Toyota 7k engine repair manual

Bệ thử được tiến hành theo nguyên lí dòng công suất hở, thu nhận tín hiệu không dây được thể hiện theo sơ đồ trên. Trong đó động cơ dẫn động loại diesel IVECO 81kW, hộp số cơ khí 5 tay số, trục các đăng lắp nghiêng trong mặt phẳng dọc có thể thay đổi góc với các giá trị alpha, cơ cấu gây tải MP100S, bộ phát tín hiệu không dây gắn trên các trục các đăng, bộ thu tín hiệu không dây lắp vào cổng COM máy tính. Động cơ này dẫn động loại diesel IVECO của Ý sản xuất, các thông số kỹ thuật bao gồm: động cơ 4 kỳ, loại xy lanh thẳng hàng, turbo tăng áp, làm mát bằng nước. Các thông số kỹ thuật của động cơ được chọn để dẫn động bệ thử trục các đăng tương ứng với động cơ trên ô tô thực. Hộp số cơ khí dùng để thay đổi momen xoắn truyền động qua trục các đăng, đồng thời thay đổi tốc độ phù hợp theo các yêu cầu. Trục các đăng dùng để truyền mô men xoắc từ động cơ diesel IVECO 81kW qua hộp số tay 5 số đến cơ cấu gây tải MP 100S. Cơ cấu gây tải MP 100S do hãng của Đức sản xuất bao gồm chủ yếu: cụm điều khiển máy tính MP ở bên trong, panel điều khiển, cụm phanh và đo được nối với động cơ thông qua một trục các đăng và hộp số.

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©1995TOYOTA MOTOR CORPORATION

All rights reserved This book may not be

reproduced or copied, in whole or in part,

withtlut the written permission of Toyota " - ,

FOREWORD

This repair manual has been prepared to provide informatio"

· covering general service repairs for the 7K engine equipped in the TOYOTA TUV

Applicable models: KF42, 52 series Please note that the publica lions below have a!so been prepared as relevant service manuals for the components and system in this engine

All information in this manual is based on the latest product formation at the time of publication However, specifications and procedures are subject to change without notice

in-TOYOTA MOfOR CORPO{Ul.TION

SPECIFICATIONS··· IN- B

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 y.:OtJ in finding your way through the manual, the Section Title and major heading are given at the top of every page

-

,

The procedures are presented in a step-by-step format:

and warnings

Example:

This format provides the experienced technician with a FAST TRACK to the information neaded The upper case task heading can be read at a glance when necessary, and tho text below it provides detailed information Important specifications and warnings always stand out in bo:d type

CAUTIONS, NOTICES, HINTS:

other people

components being repaired

information to help you perform the repair efficiently

IDENTIFICATION INFORMATION

ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block as shown

GENERAL REPAIR INSTRUCTIONS

Observe the fo!lowing:

neg-ative cable from the battery terminal

in.spection or repair, always disconnect the cable from the negative(-) terminal which is grounded

(c) To prevent damagll to the battery terminal post lcosen tho terminai nut and rais~ the cabl<:l strai-ght up without twisting or pryin9 it

nals with a clean shop rag Do not scrape them

the nut loose, and tighten the nut after tion Do not use a hammer to tap the terminal onto the post

properly in place

they are socuro and correct

f

'

•

oil seals etc with new ones

compo-nent illustrations by the ••• symbol

caused to move in any way, it must be recoated with the specified adhesive

(b) When reusing precoatsd parts clean off the old

nut or threads

illustrations by the "*" symbol

le~ks

torques Always use a torque wrench

where specified and follow the prooer work dure A list of SST and SSM can he found in the preparation ;:>art at tho front o~ eacn section in this manual

correct amperag(> rating DO NOT exceed tha rating or use one with a lower rating

the 'lehicle Be sure to lift and support the vehicle at 1

the proper locations

(a) If the vehicle i~ to be jacked up only at the front

or rear end be sure to block the whesls at the

(b) After the vehicle is jacked up be sure to support

it on stands It is extremely dangerous to do any work on a vehicle raised on a jack alone even for

parts:

·absolutely necessary (If the IC terminals are ched t:1o IC may be destroyed by static electric· ity.)

tou-(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

such as sensors or relays If they are dropped on

reused

(e) When steam cleaning an engine, protect the tronic components &ir filter and emissions relat- •

elec.-ed components from water

temperature switches or temperature sensors (g) When checking continuity at the wire connector insert the testGr probe carefully to !Jrsvont termi-nals from bending

(h) When using a vacuum g<:lJge never force the hose onto a connector that is· too large Usa a

b'3en stretched, it may ldak

13 Tag hosas before disconnecting them:

identify how they should be reconnected

vacuum hoses are properly connected A label under the hood shows the proper layout

14 Unless otherwise stated all resistance is measured at

resistance m9y be out;ide specifications if measured

at high temperatures immediately after the vehicle has been running measurements should be made when the engine has cooled down

'

ABBREVIATIONS USED IN THIS MANUAL

A/G Air Conditioner Approx Arproxlmatelv

BOG Bottom Oe11d Center

FIPG Formed In Placa Guket

MP Multipurpoa.:J

PGV Positive Crnnkca~e Vflntil~tion

SSM Special SOrvice Meteriela

SST Special Service Tools

IN-8 IN.TRODUCTIO'I'< -STANDARD BOLT TORQUE SPECIFICATIONS

\

.-

IN-9

INTIC!ODUCTION -STANDARD i'lOLT TORQUE

S,_P-"E-"C::_IF~!'-'C'-'A"-T'-'Ic:O: cN-"S" -SPECIFIED TORQUE FOR STANDARD BOLTS

430

890 1,600

480

990 1,800

CLEANING ···•·•··· ··· EG- 6 IDLE CO CHECK AND ADJUST .• ; EG- 6

COMPRESSION CHECK ····•····••···•·•···•·· EG- 9 VALVE CLEARANCE INSPECTION AND

ADJUSTMENT··· EG- 10 IGNITION TIMING INSPECTION AND

ADJUSTMENT··· EG- 11 IDLE SPEED INSPECTION AND

ADJUSTMENT··· EG-11 CYLINDER HEAD .- EG- 1 r TIMING CHAIN EG- 27 CYLINDER BLOCK EG- 34 SERVICE SPECIFICATIONS EG- 55

FUEL SYSTEM

PREPARATION , EG- 60 PRECAUTION , EG- 60 ON-VEHICLE INSPECTION EG- 6! CARBURETOR EG- 61 FUEL PUMP EG- 76 SERVICE SPECIFICATIONS EG- 78

COOLING SYSTEM

PREPARATION EG- 79 COOLANT CHECK AND REPLACEMENT EG 80 WATER PUMP ; EG- 81 THERMOSTAT EG- 85 RADIATOR EG- 87 SERVICE SPl:CIFICATIONS EG- 88

LUBRICAT!ON SYSTEM

PREPARATION EG- 89 OIL PRESSURE CHECK EG- 90 OIL AND FILTER REPLACEMENT EG- 91 OIL PUMP EG- 92 SERVICE SPECIFICATIONS EG- 96

EG-2

ENGINE· : ENGINE MECHANICAL

ENGINE MECHANICAL

PREPARATION

SST (SPECIAL SERVICE TOOLS)

09201-10000 Valva Guido Bushing Remover &

(09215-00211) P.omovor & Aflplacor

(09215-0022l) Remover & Aoplacor

(09215-00231) Remover & Rop/occr

09221-25025 Piston Pin Romovor & Raplacor

EG-4

ENGINE -.ENGINE MECHANICAL

09330 00021 Companion Flange Holding Tool

•

09960: 10010 Variob/o Pin Wronch Set Camshaft cprcekot

(09962-01000) Vor;oblo p;n Wrench Arm A"y

09200-00010 Enpino Adjust Kit

09258-00030 Hose Plug Set

-EG-6

ENGINE - ENGINE MECHANICAL

Seal Packing Black or equivalent

(FIPG)

Timing chain cover oil pan and ,

rear oil sear retainer

NOTICE: Use care to prevent dirt or other foreign matter

from entering into the carburetor

Visually check that the element is not excessively dirty, damaged or oily

REINSTALL AIR FILTER

IDLE CO CHECK AND ADJUST

_ ,.M~~

manifold

axcessive looseness in the throttle shaft, Correct any problems found

(c) Ali accessories switched off

(d) Ali vacuum lines connected

(f) Transmission in the "N" range

(g) CO meter operates normally

Connect the test probe of a tachometer to the ignition coil negative{-) terminaL

•

•

"

• As some tachometers erll not compotible with this ignition system we recommend that you confirm

in good condition If a CO meter is r>ot available, £9

NOT ATTEMPT TO ADJUST WITH THE SCREW

• If a CO meter is not available and it is absolutely

necessary to edjust with the Idle mixture adjusting

screw use the alternative method

IDLE

(a) Start the engin9

the exhaust turn the idle speed and idle mixture adjusting screws to obtain the speclfied concentra-tion value at idle speed

,Idle speed:

' 750 ±50 rpm (c) Check that the CO meter is properly calibrated

(d) Race the engine 30-60 seconds at about 2,000 rpm before measuring concentration

(e) Wait 1-3 minutes after rucin!l the engine to allow the ccncentration to stabilize

time

Idle CO concentretion: 1.0 ± 0.5 %

•

this adjustment is complete

If the CO concentration is not within tion, turn the idle mixture adjusting screw to obtain the specified concentration valt e

adjusting the idle mixture, see tacle below for other possible causes

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•·

,

• Fouled,shorted or Improperly gapped plugs

• Open or crossed Ignition wires

• Cracked distributor cap

2 Leaky exhaust valves

3 Leaky cylinder Rough Idle 1 Vacuum leak:

• Vacuum hose (Fluctuating HC reading) • Intake manifold

Rough idle 1 Restricted air filter

2 Plugged PCV valve \ (Black smoke from exhaust) 3 Faulty carburetlon:

• Incorrect float setting

• Leaking needle or seat

• Leaking power valve

(e) Set to the idle spe~d by screwing in the idle mixture adjusting screw

Allow the engine to warm up to normal operating

SPARK PLUGS

pressure

engine speed of 250 rpm or more

low, pour a small nmount of engine oil into the der through the spark plug hole and repeat steps (a) · through (c) for cylinders with iow compression

worn or damage

If pressure stays low, a valv& r:1ay be stickinr, or seating is improper, or there may be leakage past the gasket

(a) Turn the crankshaft pulley, and align its groove with

(b) Check that the rocker arms on the No.1 cylinder are

''''l~ll ~nd mr,h, nrrr1.~ on fhij NoA r:ylill(lllr hill titllol

align the marks as above

Valve clearance (Cold):

Intake 0.13 mm (0.005 ln.) Exhl!ust 0.23 mm (().009 in.)

clear-ance between· the valve stam and rocker arm Loosen the lock nut "nd tum the adjusting screw

to set the proper clearance Hold the adjusting

the mark above

4

Adjust Qnly the valves indicated by arrows

(Seo step 5 in cylinder hoad ir.;;tallation)

·''

~.r~>:

CONNeCT TACHOMET[;R TO ENGINE

(See step 3 in idle CO check and adjust)

3 INSPECT DWELL ANGLE

(See distributor assembly in Ignition System)

DISCONNECT VACUUM HOSE

5 CONNECT TIMING LIGHT TO ENGiNE

6 INSPECT AND ADJUST IGNITION TIMING

to check the timing

Ignition timing:

5±2• BTDC @.Idle

If necessary, loosen the distributor bolt and turn the

after tightening the distributor bolt

Torque: 12 N·m (120 kgf·cm, 9 ft.fl!f) _

7 RECONNECT VACUUM HOSE

Ignition timing:

12±3°BTDC@ idle

9 DISCONNECT TACHOMETER AND TIMING LIGHT

IDLE SPEE'J INSPECTION AND ADJUSTMENT

-·-·.~:f~

;

CYLINDER HEAD REMOVAL

1 DRAIN ENGINE COOLANT

2 DISCONNECT HIGH-TENS10i4 CORDS FROM SPARK PLUGS

3 REMOVE SPARK PLUGS

· ··

4 REMOVE SPARK PLUG TUBES AND 0-RINGS

5 DISCONNECT FUEL HOSE AND VACUUM HOSES (a) Disconnect the fuel hose and vacuum hoses ,

(b) Remove the fuel pipe and vacuum hose from the clamp

6 REMOVE INTAKE, EXHAUST MANIFOLDS AND CARBURETOR ASSEMBLY

(a) Disconnect the PCV hose from the cylinder head

as-7 DISCONNECT WATER BYPASS HOSE

8 REMOVE CYLINDER HEAD COVER Remove the 2 cap nuts seal washers, cylinder head cover and gasket

9 REMOVE ROCKER ARM AND SHAFT ASSEMBLY

(a) Uniformly loosen and ramove the 6 bolts and 2 nuts in several passes, in tha sequence sho)!Vn

(b) Remove the rocker arm and shaft assembly

Remove tho 8 push rods in o;der, begi11ning from tho No.1 push rod

NOTE: Arrange the push rods in correct order •

11 REMOVE CYLINDER HEAD (a) Uniformly loosen and remove the 3 head bolts in several passes in the sequence shown

CAUTION: Head werpage or cracking could result from

removing out of sequence

.:::·

P149SO

P149Sl

ENGINE - ENGINE MECHANICAL EG-15

ZI6SJS

several passes, in the sequence shown

CAUTION: Hond wnrpngo or cracking could result from

removing out of sequence

bench

HINT: If the cylinder head is difficult to lift off, pry betwee;, the cylinder head and block with a screw-driver

CAUTION: Be careful not to damage the cylinder head or·

b!ock surface on the cylinder haad gasket sides

CYLINDER HEAD DISASSEMBLY

1 REMOVE WATER OUTLET ~lOUSING AND REAR PLATE

EG-16

(d) Remove the B spring seats

and· spring· retainers in correct order

CYLINDER HEAD COMPONENTS INSPECTION CLEANING AND REPAIR

ENGINE - ENGINE MECHANICAL EG-17

Using a valve guide bushing brush and solvent, claan all the guide bushings

Using a soft brush and sclvent, thoroughly clean the cylinder head

-

Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder hlock and the manifolds for warpage

cham-ber, intake ports, exhaust ports and cylinder block side surface for cracks

5 INSPECT VALVE STEMS AND GUIDE BUSHINGS

the guide bushing

Bushing inside diameter:

the guide bushing inside diameter measurement

valve and guide bushing

Both intake and exhaust

Bushing bore diameter

di-ameter of the cylinder head

If the bushing bore diameter of the cylinder head is

bushing bore to these dimension:

until the snap ring makes contact with the cylinder

09950-70010

(09951-·07150)-(g) Using a sharp 8 mm reamer ream the guide bushing

to obtain the standard specified clearance (See step 5) between the guide bushing and valve stem

Grind the valve enough to remove pits and carbon

face angle

Valva face angle:

44.5°

Stand&rd margin thickness:

Intake: 1.0 - 1.6 mm (0.039 - 0.063 ln.) Exhaust: 1.2 - 1.8 mm {0.047 - 0.071 ln.) Minimum margin thickness:

Intake: 0.8 mm (0.031 ln.) Exhaust: 0.9 mm (0.035 ln.)

If the margin thicknar.s is Jess than minimum, replace the valve

(d) Check the valve overall length

(e) Check the surface of the valve stem tip for wear ·

If the valve stem tip is worn, resurface tho tip with a grindar or replace the valve

NOTICE: Do not grind off more than ,;inlmum

8 INSPECT AND CLEAN VALVE SEATS

Remove only enough metal to' clean the seats

::

(b) Checl( the valve seating position

Apply a light coat of prussian blue (or white lead) to the valve face Lightly press the valve <Jgainst the seat Do not rptate valve

(c) Check the -valve face and seat for th.,so:

concentric If not, replace the valve

guide and face are concentric If not, resurface the saat

valve face with these width:

Intake

Exhaust

If not correct the valve se,ts as follows:

45" and 65" cutters to correct the seat

45" and 30" cutters to correct.the seat

compnund

(e) After hand-lapping, <;!san tha valve and valve seat

10 INSPECT ROCKER ARM AND SHAFT

'

for wear

Correct or replace if necessary

(b) Inspect the rocker arm to the shaft· clearance by moving each rocker arm as shown in the figure Little or no movement should be possible

If movement is felt disassemble afld inspect

HINT: Arrange th6 rocker arms and rocker supports in

'

Valve Rocker Shaft

V&lv.o Recker Support

( 1)

Valve Rocker Arm No.1

{2)

·Inspect the oil clearance between the rocker arm and shaft ,

diarne- tar of the rocker armdiarne- , Rocker arm inside diameter:

from the inside diam<'lter measurement of the rocker arm

Valve Rocker Arm No.1

(b) Using a dial indicator, measure the circle runout at the

· center of the push rod

Maximum circle runout:

to all sliding and rotating surfaces

new ones

(b) Install theso parts:

(2) Spring seat (3) Valve spring (4) Spring retainer

keepers around the valve stem

SST 09202-70020 (09202-01010 09202-01020, 90154-80004)

.· '"

stem tip to assure proper 'fit

ing with 2 bolts

CYLINDER HEAD !NST ALLAT!ON

(a) Place a new cylinder head gasket in position on the cylinder block

NOTICE: Be careful of the lnstollution direction

head gasket

HINT:

gressive steps (steps (b) and (d)).'

under the heads of the cylinder hGad b.:> Its

(b) Install and uniformly tighten the 1 0 cylinder head bolts on each cylinder head, in several passes, in the sequence shown

EG-26 ENGINE I:NGINI' MCCII-1\NICI\L

c

(a) {b)

2

3

(a) (b)

4

5

Install recessed head cylinder head bolts Apply a light coat of engine oil on the thn:.ads and ur.dor the heads of the cylinder head bolts

Install the cylinder head boits as shown

Torque: 19 N-m (1 95 kgf-crn 14 ft·lbf) INSTALL PUSH RODS

Install the 8 push rods

INSTALL VALVE ROCKER SHAFT ASSEMBLY Place the rocker shaft assembly on tha cylinder head

Install and uniformly tighten the 6 bolts and 2 nuts in several passes in the sequence :;hov.;n

Torque: 21 N·m (210 kgf-cm, 16 ft·lbf) CHECK AND ADJUST VALE CLEARANCE (See valve clearance inspection and adjustment) INSTALL CYLINDER HEAD COVER

(b) Install the cylinder head cover with 2 seal washers and cap nuts

Torque: 2 N-m (25 kgf-cm, 18 in.-lbf)

CARBURETOR ASSEMBLY

and carburetor assembly with the 6 nuts

Torque: 49 N-m (50_0 Y.gf-crn, 36 ft-lbf) (b) Connect the PCV hose to the cylinder head cover

(b) Install the spark plug tubes to the cylinder head

10 INSTALL SPARK PLUGS

11 CONNECT HIGH-TENSION CORDS TO SPARK PLUGS

13 START ENGINE AND CHECK ·FoR LEAKS

14 CHECK ENGINE OIL LEVEL

l'ming Chain +Gasket

;

I I

EG-28

TIMING CHAIN AND CAMSHAFT REMOVAL

·1

1 REMOVE WATER PUMP PULLEY AND DRIVE BELT {See water pump removal in Cooling System)

{See cylinder head removal)

(See distributor removal in Ignition System)

{See fuel pump removal in Fuel System)

(See-oil pump remove! in Lubrication System)

SST 09213-1401 0 (91651-60865), 09330-00021 (09330-00030)

HINT: If necessary, remove the pulley with SST

SST 09950-4001 0 (09957 -0401 0),

09953-05020, 09954-050:.10)

chain covor and gaskat

Mensure the timing chain slack