TOYOTA 18r ENGINE SERVICE MANUAL HƯỚNG dẫn sửa CHỮA ĐỘNG cơ TOYOTA 18r

HƯỚNG DẪN SỬA CHỮA ĐỘNG CƠ 18R TOYOTA

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18R ENGINE SERVICE CUTAWAY VIEW CYLINDER HEAD

Includes: Cylinder Head, Valve-and Spring Rocker Arm, Camshaft, Manifold DISASSEMBLY

INSPECTION & REPAIR ASSEMBLY

TIMING GEAR

Includes: Timing Gear, Chain, Damper and Slipper Pump Drive Shaft and Bearing, Front Qi! Seal DISASSEMBLY INSPECTION & REPAIR ASSEMBLY CYLINDER BLOCK Includes: Cylinder Block, Piston and Connecting Rod Piston Ring

Crank pin and Bearing, Crankshaft and Bearing

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18R ENGINE SERVICE — Cylinder Head 4-5

Remove the plug cords try :carefully pulling ơn |

A the rubber boots |

Loosen each rocker support bolt a litte ata tine 429] and in the sequence shawn in the figure

SS Set the No.1 eylinidar tb» TOC/cumpression

The camshaft knock pin should be facing upward

Measur aft thrust clearance

>) Thrust clearance limit 0.25 min

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ABR ENGINE BI Hi: — yli

Inder Head

‘Arrange the camshaft bearings and bearing caps

Loosen each cylinder head bolt a little at 3 time 49] and in the sequence shown inthe figure ~~ Wf the cylinder head is difficult to lift off, pry,

4m] with a scrowdriver between the head and block ar

is shown in the figure:

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18R ENGINE SERVICE —* Cylinder Head 47 Compress ale valve airing with SST 109202 43013]

Arrange the disassembled parts in order:

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4-8 18R ENGINE SERVICE — Cylinder Head INSPECTION & REPAIR Fig Cylinder Head E

1 Clean the combustion chamber and remove any’ gasket material Irom the manifold and head surface,

Check the cylinder heads for cracks of ‘excessively burnt valve Surfaces,

2 Check the cylinder head’ surface flatness with a precision straight edge,

3 IF warpage exceeds the linilt, correct it by machining, oF replace the head

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SS 3 a,

18R ENGINE SERVICE — Cylinder Hood 49 Check the valve stem ta valvilyiiele lear ance of gach valve by Inserting tha valve stem inta the guide and moving back and forth as is shown in the figure

Measure the valve stem oil clearances (1) Measure the inside diameter of the

valve quide at sevaral places with ar inside dial gauge,

(2) Measure the valve ster diameter (8) Calculate the clearance between the

yalve stem and valve guide by sub: ‘trecting the difference where the clearance is the largest

Clearance limit

Intake 0.08 mm (0.0032 in) Exhaust 0.10 mm (0.0039 in} It the clearance mxoaad the limit, replace both valve and guiđe,

Heptacing quide

(| From the top, drive: out the guide toward the combustion chamber with SST

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18R ENGINE SERVICE — Cylinder Head | 368 ~ 162 mm 5

(2) With SST, drive in the new guide to tus specified depth,

SST [09201-60011] —Note—

41 Insure that the hole is clean

2, Batore inserting the guide apply a thín ‘coat of oil to it and the guide holo, 3 Do not drive in past the specified

dapth,

Guide protrusion 18.8~16.2 mm (0.622~0,638 in]

(3) Ream the guide to the specifiod cleat: anos with an 8 mm (032 In} raarmer:

Intake 0,025 ~ 0.060 mm (0.0010 — 0.0024 in} Exhaust 0.035 —0.070 mm

(0.0014 — 0.0028 in]

Grinding valves and saats

(1) Grind all valves to remove the pits and carbon,

Valve face angle: 45.5"

(2) Chock the valve head margin and replace if lass thar specified,

Margin limit

Intake 0.6 mm (0,024 in) Exhaust 0.6 mm (0.024 in)

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18R ENGINE SERVICE — Cylinder Head 4-11

{3} _If the valve stem and is worm, resur- aca with w valve grinder, but'do not grind off more than 0.5mm (0.02in)

Ovarall length timit Ex 1132mm (4.857 in) In 1127mm (4.437 in) (4) Resurfoce valve seats with 48° vearbidler cutter Hemove only enough metal to clean seat

(5) Coat valve face with prussian blue or

* lead Locate enntaet point on

vaive liy rotating valve against seat, — Note —

Seat contact should be in middle of vata face with following width:

Intake 1.2-1.8 mm (0.047-0.063in) Exhaust 1:2 1.6 mm (0.047~0.083 in}

(6) Correct the seat position To correct seating that Is t6o high,

use 30° and 45° cutters If seating

is 100 low, uso 65° and 45° cutters,

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412 18R ENGINE SERVICE — Cylinder Head 1 2ì

(7) Check valve concentrivity

Liphtly coat seat with peussian blue, linstall valve and rotate, If blue appears 360" around face, velve ste and fom are concantrin If nat, replace valve

(8) Chock seat/yuide coneentrivity Apply a light cox at prssian, lit fon valve face Install and rotate valve |f blue appears 360” sroud valve meat, guide and seat are cancenttic It nat, recut seat,

Valve Springs

Check the squargness of the valve springs

will a steal square and surface plate, Turn

‘the spring around slowly and observe the

space between the top of the spring and

‘the square, Replace the spring if it is out of

squire more than the specified limit Limit Inner 1.6mm (0.063 in)

‘Outer 1.6 mm (0.063 in)

Measure the spring free heiuht, Replack springs that do not inet specification

Free haight

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18R ENGINE SERVICE — Cylinder Head A-18 Bi +

3 Using’ spring tester, measure the tension

of each spring at the specified instafled height Replace any spring that does not man apacification, Inner Outer Limit 68kg 23.9 kg (16.01) (62.7 1b) Standard 7/8 kụ 26.3 kụ (168lp] (58.0 Ib) Rocker Arm and Shaft

1 Check the rocker arm to shatt clearance If worn excessively, disassemble and inspect

2 Measure the clearance with 0 dial indicator and qutsida micrometar If clearance: ex- ‘eveds the llmit, replsoe tha rocker arm bushings and/or shaft

Clearanca limit 0.08 mm (0.0032 in} ‘Standard 0.02-0.05 mm

(0.0008-0.0020 in)

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Figs

4, When’ assembling the bushing align the

A Goll Note withy that of the rocker arm A ft

assamhly, ream the bushing to obtain thn specified oil clearance, Standard 0.020 — 0.041 mm (0.0008 — 0.0016 in) Align Ot Hole Fig 5 If the valve rocker arm surface contacting:

the valve stem end |s worn excessively, tlther grind or replace the rocker arm,

6, Assembla the rockers and shaft

(1) Assemble the rocker shaft and No.1 support as shown in the figure

{2} Assemble the rocker arm; springs and supports as shown: in the figure:

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ENGINE SERVICE — Cylinder Head 4-15

J Check the camshaft for runout Replace cainshatt if it exceeds limit

Limit 0.1 mm (0.004 in)

Bl Camishaft and Beating

2 Measure the cam fobe height and check for

BI wear It wear exoeeds the limit, raplace the camshaft Haight limit Intake 43.7 mm {1.720 in] Exhaust 43.8 mm (1.724 In] IỊE| ” Revie earings tt domones 3: Chace th borne for fokngor caring

4 — Measure the camshaft oil clearance

BK] 1) Ce the bearing, cap ane carat

Journal

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16 Fig 4-47 Fig 4-48

18R ENGINE SERVICE — Cylinder Head

(2) Place @ piece ot plastigage across the full width of the journal surface,

(3) Install the bearing cap ‘and tighter bolts to specified torque Torque _ 17-23 kgrm (12.3-16.6 ftlb] —Note— Do not twrn camshaft whife plästig in place

(4) Remove the besring cap

With the plastigage scale, rneesure the:

width of the plastignge tits widea

point, |t clearance exceeds the spect fication limit, adjust with a suitable: bearing sie, Oil clearance limit 0.1 mm (0.0038 in} Standard 0.012 — 0.052 mm (0.0005 — 0.0020 in) Bearing Size | Journal Diamatar STD 34.97- 35.00 mm (1:3788—1-3780) U/S0.125 | 34.84-34.85mm (1.8717~1.3720 inl uiso25 | 34.72-34.73 mm (1.3670—1.3873 in] Manifold

Inspect thơ oylinder head contacting surfaces for warpaye and replace the manifold if it excarde the limit

Warpage limit 0.1 mm (0.004 in)

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18R ENGINE SERVICE — Cylinder Head 4-17 ASSEMBLY ni “Assemble In numerical ord, Fig 4-51

* Thoroughly clean the parts to be assembled,

* Apply clean engine oil on the sliding and rotating surfaces of the parts before assembly pen ag in rs 4-60" B8 =a Oe ree I mt na 457 rethe Fig 4-50 in 59 pest a 10 nie Là able 6— in} 9 k— 0 In Tụ an Fees n h Me vie 2 Cylinder Head n 3 Gamat in) ‘ n 5 in) 6 Na:ZPhinTandoner _¬ 7 Vale Rocke 8 GIm

, @ Oyler Head Cover : 10 Spur pln

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4-18 Fig, 4-63

Install the: spring seat and olf sea! as shown in the figure, The head must be clear| and the oll seal insarted to where the end contacts the spring seat tap

‘Assemble the valve spring and install the retainer locks

Use SST 109202-03012)

‘Tap the valve stems lightly to assure proper tit

Apply a coat ot sealer to the cylinder head, arnund the hales in the block, and in the vicinity of the timing chain cover and cylinrier block,

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18R ENGINE SERVICE — Cylinder Head 4419

Tighten each cylinder head bolt a tittle at ø time

10 the specified torque in the sequance:stiown int the figure

Torque 10-12kgm (72,3-86.8 ft-lb)

hack the carnshaft thrust clesrance, Thrust clearance standard

0,042 ~ 0.167 mm (0.0017 — 0.0118 in)

Set the No.1 cylinder to 119C/enmpression, The camshaft knack pin should be pointing upwards,

‘Allan the matchmarks on the chain and year, and Install, the No,2 chain, Align the gear pin hole and camshaft knock pin and install them,

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4-20 18R ENGINE SERVICE — Cylinder Head Fig 4-60

Tightan each rocker stipprt hott a little at a time, ‘to the specified torque In the sequence shown in the figure Torque 1.72.3 kgm (12.3-16.6 fh)

Firsi, adjust the valve clearance Of only the valVex indicated by arrows in the figure

Intake 018mm (0.0071 in) Exhaust 033mm (0.0130 in) Turn crankshaft 360° and align timing mark

Next, adjust the clearances of the remaining

valves {indicated by arrows) Y

ee ee LÍ eS eile

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4-22 18R ENGINE SERVICE — Timing Chain

TIMING CHAIN Fig DISASSEMBLY Disassemble in numierieal order Fig, 4-86

2 4 Bittrbutor 5 Crankshafe Pulley 9 No.1 Chain Damper

Fuel Pump 6 — TimingGsarovme 10 Nơ.1ChuinTemlonar 3 Fan snd Water Pump 7 No.2 Timing Chein 11 Gamshsfr Drive Gear 4 Gan 8 NG.2ChainDampw 12 Na.1TimingChưmandGoạr

and OW Jot 19 Pump Drive Shatt

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18R ENGINE SERVICE — Timing Chain 4-23 Remove the crankshaft pulley with SST #9) Use SST 109213-31021) Remmdve the cairishatt drive gaar with SST ee) Use SST (09213-36020)

Attach the SST to the two gears and slide out #9] both gears and chsins asa unit

Use SST {09213360201

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4-28 18R ENGINE SERVICE — Timing Chain

Fig 4-70, INSPECTION AND REPAIR

Timing Gear and Chains

1 Inspect the gears and chaing for cracks, wear or chipped teeth,

2 Measure the gsar for wear in tho mộtHo4 shawn in the figure, If messuroment i bolow llinit, replace pears and chai Woar limit

A:Grank shaft gear 60.0 mm (2.362 in} B:Pump drive shaft gear “114.5 mm (4.508 in) C:Camshatt drive gear 78.2 mm (3.079 in} D:Camshaft timing gear 78.2 mm (3.079 in) 3 Messure the elongation of the No, † tìmlnj chin, Elongstion limit 281.4 mm (11.47 in) tension at 5 kẹ (11 lb}

4, Mesure the 17link:elongation of tha No 2 timing chain Replace the chain if over ‘the clongation limit,

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18R ENGINE SERVICE — Timing Chain) 4-25

No 1 Chain Tensioner

Check the body and plunger for wear und meas lure the tensioner head as shown |n the figure It worn down over the limit, replace as a unit

Wear limit 11.6 mm (0.463 in)

Chain Damper and Slipper

‘Maasuira each chain damper and check tor wear

U1 either is visibly worn or measures fess than

Vimiry reptare unit

Wearlimit A Slipper 6.8 mm (0.26 in) 8: No.2 damper : No T damper 8.7 mm (0.224 in} 5.0 mim (0.20 in) D: No 1 tensioner 11.5 min (0.45 ind

Timing Gear and Thrust Plate

Measure thrust clearance,

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4-268 Fig 4-78 Fig 4.79 18R ENGINE SERVICE — Timing Chain IP Pump Drive Shaft and Bearing 1 Inspect distributor drive gear If damaged Teplacd, and also inspect distributor pc

2 Meastire oll clearance

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18R_ENGINE SERVICE — Timing Chain 4-27 (2) Remove frunt bearing, = Usa SST [09233-33010] as shown,

Ậ (3l Aligh bering oil hole

(4) Install front bearing,

báu Use SST [0823333010] ns shown,

Bearing fitting tolerance 0,02 0.05 mm (0.0008-0.0024 in)

(5) Remove-the rear beating

hand —Nota — (6) {natal the eer bearing,

Installation procedure is the same ax for the front bearing

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4:28 18R ENGINE SERVICE — Timing Chai: (7) Apely sealer to the new plug and install Liquid Sealer Fig 4-87

Crankshaft Front Oil Seal Replacement

1 Remove ail seal with a screwdriver 2 tall new oil sel Use S811 10822-60010) asshown,

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| ASSEMBLY

ese In numerival order

18R ENGINE SERVICE — Timing Chain

Pump Orive Shaft

‘No.2 Timing Chain and Gear ‘No 1 Chain Tensioner No.1 Chain Darmpor

`

© Thoroughly cloan the parts to be assembled

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4-30 18R ENGINE SERVICE — Timing: Chain Fig 4-91 A Fig 4.92 A +«

Sel the crankshaft kayway.and the puma drive

shaft kayway vertically unward

‘Assemble the crankshaft timing gear and pume Uriva shatt gsar to the No, 2 chain so that thelr fespectivo marks are oligrted,

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18R ENGINE SERVICE — Timing Chain 4-31 ‘Align the No 2 chain and gear matchmarks and LN, insta, Be! carefull not! to Bop the chain inside the housing

Bafore installing) the upper right hand bolt tor the chain cover mount, insert a seal washer and apply 8 sealer to the threads

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do 18R ENGINE SERVICE — cylinder Block CYLINDER BLOCK DISASSEMBLY Disassemble in) numerical order Fig 4-110

1) Inpur Shate Bearing Wor M7) Bushing (for A/T) Hywhes! Rear End Plate Rar OU Seal Front End Plate WF Purp

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48R ENGINE SERVICE — Cylinder Block 4-35 Using SST [09903-35071], remove Inpur shaft 9b) bevring

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4-38 Fig 4-115

18R ENGINE SERVICE — cytinder Block

Ạ Keop connecting rod and bearing in order

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18R ENGINE SERVICE — Cylinder Block 4-37

INSPECTION & REPAIR Cylinder Block a

H2 ee \t warpage exceeds the specified fimit,

eithor machine the Block or rept Warpags limit 6.05 mm (0.0019 in)

2 Visually inspaet eylinders for vertical

lo scratchas, Hf deep scratches are present,

£ylinder must bơ rebored, Machine piston ring riđge trom top of cylinder, — Note —

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ong 18R_ENGINE SERVICE — cylinder Blovk Fig 4122

Piston and Gorinecting Rod

1 Check pin fit by trying to rock piston at Fight angle to pin If any movement is felt, Piston with pin must be replaced, 2) Remove piston ting, ting the plston ring expander A 3, Heat piston i piston) hearer 10 about 10°C (212°) and remove piston pin,

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18R ENGINE SERVICE — Cytindar Block 4-39

Heat piston to 100°C (212°F) coat pin

UE] with engine The pin should be able to be pushad into ai

histor hole with thumb pressure, Bị 6 Measure ail clearance betwen hush and 9.02 mm (0.0008 in} ‘Standard 0.006-0.014 mm (0.00020~0.00055 in) 7 Replace butting with SST 10822-40010)

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4-40 18R ENGINE SERVICE — Cylinder Block

Fig 4-130 £

9 Coat the pin with engine oil, Av normal Foon temperature, you should be able t0 press the pin into the rod your thumb,

part of the cylindsr bore, measure ‘the ond wap,

fon Skirt of evtinder ting Fig Piston Ring

A 1 Measure the ring end aap,

(1) Insert the ring inta the cylinder using

* a piston, With the ring at the lower

Fig

(2) Measure-endl yay LT it wxcencds Speck firation, ring must be replaced, End g No.1 0.19 — 0.34 mm (0.0076 — 0.0133 in.) No.2 0.15 — 0.48 mm {0.0069 — 0.0189 in.) 10.0079 ~ 0.0346 in.) z

2 Measure’ fing groove clearance, If it D faxcaeds sperification, realace ring and/or

piston,

Ring groove claarance No 1 and No, 2

.0.02~0.06 mm (0.0008 0.0024 in)