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

HƯỚNG DẪN SỬA CHỮA ĐỘNG CƠ 18R TOYOTA

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

Flywheel, Rear Oil Seal Input Shatt Bearing DISASSEMBLY

INSPECTION & R ASSEMBLY

18R ENGINE SERVICE — Cutaway View

18R ENGINE SERVICE — Cutaway Viow 4-3

a8 18R_ENGINE SERVICE — Cylinder Head

Comshstt Gear Bearing Cap Garashatt

18R ENGINE SERVICE — Cylinder Head 4-5

Remove the plug cords try :carefully pulling ơn |

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

The camshaft knock pin should be facing upward

(0.0098 in}

‘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

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

is shown in the figure:

Fig:

18R ENGINE SERVICE —* Cylinder Head 47

Compress ale valve airing with SST 109202 43013]

Arrange the disassembled parts in order:

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 Head surface warpage limit

0.05 mm (0.0019 in) Maximum raface limit

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

SST [08201-60011]

18R ENGINE SERVICE — Cylinder Head

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:

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)

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)

(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,

(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

Inner 44.1 mry (1.736 ind Outer 46.5 mm (1.830 in)

of each spring at the specified instafled height Replace any spring that does not man apacification,

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)

3 With $ST, remove the rocker arm bushing SST [09222-30010]

Figs

4, When’ assembling the bushing align the

assamhly, ream the bushing to obtain thn specified oil clearance,

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:

ENGINE SERVICE — Cylinder Head 4-15

2 Measure the cam fobe height and check for

BI wear It wear exoeeds the limit, raplace the

4 — Measure the camshaft oil clearance

BK] 1) Ce the bearing, cap ane carat

Journal

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

(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

(1.8717~1.3720 inl uiso25 | 34.72-34.73 mm

Warpage limit 0.1 mm (0.004 in)

18R ENGINE SERVICE — Cylinder Head 4-17

* Thoroughly clean the parts to be assembled,

* Apply clean engine oil on the sliding and rotating surfaces of the parts before assembly

_¬ 7 Vale Rocke 8 GIm

, @ Oyler Head Cover

: 10 Spur pln

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,

Fig Fig

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,

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)

Next, adjust the clearances of the remaining

valves {indicated by arrows) Y

ee ee LÍ eS eile

Tighten the manifold bolts and nuts to the spect

fied torque in the sequence shown in the figure, Torque 45-55 kgm

MEMO.

4-22 18R ENGINE SERVICE — Timing Chain

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

18R ENGINE SERVICE — Timing Chain 4-23

Attach the SST to the two gears and slide out

#9] both gears and chsins asa unit

Use SST {09213360201

4-28 18R ENGINE SERVICE — Timing Chain

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,

B:Pump drive shaft gear

“114.5 mm (4.508 in) C:Camshatt drive gear

4, Mesure the 17link:elongation of tha No

2 timing chain Replace the chain if over

‘the clongation limit, Elongation timit (at 17-links)

18R ENGINE SERVICE — Timing Chain) 4-25

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

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

Measure thrust clearance,

It itexceads limit, replace thrust plat, Thrust clearance

(0.0010 ~ 0.0026 in}

3 Bearing raplacetenl (1) Drive out plug from cylinder block

18R_ENGINE SERVICE — Timing Chain 4-27

Ậ (3l Aligh bering oil hole

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

4:28 18R ENGINE SERVICE — Timing Chai:

Crankshaft Front Oil Seal Replacement

1 Remove ail seal with a screwdriver

| 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

© Apply clean engine oil on the sliding and rotating surfaces of the parts before azsembly

11

9 Fg 4-100 Fin 496 8 Fig 4-101 | Fig 497 12

For Installation refer t0 Distrinutar Section

4-30 18R ENGINE SERVICE — Timing: Chain

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,

Drive in No 1 chain and gears on ta the crankshaft and ump driveshaty,

18R ENGINE SERVICE — Timing Chain 4-31

A Apply soalor to the areas indicated in the figure,

4-32 18R ENGINE SERVICE — Timing Chain

Driv in crantishate pulley with use SST [00214 0070],

Fighten claw qut, Torque 12.0 ~ 15.0 kgm {86.8 — 108.4 ft4b)

MEMO.

do 18R ENGINE SERVICE — cylinder Block

WF Purp anneelini Rou Dan Péston with Connacting Rod Main Bearing Cap

48R ENGINE SERVICE — Cylinder Block 4-35

Using SST [09903-35071], remove Inpur shaft

9b) bevring

‘exceeds limit, replace connecting bd,

‘Thrust clearanes fimit

0.4 mm (0.016 in) Standard 0/21—0.34mm

4-38

Fig 4-115

18R ENGINE SERVICE — cytinder Block

Ạ Keop connecting rod and bearing in order

Measure the crankshaft thrust clearance It the

clearance excaeds the limit, ruplace the bearing asa sot

© Thrust clearance limit

Ậ Keap tranlshafl bemring and ap in) order

Fig,

18R ENGINE SERVICE — Cylinder Block 4-37

INSPECTION & REPAIR Cylinder Block a

eithor machine the Block or rept

2 Visually inspaet eylinders for vertical

lo scratchas, Hf deep scratches are present,

£ylinder must bơ rebored,

ong 18R_ENGINE SERVICE — cylinder Blovk

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,

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,

After prassing) in’ the bushing, finish the:

‘ushing bore with a pin hole grinder

4-40 18R ENGINE SERVICE — Cylinder Block

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.)

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)

18R ENGINE SERVICE — Cylinder Biock 4-41

Piston clearance 0.05-0.07 mm (0.0020-0.0028 in)

Grankpin and Bearing

1 inspect bearings for flaking ar souring If bearings are damaged, replace

2 Méasuré crankpin all elearanee (1) Clean crankshafL pin, tod, cạp 3g bearing

(3), Tighten cap nuts 10 specitied torqu Torque

1GR, 18R 5.4-6.6 kgm

(39.1-47.7 fttb) 1BR-G 6.4-7.0 kgm

(46.3-50.6 felb)

— Note —

Bo not turn connecting rod

(4) Measure plastigige ar its widest point,

If clearance is pot within specie fication, replace bearings

Clearance limit 0.08 mm (0.0032 in) Standard

0.24 ~ 0.48 mm

(0.0094 — 0.0189 in) UIS Bearing sizes

US 0.05, 0.25, 0.50

‘Assemble piston and fod os follows

1 Install snap ring on one side,

Fig 41 map

18R_ ENGINE SERVICE — cylinder Block 443

Heat piston to about 100? (212°F}

Y AI” dem 8 Aligning piston notch and tod mark as

+« 4, Install piston pin

bón ‘Make suro snap ring js completely im place,