells how to perform the task and gives other information such as specifications and warnings 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 IN–4 INTRODUCTION – IDENTIFICATION INFORMATION 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 the possibility of damage to the components being repaired • HINTS are separated from the text but not appear in bold They provide additional information to help you perform the repair efficiently SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT(Internationai System of Unit), and alternately expressed in the metric system and in the English System Example: Torque: 30 N–m (310 kgf–cm, 22 ft–lbf) IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label A Vehicle Identification Number Plate B Certification Label ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown IN–5 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 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: (a) Before performing electrical work, disconnect the negative cable from the battery terminal (b) If it is necessary to disconnect the battery for inspection 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 str– aight up without twisting or prying it (d) Cleah the battery terminal posts and cable ter– minals with a clean shop rag Do not scrape them with a file or other abrasive objects (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installa– tion Do not use a hammer to tap the terminal onto the post (f) Be sure the cover for the positive (+) terminal is properly in place Check hose and wiring connectors to make sure that they are secure and correct Non–reusable parts (a) Always replace cotter pins, gaskets, 0– rings and oil seals etc with new ones (b) Non–reusable parts are indicated in the com– ponent illustrations by the“♦” symbol Precoated parts Precoated parts are bolts and nuts, etc that are coated with a seal lock adhesive at the factory (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive IN–6 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air Then apply the specified seal lock adhesive to the bolt, nut or threads (c) Precoated parts are indicated in the component illustrations 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 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 10 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 FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE L!1VK CIRCUIT BREAKER IN–7 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS 11 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the proper locations (See page IN–9) (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 (6) After the vehicle is jacked up, be sure to support it on stands It is extremely dangerous to any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly 12 Observe the following precautions to avoid damage to the parts: (a) Do not open the cover or case of the ECU, ECM, PCM or TCM unless absolutely necessary (If the IC terminals are touched, the IC may be destr– oyed by static electricity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose (c) To pull apart electrical connectors, pull on the connector itself, not the wires (d) 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 (e) When steam cleaning an engine, protect the distributor, air filter, and VCV from water (f) Never use an impact wrench to remove or install temperature switches or temperature sensors (g) When checking continuity at the wire connector, insert the tester probe carefully to prevent ter– minals from bending (h) 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 identify 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 IN–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 Use only unleaded gasoline Avoid prolonged idling Avoid running the engine at idle speed for more than 20 minutes 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 Avoid prolonged engine compression measurement Engine compression tests must be done as rapidly as possible 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 Avoid coasting with ignition turned off and prolonged braking Do not dispose of used catalyst along with parts contaminated with gasoline or oil 01 FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT–IN ANTI–THEFT SYSTEM IN=– Audio System displaying the sign ”ANTI –THEFT SYSTEM” shown on the left has a built–in anti–theft system which makes the audio system soundless if stolen If the power source for the audio system is cut even once, the anti–theft system operates so that even if the power source is reconnected, the audio system will not produce any sound unless the ID number selected by the customer is input again Accordingly, when performing repairs on vehicles equipped with this system, before disconnecting the battery termi– nals or removing the audio system the customer should be asked for the ID number so that the tech– nician can input the ID number afterwards, or else a request made to the customer to input the ID number For the method to input the ID number or cancel the anti–theft system, refer to the Owner’s Manual IN–9 INTRODUCTION – VEHICLE LIFT AND SUPPORT LOCATIONS VEHICLE LIFT AND SUPPORT LOCATIONS IN–10 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL ADD Automatic Disconnecting Differential ALR Automatic Locking Retractor A/T Automatic Transmission ATF Automatic Transmission Fluid BTDC Before Top Dead Center Calif California Circuit Breaker C&C Cab and Chassis Dash Pot DRW Double Rear Wheel ECU Electronic Control Unit ELR Emergency Locking Retractor ESA Electronic Spark Advance Exhaust (Manifold, Valve) Ex Except Fed Vehicles Sold in USA except California FIPG Formed in Place Gasket Fusible Link Front Ignition Intake (Manifold, Valve) J/6 Junction Block LSPV Left–Hand Load Sensing Proportioning Valve LSP & BV Load Sensing Proportioning and By–Pass Valve Max Min Maximum Minimum Multipurpose M/T Manual Transmission 0/D, OD Overdrive OHC Over Head Camshaft o/s Oversize PCV Positive Crankcase Ventilation PPS Progressive Power Steering Power Steering Right–Hand SRW Rear Single Rear Wheel SSM Special Service Materials SST Special Service Tools STD Standard Switch CH–3 CHARGING SYSTEM – On–Vehicle Inspection (b) Using a belt tension gauge, check the drive belt tension Belt tension gauge: Nippondenso BTG–20 (95506–00020) or Borroughs No BT–33–73F Drive belt tension: 22R–E New belt 125 ± 25 lbf Used belt 80 ± 20 lbf 3VZ–E New belt 160 ± 20 lbf Used belt 100 ± 20 lbf , If necessary, adjust the drive belt tension HINT: • ”New belt” refers to a belt which has been used less than minutes on a running engine • ”Used belt” refers to a belt which has been used on a running engine for minutes or more • After installing the drive belt, check that it fits properly in the ribbed grooves Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley • After installing a new belt, run the engine for approx minutes and then recheck the tension INSPECT FUSES FOR CONTINUITY • ENGINE 10A • CHARGE 7–5A • IGN 7.5A VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition (b) Check that there is no abnormal noise from the gener– ator while the engine is running INSPECT DISCHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch ON Check that the discharge warning light is lit (b) Start the engine Check that the light goes off If the light does not operate as specified, troubleshoot the warning light circuit CH–4 CHARGING SYSTEM – On–Vehicle Inspection CHECK CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufac– turer’s instructions (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: • Disconnect the wire from terminal B of the gener– ator and connect the wire to the negative (–) ter– minal of the ammeter • Connect the test lead from the positive (+ ) termi– nal of the ammeter to terminal B of the generator • Connect the positive (+) lead of the voltmeter to terminal B of the generator • Ground the negative (–) lead of the voltmeter (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter Standard amperage: 10 A or less Standard voltage: 13.9 – 15.1 V at 250C (770F) 13.5 – 14.3 V at 1150C (239S F) If the voltage reading is greater than standard voltage, replace the IC regulator If the voltage reading is less than standard voltage, check the IC regulator and generator as follows: • With terminal F grounded, start the engine and check the voltage reading of terminal B • If the voltage reading is higher than standard voltage, replace the IC regulator • If the voltage reading is less than standard voltage, repair the generator INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater fan control switch at Hl (b) Check the reading on the ammeter Standard amperage: 30 A or more If the ammeter reading is less than 30 A, repair the gener– ator (See page CH–5) HINT: If the battery is fully charged, the indication will sometimes be less than 30 A CH–5 CHARGING SYSTEM – Generator GENERATOR COMPONENTS CH–6 CHARGING SYSTEM – Generator REMOVAL OF GENERATOR (22R–E) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY (w/ PS) DRAIN COOLANT DISCONNECT WIRING FROM GENERATOR (a) Disconnect the connector from the generator (b) Remove the nut and wire from the generator (w/ PS) REMOVE WATER INLET HOSE (a) Remove the engine under cover (b) Remove the water inlet hose (c) (with A/C) Remove the No fan shroud REMOVE GENERATOR DRIVE BELT (a) Loosen the generator pivot and remove the adjusting bolt (b) Remove the drive belt REMOVE GENERATOR (a) Hold the generator and remove the pivot (b) Remove the generator CH–7 CHARGING SYSTEM – Generator REMOVAL OF GENERATOR (3VZ–E) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DISCONNECT WIRING FROM GENERATOR (a) Disconnect the connector from the generator (b) Remove the nut and disconnect the wire from the generator REMOVE GENERATOR DRIVE BELT Loosen the generator pivot bolts, adjusting nut and lock bolt and remove the generator drive belt REMOVE GENERATOR (a) Remove the pivot bolt and adjusting lock bolts (b) Remove the generator CH–8 CHARGING SYSTEM – Generator DISASSEMBLY OF GENERATOR (See page CH–5) REMOVE REAR END COVER (a) Remove the nut and terminal insulator (b) Remove the three nuts and end cover REMOVE BRUSH HOLDER Remove the two screws, brush holder and cover REMOVE IC REGULATOR Remove the three screws and IC regulator REMOVE RECTIFIER HOLDER (a) Remove the four screws and rectifier holder (b) Remove the four rubber insulators REMOVE PULLEY (a) Hold SST A with a torque wrench, and tighten SST B clockwise to the specified torque SST 09820–63010 Torque: 39 N – m(400 kgf – cm, 29 ft – Ibf ) (b) Check that SST A is secured to the rotor shaft CH–9 CHARGING SYSTEM – Generator (c) As shown in the illustration, mount SST C in a vise, and install the generator with SST (A and B) to SST C (d) To loosen the pulley nut, turn SST A in the direction shown in the illustration NOTICE: To prevent damage to the rotor shaft, not loosen the pulley nut more than one–half of a turn (e) Remove the generator with SST (A and B) from SST C (f) Turn SST B and remove SSTs A and B (g) Remove the pulley nut and pulley REMOVE REAR END FRAME (a) Remove the four nuts (b) Using SST, remove the¿ rear end frame SST 09286–46011 REMOVE ROTOR FROM DRIVE END FRAME CH–10 CHARGING SYSTEM – Generator INSPECTION AND REPAIR OF GENERATOR Rotor INSPECT ROTOR FOR OPEN CIRCUIT – Using an ohmmeter, check that there is continuity between the slip rings Standard resistance (Cold): 2.8 – 3.0 If there is no continuity, replace the rotor INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity be– tween the slip ring and the rotor If there is continuity, replace the rotor INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored If rough or scored, replace the rotor (b) Using vernier calipers, measure the slip ring diameters Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor Stator INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads If there is no continuity, replace the drive end frame as– sembly INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity be– tween the coil leads and drive end frame If there is continuity, replace the drive end frame assembly CH–11 CHARGING SYSTEM – Generator Brushes INSPECT EXPOSED BRUSH LENGTH Using a scale, measure the exposed brush length Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm l0.059 in.) If the exposed length is less than minimum, replace the brushes IF NECESSARY, REPLACE BRUSHES (a) Unsolder and remove the brush and spring (b) Run the wire of the brush through the hole in the brush holder, and insert the spring and brush into the brush holder (c) Solder the brush wire to the brush holder at the ex– posed length Exposed length: 10.5 mm (0.413 in.) (d) Check that the brush moves smoothly in the brush holder (e) Cut off the excess wire (f) Apply insulation paint to the soldered point Rectifier INSPECT POSITIVE SIDE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive stud and the other to each rectifier terminal (b) Reverse the polarity of the tester probes (c) Check that one shows continuity and the other shows no continuity If not, replace the rectifier holder CH–12 CHARGING SYSTEM – Generator INSPECT NEGATIVE SIDE RECTIFIER (a) Connect one tester probe to each rectifier terminal and the other to each rectifier negative terminal (b) Reverse the polarity of the tester probes (c) Check that one shows continuity and the other shows no continuity If not, replace the rectifier holder Bearings INSPECT FRONT BEARING Check that the bearing is not rough or worn IF NECESSARY, REPLACE FRONT BEARING (a) Remove the four screws and bearing retainer (b) Using a press and socket wrench, press out the front bearing CH–13 CHARGING SYSTEM – Generator (c) Using SST and a press, press the front bearing into the drive end frame SST 09608–20012 (09608–00030) (d) Install the bearing retainer with the four screws INSPECT REAR BEARING Check that the bearing is not rough or worn IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover and bearing SST 09820–00021 (b) Using SST and a press, press in a new bearing and the bearing cover SST 09285–76010 CH–14 CHARGING SYSTEM – Generator ASSEMBLY OF GENERATOR (See page CH–5) INSTALL ROTOR TO DRIVE END FRAME INSTALL REAR END FRAME (a) Using a plastic–faced hammer, lightly tap in the rear end frame (b) Install the four nuts INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand (b) Hold SST A with a torque wrench, and tighten SST B clockwise to the specified torque SST 09820–63010 Torque: 39 N–m (400 kgf –cm, 29 ft–Ibf) (c) Check that SST A is secured to the pulley shaft (d) As shown in the illustration, mount SST C in a vise, and install the generator with SST (A and B) to SST C (e) To torque the pulley nut, turn SST A in the direction shown in the illustration Torque: 110 N–m (1,125 kgf –cm, 81 ft–lbf ) (f) Remove the generator with SST (A and B) from SST C (g) Turn SST B and remove SSTs A and B INSTALL RECTIFIER HOLDER (a) Install the four rubber insulators on the lead wires (b) Install the rectifier with the four screws CH–15 CHARGING SYSTEM – Generator INSTALL BRUSH HOLDER AND IC REGULATOR (a) Place the brush holder cover to the brush holder (b) Install the IC regulator and brush holder to the rear end frame horizontally as shown in the illustration HINT: Check that the brush holder’s cover doesn’t slip to one side during installation (c) Tighten the five screws until there is a clearance of at least mm (0.04 in.) between the brush holder cover and connector INSTALL REAR END COVER (a) Install the end cover with the three nuts (b) Install the terminal insulator with the nut MAKE SURE ROTOR ROTATES SMOOTHLY CH–16 CHARGING SYSTEM – Generator INSTALLATION OF GENERATOR (22R–E) INSTALL GENERATOR Mount the generator on the bracket with the pivot and ad– justing bolt INSTALL AND ADJUST DRIVE BELT (See page MA–6) INSTALL WATER INLET HOSE (a) Install the water inlet hose (b) Install the engine under cover (c) (with A/C) Install the No.2 fan shroud CONNECT WIRING TO GENERATOR (a) Connect the wire to the generator and install the nut (b) Connect the connector to the generator FILL WITH COOLANT Close the radiator drain cock and fill with coolant CONNECT NEGATIVE CABLE TO BATTERY PERFORM ON–VEHICLE INSPECTION (See page CH–2) CH–17 CHARGING SYSTEM – Generator INSTALLATION OF GENERATOR (3VZ–E) INSTALL GENERATOR Mount the generator on the generator bracket with pivot bolt and adjusting lock bolts Do not tighten the bolts INSTALL DRIVE BELT (See step on page CH–2) CONNECT WIRING TO GENERATOR (a) Connect the wire to the generator with the nut (b) Connect the connector to the generator CONNECT NEGATIVE CABLE TO BATTERY PERFORM ON–VEHICLE INSPECTION (See pages CH–2 to 3)