ENGINE - LU.BRICATION SYSTEM
, LUBRICATION·SYSTEM :. i
PREPARATION
SST (SPECIAL SERVICE TOOLS) MU\1··
~... -- 09228 22020 Oil Filter Wrench ,.....,__
09816-30010 Oil Pressure Switch Socket
0
RECOMMENDED TOOLS
09200-00010 Engin~t Adjus~ Kit.
EQUIPMENT
Oil pressure gauge ~-
~TS~torarig=hqt~eud.g~e .w:=re=n~ch~--------------------------~----+------------------------ .
_,,.,_..
LUBRICANT
- Item - Cap~city C/ossificllltlon I
API grade SG, SH or !LSAC owltigrade
En;ine oil 3,9 liters (4.1 US qts, 3.4 Imp. qts) engbe oli
Dry fill
Drain and refill 3.7 litero (3.9 US qts, 3,3 Imp. qts) Oil ran
3.4 liters (3,6 US qts, 3.0 Imp. qts)
w/ Oil filter charge
w/o Oil filter change
SSM {SPECIAL SERVICE MATERIALS)
08826-00080 Soa/ Pecking Black ar equlvo.lent
(FIPG)
. r-------------------~~~==~--~~~--------------~------------------~
08833-00080 Adhesive 1344, Oi•11ressure switch
THREE BOND 1344,
LOCTJTE 242 or equivalent
EG-90 ENGINE:... 'LUBRICATION SYSTEM. -..
! ·· OIL PRESSU'RE CHECK
1. CHECK ENGINE OIL QUALITY
Check 'the oil for det-erioration, entry of water, dis- ' ·
coloring or thinning.
If oil quality is visibly poor. replace ft.
2. CHECK ENGINE OIL LEVEL
The oi: level should be between the "L" and "F" marks
on the dipstick
If low, check for leakage and add oil up to ·r:· mark.
3. REMOVE OIL PRESSURE SWITCH
Using SST. remove the oil pressure switch.
SST 09816-30010
=
~'25m 4. INSTALL OIL PRESSURE GAUGE
5. START ENGINE
Adh.e....s._i_v__e_ J~
Start the engine and warm it up to normal operating
temperature.
6. MEASURE OIL PRESSURE
Oil pressure:
At idle:
29 kPa (0.3 kgf/cm', 4.3 psi) or more
At 3,000 rpm:
245 - 490 kPa (2.5 - 5.0 kgfjcm', 36 - 7l psi)
7. REMOVE OIL PRESSURE GAUGE
8. REINSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive:
Part No. 03833- 00080, THRF.E BOND 134-4,
LOCTITE 242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816-30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
9. START ENGINE AND CHECK FOR LEAKS
.'
•
ENGINE- LUBRICATION SYSTEM. EG·91
·OIL ·AND FILTER REPLACEMENT
CAUTION:
.• Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation end dermatiti~. In addi-
tion, used engine oil contains rotentially harmful
contaminants which may cause skin cai1eer. Ade- ~·
quate means of skin protection and washing facilit·
ios should ba provided.
• Care should be taken, therofo>re, whan changing
engine oil. tc minimize the frequency and length of
time your sk!n is exposed to used engine oil. Pro'i:ec-:
tive clothing and gloves, that carmot be penetrated
by oil, should be worn. Wash your'skin ~horoughly
with soap and water. or use water-l~ss h.and clean-
er, to remove any usod engine oiL Do not use gaso-
line. thinners. or solvents.
• In order to preserve the environment, used oil snd
used oil filter must be disposed of •mly at d~signated ·
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug. and drain the oil into a
contain~r.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-22020
(b) Clean the oil filter contact surface on the oil filt~r
mounting.
(c) Lubricate the filter rubber ga£ket with cJe;,n omgina
oil.
., (d) Tighten filter until the gasket contacts seat of the
filter mounting. Then using SST, give it an additional
3/4 turn lo seat the filter.
SST 09228-22020
·.
LU0490
EG-92 ENGINE:"'- LUBRICAT.JON;SYSTEM ,
Reex>mmended Viscosity (SAE:) •· '3.·; FIL)-·WITH l;i'IGINE OIL
(a) Clean and ·install the oil drain plug with a new gasket·.
·~: 2nw.,o
Torque: ..25 N·m (250 kgf·cm. 18 ft·lbf)
15V/-40 (b) · Fill with new engine oil.
' 10W-30 > Oil grade:
API grade SG, SH or ILSJI.C multigrade engine oil.
' I I II II Recommended vi•cosity is as shown in the
.illustration.
: SW-30
Capacity:
'C ·29 -18 -7 4 16 27 38 Drain and ref111
w/ Oil filter change
'F -~0 0 20 40 60 80 100·
3.7 liters (3.9 US qt;, 3.3 Imp. qts)
TEMPERATURE RANGE .~NTICIPATED w/o Oil filter change
BEFORE NEXT OIL CHANGE - - - - -T :1'23182 3.4 liters (3.6 US qts, 3.0 Imp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL
•
OIL PUMP
COMPONENTS FOR REMOVAL AND
INSTALLATION
+Gasket
Oil Pan
~~~.-;1/:::...~-...-- ~~~1I
I L~.-~1 . III
+ Gasket--eI Oil Pump·-------1~'-'1 I
Drain Plug-~ I+Gasket I
~~~ I
.-:sb r~~~~~~~~~
I
[}G"n lkaf·cm, ft·lbf) j Specified torque
+ Non-rcus-a-bie-p-ar~l --------------------------------------------P'2~564=9
ENGI1'~i: - LUBRICATION SYSTEM EG-93
OIL PUMP REMOVAL
HINT;. When repairing the oil pump, the oil pan and
-. strainer should be removed and cleaned.
1. DRAIN ENGINE OIL
2. REMOVE OIL PAN
Remove the 22 nuts. oil pan and gasket. I
3. REMOVE OIL STRAINER AND OIL PUMP
(a) Remove th~ 3 bolts, oil strainer and gasket.
(b) Remove the bolt and oil pump.
. ron•~u
COMPONENTS FOR DISASSF.MBLY AND
ASSEMBLY
Oil Pump Body __.,
+ Cotter Pin ~I
t I
I
I
~..,
I
( r -- . I
· Relief Valve ({It?)
·. Dri~en Rotor---c:.J
Valve Spring
I
~&I . I
I I
) I
Drive Rotor----1 I
I
I ~:;_;YI
I II I
I 11 1
f I JI !
I (I
£I ~)
~Q' :
: .;"'""
;, ~ r--c-::- ~;;--] I
L &.9i/0,6tl~
[}Tm (kgf·cm, f:·lbf) \ : Specified torque
+ Non-reusable part
OIL PUMP DISASSEMBLY
1. REMOVE RELIEF VALVE
(a) Remove the cotter pin.
ASSEMBLY HINT: Use a new cotter pin.
(b). Remove the retainer, spring and relief valve.
EG-94. ENGINE:- lUBRICATION:SYSTEM.-.
, - - - - - - - - - - - - - - - - : - - .'·· 2 · REMOVe: DRIVE AND DRIVEN ROTORS
RemovB the 3 bolts. oil pump cover, the drive and
driven rotors.
Torque:. 6.9 N·m (70 kgf·cm, 61 in ..Jbf)
ASSEMBLY HINT: Install the rotors so that the mark
are facing thB pump cover side (upward), as shown.
(
1'25368 I<:IU-01
OIL PUMP INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its ow,, weight.
If the valve does not fall smoothly, replace the valve or
oil pump assembly. .
. .,...,
'
l 2. INSPECT DRIVE AND DRIVEN ROTORS
A. Inspect rotor body clearance
'--- Using a thickness gauge, measure the clearance be-
tween the driven rotor and body.
StDndard body ci.,Dronco:
v.li)O- 0.160 mm (0.0039- 0.0063 in.)
~J Maximum body claar.,nca:
0.20 mm (0.0070 in.)
If the clearance is greater than the maximum, repl;3ce
the rotors as a sst or pump assembly.
B. Inspect .rotor tip clearance
Using a thickness gauge, measure the clearance be-
tween the drive and driven rotor tips.
Standard tip claarar.ce:
0.040 - 0.160 mm (0.0016 - 0.0063 in.) ..
Maximum tip cloarance:
0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum. replace
.... f'7.>X6 the rotor set.
ENGINE- 'LUBRrCATION'SYSTEM · EG-95
C: ··Inspect rotor:side clearance
Using ·a thickness gauge and precision straight edge,
· measure the clearance between the rotor::; ·and preci-
sion straigt.: c:'ge'.
Standard side clearance:
0.030 - 0.090 mm (0.0012 ;... 0.0035 ln.)
Maximuin side clearance:.
0.15 mm (0.0059 in.)
If the side clearance is _greDter thar. maximum. replace
the rotors set or pump assembly.
OIL PUMP ASSEMBLY
Assembly is in the reverse order of disass.. mbly.
OIL PUMP OPERATION CHECK ··--
CHECK PUMP OPERATION
(a) Using a screwdriver, immerse the suction end of the
shaft clockwise. Oil shoul.d come out the discharge
hole.
(b) Using a screwdriver, close the discharge hole with
your thumb and turn the shaft as before. The shaft
shou!d be difficult to turn.
OIL PUMP INSTALLATION
1. INSTALL OIL PUMP AND STRAINER
(a) Align the oil pump shaft slot of the oil pump with the
governor shaft protrusion of the distributor.
(b) Install the oil pump with the bolt.
· Torque: 19 N-m (195 kgf·cm. 14 ft·lbf)
EG-96 ENGIN.E- LUBRICATION.SYSTEM ·
(c)·· Install· a new gasket and the oil strainer with the 3 •
bolts.
Torque: 8 N-m (80 kgf-cm, 69 in.-lbf)
2. :fo.!~TALL OIL PAN .-·
(a) Remove any old packing (FIPG) mateJial and be care·
ful not to drop any oil on the contact surfaces of the
oil pan and cylinder block.
(b) Apply seal packing to the timing chain cover, cylinder
block and rear oil seal retainer as shown in the illustra·
tion.
Seal packing:
Part No. OBe26-00080 or equivaleOJt
(c) Place a new gasket to the engine.
(d) Install the oil pan with the 22 nuts.
Torque: 9 N-m (90 kgf-cm, 78 ln.-lbf)
3. FILL WITH ENGINE OIL
4. START ENGINE AND CHECK FOR LEAKS
5. RECHECK ENGINE OIL LEVEL
SERVICE SPECIFICATIONS
SERVICE DATA
Oil pres!lure At Idle sp~ed (normal Ciperating temperature) 29 kPa (0.3 kgf/cm', 43 psi) or more
:245 - 490 kPe (2.5 - 5.0 kgf/cm', 36 - 71 psij
At 3,000 rpm {normal operating temperature) 0.1 oo - 1.160 mm ·co.oo39 - 0.0063 in.)
0.20 mm (0.0079 n.)
Oil pump Body c/earar.ce STD 0.040 - 0.160 mm (0.00 16 •• 0.0063 in.)
0.20 mm (0.0079 n.)
Maximum 0.030 •• 0.090 mm (0.00 12 - 0.0035 in.) ·-
0.15 mm (0.0059 n.)
Tip clearenco STD
L___I I . Maximum
~de clearance STD
Maximum
TORQUE SPECIFICATIONS
~ I II ft-1bl
I Nm-
\ · Part tightened kgf-cm
'
- - - - - - - -~fil.er bracket x 011 lirGssuro sw1tch 15 150 11
in plog x Oil pan
25 250 18
I Oi! p~mp cover x Oil pump -body - - - - - - - · 6.9 70 61 ln.·lbf
Oil pump x Cylinder block 19 195 14
Oil strainer x Cylinder block, Oil pump 8 80 69 in.-lbf
Oil pen x Cyl!ndor block, Timing ch"in ccvcr. Roar oil ~;onl retainer 9 90 78 ln.-lbf
•
IGNITION SYSTEM - DISTRIBUTOR IG-1 3
. 2. INSTALLDISTRIBUTOR
(a) Install a new 0-ring to the distributor·housing.
(b) Apply a light coat of engine oil on. the 0-ring.
,_
New 0-Ring
(c) Align the center line of the slot at the top end of the oil
pump shaft against the mark (oil hole) at the top side
of the oil pump body.
(d) Position the distributor rotor toward the right sids of
-- No.3 plug tube, and insert the distributor housing.
(e) When the housing is inserted, the rotor should ba
point near the centar of No.2 plug tube.
~ (f) Turn the ignition switch to ON, but do not crank the.
r1 · starter motor.
I( (g) Rotate the distributor body counterclockwise until a
"""' spark jumps between the points and tigntan the clamp
bolt in that position.
3. INSTALL ROTOR, PACKING AND :::JISTRIBUTOfl
CAP
4. INSTALL DISTRIBUTOR WlRE
5. CONNECT HIGH-TENSI01J CORDS TO
DiSTRIBUTOR CAP
6. CONNECT VACUUM HOSES TO VACUUM
ADVANCER
7. CHECK IGNITION TIMING
(Sea ignition timing inspection and scijustment in
Engine Mechanicalj
IG-14 · - - - - - - - IGNITION SYSTEM- SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA Maximum 25 k0 pur ~ord --
IH.igh-tension Res:istaLlc.e ·•
cord ~ NO W16Ex-u· ..
Spark plug . Recommended spark plug NGK BP5EY
0.8 mm (0.03 1 in.)
~~ition coil Correct electrode gap at cold 1.35 - 2.09 ()
Piima:y coil resistance at hot 1.71 - 2.46 (i
at cold 8.5- 14.5 kO
. at hot 10.7- 17.1 kO
at cold 0.8 - 1.3 0
Sacondnry co:l r(;sistance at hot 1.05 - 1.52 0
0.4 - 0.5 mm (0.0 16 ·- 0.020 in.)
Resistor resistanCe 0.05 - 0.45 mm (0.002 - O.ot 8 in.)
Distributor Rubbing block gap
D:ampin~. spring gap
TORGUE SPECIFICATIONS N·m kgf.cm ft·lbf
13
Part t:ghtened 17.5 180 9
Spark plug x Cylinder head 12 120
Distributor x Cylinder head
-·
IG-1
IGNITION SYSTEM
.-
PREPARATION ....................................... IG- 2
-- ON-VEHICLE INSPECTION.......................·IG- 2
IDISTRIBUTOR •••·•·••·•····•·••······••··· •·•·•••••••·• iG- 7
SERVICE SPECIFICATIONS ........................ IG- 14
IG-2 ·IGNIT-ION SYSTEM - ON~VEHICLE 'li~SPECTION
PREPARATION -·-liD
RECOMMENDED TOOLS
~~~<~>-?~ .. 090B2 -oooso TOYOTA Eloetrict~l Tost~r Sot.
Engine Adju~t Kit .
~"""""
= ~~£ c 09200-00010
~~
EQUIPMENT
M<9gger insulation resistance meter
~~~--------------~--------------------------~
Spark plug cleaner
Torque wrench ------------------------r-----------------------·--~
•
ON- VEHICLE INSPECTION
SPARK TEST
CHECK THAT SPARK OCCURS ·.
(a) Disconnect the high-tension cords from the spark
plugs.
(b) Remove the spark plugs.
(c) Install the SJ:.>ark plugs toeach high -tension cord.
(d) Ground the spark plug.
(e) Che.;k if spNk occurs while engine is being cranked.
NOTICE: To prevent excess fuel being Injected from the
injectors during this test, do not crank the engine for
more 5 - 10 seconds at time.
If the spark does not occur, do the test as follows:
---------:C-NIT~IO~N S~YS~TE~M -~O~N-=VEH=IC~l-E~IN~SPE~CT-ION-. ------ IG-3
I SPARK TEST I
I NO I BAD·J Connect securely. I
CHECK CONNECTION OF IGNITION COIL
AND DISTRIBUTOR CONNECTOR
t OK BAD Check and adju:;tlhe gap. I
CHECK RUBBING BLOCK GAP OF DISTRIBUTOR
)See page IG-61
Rubbing block g<lj): 0.4- 0.5 mm (0.016- 0.020 ln.)
I OK ~BAD Replace the cor,; (s). l
CHECK RESISTANCE OF HIGH-TENSION CORD
(See page IG-3)
Mal<imum resistance: 25 kO per cord
I OK 0
CHECK POWER SUPPLY TO IGNITION COIL Check wiring between ignition switch
t.Turn ignition switch to ON.
2.Check that there Is bat!ery voltage at BAD to ignitcn coil.
igniton coil positive (+) terminal.
I OK
""'"""" ,,.,.,'"'· ~. Secondary 8.5 ·14.50 10.7-17.1k0
CHECK RESISTANCE OF IGNITION COli... AND
RESISTOR !See page IG-41
Cold Hot
Resistance: Coil Primary 1.35·2.090 1.i1-2.460 BAD
Resistor ·o.a -1.30 1.05 ° 1.520
~·
HIGH- TENSION CORDS INSPECTION
-· 1. DISCONNECT HIGH-TENSION CORDS
(a) Disconnect the high - tension cords at the rubbor
boot
(b) Disconnect the high-tension cord from the distribu-
tor cap and ignition coil.
DO NOT ;>ull on the cords.
NOTICE: Pulling on or bonding the cords rnay damage the
conductor ins:ide.
2. INSPECT HIGH-TENSION CORD RESISTANCE
I Using an ohmmeter, measure the resistance.
Maximum resistance:
II'-.-.-.-_-=_==::.
25 kQ per cord
If the resistance is greater than m~ximum, check the
tormb:;~\s..!f riocessary, roplacs the high ~ Tensbn
I cord.
3.. RECONNECT HIGH-TENSION CORDS
Jf?JJ:..-<
SPARK PLUGS INSPECTION
DISCONNECT HIGH-TENSION COflDS FROM
SPARK PLUGS
2. REMOVE SPARK PLUGS
Using a 16 mm plug wrench, remov~ the spark plug.
.. · :GNI"fiON SYSTEM·- ON-VEHICLE INSPECTION
;q-4. ;j. CLEAN SPARK PLUGS
Using a spark plug cleaner or wire brush, clean the
spark plug.
..
Carefully bend the outer electrode to obtain the cor-
rect electrode gap.
Correct electrode gap:
0.8 mm (0.031 ln.)
6. REINSTALL SPARK PLUGS
Torque: 17.5 N·m (180 kgf·cm, 13 ft·lbf)
7. RECONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
IGNITION COIL INSPECTION
NOTICE: "Cold" end •Hot" In these sentences express the
temperature of the co!ls themselves. ·cord· Is from -1 o•
. C (14°F) to so•c (122.F) snd··Hot"ls from so•c (122°F)
to 100°C {2~:;('f-}.
1. DISCONNECT HIGH-TENSION CORD FROM
IGNITION COiL
.--------------, 2. INSPECT PRIMARY COIL RESISTANCE
Using an ohmmeter, measure the resistance between
the + and - terminals.
Primary coil resistance: ·
Cold: 1.35 - 2.09. 0 ·
Hot: 1.71 - 2.46 0
If the electric resistance is not as specified, replace
the ignition coil.
IGOSCJ Zt6411
IGNITION SYSTEM...-'- ON-VEHICLE INSPECTION------- IG-5
Ohmmeter :3. INSPECT SECONDARY COIL RESISTANCE
Using. an· ohmmeter, measure the resistance botween
T::-I['J the Band high-tension terminals.
Secondary co!' raslstance:
0'----Hoi
Cold: 8.5 - 14.5 kQ
Hot: 10.7- 1'1.1 kQ
If the electric resistance is not 2s specified, replace
the ignition ::oil.
Zl6412
4. INSPECT RESISTOR RESISTANCE
Ohmmeter Using an ohmmeter. measure tha resistance between
l.:.n.:J the B and + terminals.
'-----roe;:_~l Resistor resistance:
Cold: 0.8 - 1.3 Q
Hot: 1.05 - 1.52 0
If the electric resistance is not· as spocified, replace
the ignition coil.
IG0585 216•113
Voltmeter 5. INSPECT ?OWER SOURCE LINE
DC] (a) With the ignition switch an ON and using a v.oltmeter.
~e 0 connect the positive (+) probe to the B tarminal and
the negative (-) probe to body ground.
Voltage: Approx. 12V
I
L'~Go::"='-------------~-~-·-----~
(b) With the ignition switch as ·srART' and using a
voltmeter, connect the positive (+) probe to the +
terminal and the negative(-) probe to body ground.
Voltage: Approx. 12V
If abnormal, check tha ignition switch and wire har-
ness.
c. RECONNECT HIGH-TENSION CORD TO IGNITION
COiL
-.
IG-6. • IGNITION SYSTEIVI ,_.,ON-VEHICLE INSPECTION
DISTR!BUTOR INSPECTION •
1. REMOVE DISTRIBUTOR CAP WITH
.H'GH.,-TENSION CORDS
2. REMOVE ROTOR·
3. INSPECT BREAKER POINT
Using a feeler gauge. measure the gap between the
cam and rubbing block.
Rubbing block gap:
0.4 - 0.5 mm (0.016 - 0.020 in.)
If the gap is not within specification, adjust the gap.
(See distributor assarnbly)
4. INSPECT DAMPING SPRING
Using a feeler gauge, measure the gap between the
cam and damping spring.
Damping spring gap:
0.05- 0.45 mm (0.002- 0.018 in.)
. If the gap is not within specification, adjust the gap.
(See distributor assembly)
5. INSPECT VACUUM ADVANCER
(a) Disconnect the vacuum hoses from the vacuum ad-
vancer.
(b) Apply vacuum to the port A or B and check that the
vacuum advancer moves.
If the vacuum advancer do_es not work, repair or re-
place as necessary.
6. INSPECT GOVERNOR ADVANCE
(a) Turn the rotor clockwise, release it and check that the
rotor re.turns quickly counterclockwise.
(b) Check that the rotor is not excessively loose.
7. REINSTALL ROTOR .
9. REINSTALL DISTRIBUTOR CAP
~I
.· '
'~
IGNITION SYSTEM _; DISTRIBUTOR IG-7
·DIS'fRJBl:JTOR
COMP•.ONENTS FOR REMOVAL AND
INSTALLATION
High-Tension - - - r -
Cord
®@~0-.
-1Dislribulor j •••
Wire
Dislribulor ----<<L•
.. I
I
+ 0-Ring----~cp I
I
I
L--- -- --- ....I
+ Non-reusable part DISTRIBUTOR REMOVAL
1. DISCONNECT HIGH-TENSION CORDS FROM
DISTRIBUTOR CAP
2. DISCONNECT VACUUM HOSES FROM VACUUM
ADVANCER
3. REMOVE DISTRIBUTOR WIRE
4. REMOVE DISTRIBUTOR
(a) Remove the mounting bolt, and pull out tha distribu-
tor.
(b) Remove the 0- ring from the distributor housing.
IG·B IGNITION SYSTEM __: DISTRIBUTOR···
COMPONENTS FOR DISASSEMBLY AND"-~
ASSEMBLY
!-----Grease Stopper
!----Governor Spring
r-- --...J
_PieceB
Packing
Rotor------@
LeodWiwrc~11
.·· I
Holder- ~ I
I
Damping I
.~
Sprin~ I- -
---"1----"
l, Distributor Housing
Assembly
Breaker Plate
+ Driven Gear~
Vacuum Advancer
+Straight Pin - = t ; 1
+Non-reusable part
DISTRIBUTOR DISASSEMBLY
,_ REMOVE DISTRIBUTOR CAP, ROTOR, AND
PACKING
2. REMOVE DISTRIBUTOR TERMINAL
(a) Remove the nut and spring washer.
(b) Disconnect the lead wires of the condenser and bre-
aker point.
P25~ (c) Remove the 2 terminal insulators and terminal.
3. REMOVE BREAKER POINT ..-. '
Remove the 2 screws and breaker point.
4. REMOVE DAMPER SPRING
Remove the screw and damper spring.
•
IGNITION SYSTEM - DISTRIBUTOR '. IG-9
5, REiv'IOVE VACUUM ADVANCER
(a) . R.i~ove the screw and condenser.
(b) Using a s~niwdriver, remove the snap ring and pull out
the vacuum advancer.
-l
6. REMOVE BREAKER PLATE
(a) Remove the 2 screws, lead wir~ and holder.
(b) Remove the breaker plate.
7. REMOVE GOVERNOR SPRINGS
Using needle- nose pliers, remove the 2 springs.
'·
8. REMOVE CAM
(a) Remove the grease stopper.
(b) Remove the screw at the end of tho governor shaft.
(c) Pull out ths cam.
·~I
9. REMOVE GOVERNOR WEIGHTS
Using a small screwdriver, remove th~ snap ring and
pull out the 2 weights.
.. .IGNITION SYSTEM -:- DiSTRIBUTOR
IG-1 0 . DISTRIBlJTOR IN3PECTION
1. INSPECT BREAKF.R PLATE
Turn the breaker plate and check that it has a slight •
d r a g ..
If it sticks or strongly resists, replace the breaker
plate.
2. INSPECT GOVERNOR SHAFT
(a) Turn the governor shaft and check that it is not rough
or worn.
If it feels rough or worn, replace the distributor hous-
ing assembly.
.,,..I
r-----------------------~ (b) Using a feeler gauge, measure the governor shaft
thrust clearance.
..
Thrust clearance:
'.
0.15 - 0.50 mm (0.0059 - 0.0197 in.)
If the thrust clearance is not as specified, rep/aced the
distributor housing assembly.
3. INSPECT CAM
lnstaU the cam to the governvr shaft and check that
they fit correctly. .
If they don't fit, replace the cam and/or distributor
houl.'ing assemblv.
I
_ _ _ _Pm»j
" '154/G014T DRIVEN GEAR REPLACEMENT
1. REMOVE DRIVEN GEAR
(a) Using a grinder, grinc the driven gear and straight pin.
CAUTION: Be careful .,ot to damage the governor shaft.
(b) Mount the driven gear in a vise.
(c) Using a pin punch and hammer, tap out the straight
pin.
Z16'1l~ (d) Remove ihe drive gear and washer.
IG-11
--~------IGN-ITI~ON ~SYS~TEM~- ~DIS~TRI~BUT~OR ----~---
2. INSTALL NEW DRI\(EN GEAR
{a) · Place the driven gear onto the governor sh,ft.
{b) Install the new straight pin.
.-
P25567
{c) Sacure the ends of the straight pin in a vise.
DISTRIBUTOR ASSEMBLY
1. INSTALL GOVERNOR WEIGHTS
Using l)eedle- nose pliers, install the 2 weights with
the snap ring.
2. INSTALL CAM
{a) Lightly coat the governor shaft with high-t~mpera-·
tum grease,
{b) Place the cam on the governor shaft.
{c) Po.sition the &ill m~rk on the driven gear and cutout
I {d) as ~hown.
Install ths screw.
Drill Mark-·--..__.
L _ _ ____,_,:=..~"'""
(d) Pack high-temperature grease into the c"m.
{e) Push on the grease stopper with your finger.
3. INSTALL GOVERNOR SPRINGS
Using needle- nose pliers, in~tall the 2 springs.
IG-1:.!. IGNITION SYSTEM - DISTRIBUTOR
~-- .. . . <l• INSTALL BREAKER PLATE •
Align tl.a 4 clips on the breaker plate with the cutout
{a) parts of the housing and insert the breai<er plate.
lnstali the 2 holders. lead wire and 2 screws.
(b) INSTALL VACUUM ADVANCER
5. Insert the vacuum advancer into the housing connect-
{a) ing the pivot pin to the link.
Usir:g needle-nose pli;;rs, install the snap ring.
{b) Install the condenser with the screw.
{c)
6. INSTALL AND ADJUST BREAKER POINT
(a) Clean the contact surfaces of the points with a piece
of cloth saturated in solvent.
(b) Apply high--temper<tture grease to the rubbing block.
(c) Temporary install the breaker point and lead wire with
the 2 screws.
{d) Adjust the gap between the c<:m and rubbing block.
Rubbing block gap: 0.45 mm {0.018 in.)
(d) Tighten the 2 screws and recheck the rubbing block
gap.
7. INSTALL AND ADJUST DAMPER SPRING
~··, {a) Apply high-temperature grease to the heel of the
damper spring.
(b) Temporary install the damper spring with the screw.
(c) · Adjust thfl gap between the cam and damper spring ..
Damper spring gap: 0.25 .mm (0.01 0 ln.)
(d) Tighten the screw and recheck the damper spring gap.
8. INSTALL DISTRIBUTOR TERMINAL
(2). Install the 2 insulators and terminal to the housing.
(b) Connect the lead wires of the breaker point and con-
denser to the terminal.
(s) lnst~JI thtJ spring wash.:r Dnd nut.
DISTRIBUTOR INSTALLATION
1. SET N0.1 CYLINDER TO TDC/COMPRESSION
(a) Remove the No.1 spark plug.
{b) Place your finger over the hole of the No.1 spark plug
and rotate the crankshaft clockwise to TDC. If pres-
sure is felt on your finger, this is TOG/compression of
the No.1 cylinder. If not, repeat the process.
(c) Install the No.1 ~park plug.
IGNITION SYSTEM '--- DISTRIBUTOR IG-13
2. ·INSTALL DISTRIBUTOR
(a) Install a new 0- ring to the disiributor housingc
(b) Apply a light coat of engine oil on the 0-ring.
.."
,. ...., ~-
l~ew o-Ring
(c) Align the center line of the slot at the top end of the oil
pump shaft against the mark (oil hole) at the top side
of the oil pump body.
.-
.. - (d) Position the distributor rotor toW3rd the right side of
· No.3 plug tube, and insert the distributor housing.
; (e) When the housing is inserted, tho rotor should be
point near the center of No.2 plug tube.
(f) Turn the ignition swit,ch to ON, but do not crank the
starter motor.
(g) Rotate the distributor body counterclockwise untir" a
spark jumps between the points and tighten the clamp
bolt in that position.
3. INSTALL ROTOR, PACKING AND !:JISTRIBUTOR
CAP
4. INSTALL DISTRIBUTOR WIRE
5. CONNECT HIGH-TENSION CORDS TO
DISTRIBUTOR CAP
6. CONNECT VACUUM HOSES TO VACUUM
ADVANCER
7. CHECK IGNITION TIMING
(Sea Ignition timing inspection ond adjustment in
Engine Mechonlcel)
\.
IG-14 IGNITION SYSTEM SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS og01t•OO
SERVICE OATA ft·lbf
13
!Maximum 25 kO per cord 9
" Iw"~-o
NGK BP5EY
0.8 mm (0.031 in.)
at cold 1.35 - 2.09 0
nt hot 1.71 - 2.46 0
at cold 8.5 - 14.5 kO
at hot 10.7- 17.1 kO
at cold 0.8 - 1.3 0
ot hot 1.05 - 1.52 0
O.A - 0.5 mm (0.0 16 - 0.020 in.)
0.05 - 0.45 mm (0.002 - O.Q18 in.)
. TORQUE SPECIFICAJtON~,~. N-m kgf·cm
17.5 180
r-· ;..,: 12 120
Part tightened
Spark plug X Cylinder hood
Distributer x Cylinder head
•
ST-1
STARTING SYSTEM
..
?REPARATION ······································· ST- 2
STARTER ·················································sr- 3
SERVICE SPECIF:CATIONS···········............. ST-- I~
'.
ST-2 STARTING S'(STEM -·PREPARATION
PREPARATION •
SST (SPECIAL SERVICE TOOLS)
I 09221 -25025 Piston Pin Remover & Replacer
I
....... ···································································· ·················· ················ ···································································
(09221 -00090) Gu;de ·c· Center besring
•
noor-or
=tECOMMENDED TOOLS
09082-00050 TOYOTA Electdcel Tester Set.
09804-00010 Expondor Set.
:OUIPMENT
Micromet9r Planetary aheft
Caliper gauge
-Dial indicator Comm11tator
Magnetic finger
Pullacale Brush spring
Sandpaper - Commutator
l'>rqu.t wronch
__-==:JVvtrmbleorckeau..pe._r_•---------~-----·---..L..:C::o:::":::'m::_u::t::•:::to::_r•:_:B::r.:u::•h:__ _ _ _ _ _ _ _ _ ,_ _ _ _ j
•
STARTING: SYSTEM-. STARTER ST-3
·• STARTER
. .' COMPONENTS FOR DJSASSEMBLY AND--~
ASSEMBLY
®@~~Covetfr .Magneti~ Switch Cover l
$~ e
Magnetic Switch Starter Housing
Drive Lever
l ""~@®--Snap·1· Stop Co/l;;r Ring
Plate Washer
· ShoAcbsko(rb}e)r
Planetary Gear~PianetaSrhya~(j/fff\ ~~~Starter Clutch
rQ;\ loi I I I~ ~ 'fiPlate ~~~
Snap Rmg
-. ~-ArmaturePlate Washer
Plate Washer Center Bearing
Internal Gear
tocomm"'"" Eo' '"m' -.;:-- "- '
Brush Holder
~ ~-~- l<l>' - __ < +o-"'"'
+ 0-Ring Field Frame _JI
~Non-reusable part ~--~+O-Ring '(j---oust Protector
--------------~--------~
STARTER D!SASSEMBLY
1. REMOVE MAGI'IETlC SWITCH CO\'Efl .. :
2. REMOVE MAGNETIC SWITCH
(a) Remove the nut and magnetic switch ccwer,
(b) Remove the nut, and c::;~connact the l&ad wire from
the magnetic switch terminal.
(c) Loosen the 2 nuts holding the magnetic switch to the
.. starter housing.
(d) ·Pull the magnetic switch and while lifting the front
part of the magnetic switch. release tho plunger hook
from the drive levar, then release the magnetic switch.
(e) Remove th;; plunger r.over.
3. REMOVF. FIELu FRAME AND ARMATURE
Remove the 2 through bolts, and pull out tho fi6ld
frame together with the armature.
·:T-4 .STARTING. SYSTEM -STARTER
. 4. R:;MOVE COMMUTATOR END FRAME .•
Remove· the 2 screws with 0-rings and commutator
end frame, and hold down the lead wire while releas-
ing the commutator end frame.
NOTICE: To avoid interference between the brush holder
and the dust protector, pull the commutator end frame
away at flO angle.
ST0728
. 5. REMOVE BRUSH HOLDER
(a) Using a screwdriver, hold the spring back and discon·
nect the brush holder.
(b) Disconnect the 4 brushes, and remove the brush
holder.
6. REMOVE ARMATURE FROM FIELD FRAME
7. REMOVE 2 0-RINGS FROM FIELD FRAME
8. REMOVE DRIVE LEVER AND STARTER CLUTCH .'
·wiTH SHOCK ABSORBER FROM STARTER
t HOUSING
;v~
------------------ ST~711
9. REMOVE PLANETARY GEARS
Ramcve these parts from the shock absorber.
(1) Plzte '
·(2) 3 planetary goars
(3) Plate washar
1\0252 (1 J Z00210
10. REMOVE STARTER CLUTCH
(a) Usi! .g a screwdriver, tap in the stop collar towards the
sta"ter clutch.
(b) Using a screwdriver, pry off the snap ring.'
(c) Remove the stop collar and starter clutch from the
planetary shaft.
.r '--------------~~--~~S~T~A~R~T~I~N~G~-s~v~:s~T~E~M~-~-~S~T~A~R~TE~R~--------------------s_T_-5_
11.' REMOVE P-lANETARY SHAFT AN~ INTERNAL
GEAR
(a) Using snap ring plierz. remove the snap ring and plate
washer. ·
(b) Removo the planetary shaft and plat'l washer.
c;ontinuity SICISSil
STARTER INSPECTION AND REPAIR
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
bet\~een the ;;egments of the commutator.
If there is no continuity between any segments, re-
place the umature.
2•. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no cc-.ntinuity
between the commutator and armature coil core.
If there is continuit-y, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR'DIRTY AND BURNT
SURFACES
If the surface is dirt-y or burnt, correct with sandpapsr
(No.400) or a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Piace tha <•om mutator on V -0!ccics.
(b)-· Usin;J a dial gauge, measure tha circle run out;
Mexlmum circle runout:
0.05 mm (0.0020 ln.)
If the circle runout is greater1h1m maximum, correct it
on a lathe.
-,:J)J~E=- · =::1=·1 3. INSPECT COMMUTATOR DIAMETER ~ i'
Using vernier calipers, measure the commutator diam-
-;~]~-_"-0~·___;,j eter. :II
Standard diameter:
28 mm (1.10 ln.)
Minimum diameter:
27 mm (1.06 ln.)
If the diameter is less than minimum, replace the
armature.
ST-6 STARTING SYSl'EM -STARTER
ST0040 1 4. INSPECT UNDEi)C:..'T DEPTH
Check that the undercut depth is clean and free of
foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum. correct it
wi~h a hacksaw blade.
Field Frame (Field Coil)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT .r.
Using an ohmmeter. check that there is continuity
between the lead wire and field coil brush lead.
If> there is no continuity, r~place the field frame.
Continuity
2. INSPECT FIELD COIL GROUND
Using an ohmmeter, check that there is no continuity
between the field coil end and field frame:
If there .is continuity, repair or replace tho field frame.
No coiitinuit\'
l Brushes -·
INSPECT BRijSIJ LENGTH
Using vernfer calipers, measure the brush length.
Stondord length:
14.0 mm (0.551 ln.)
Minimum longth:
9.0 mm (0.354 in.)
ff thq Jqngth k Jqu lh;m minimum. mplilGii !hr. /;ru~l.
holder and filed frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
·Take the pull scale reading the instant the brush
spring separates from the brush.
Spring installed load:
8.8'- 17.7 N (0.9 - 1.8 kgf, 2.0 - 4.0 lbf)
< ·t.
. STARTING.SYSTEM- STARTER . '~
'i
-.__ ;•.------------'-~--,
f
•. No continuity
I:
•!' -· .
Brush'Hoider
INSPECT BRuSH HOLDER INSULATION
Usin·g an ohmmeter, check that there is no continuity
between the positive{+) and negative(-) brush hol-
ders.
If there is continuity, repair or replace the brcsh
holder.
---------------""'-" I .
Clutch and Gears
1. INSPECT GEAR TEETH
Check the gear teeth on tha planetary gear.- internal
gear and starter clutch for woar or damage.
If tl;le gear is damaged, repiBce it.
If the starter clutch teeth are damaged; replace the
,. starter clutch and also inspect the fl~wheel ring gear
for wear or damage.
. 2. INSPECT STARTER CLUTCH
• Rotate the clutch pinion gear clockwise and check
that it turns freely.
Try to rotate the clutch pinion gear counterclockwise
and check that it locks.
If necessary, replace the starter clutch.
Magnetic Switch
1. INSPECT PLUNGER
Push in the plunger and replace it.
Check that it returns quickly to it:? original position.
If necessary, replace the magnetic> swit!:h.
i; STOC:67 2. DO PULL--'I.N COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity
Contjnuity Terminal 50 between terminals 50 and C.
If there is no continuity. replace the magnetic switch.
Terminal C
P10134
.,•,.
ST-8 STARTING SYSTEM·,... STARTER.
3. DO .HOLD....., IN COIL OPEN CIRCUIT TEST
.I • •
Using M ohmmeter, check that there is continuity
between terminal 50 and the switch body. · •
If there is no continuity, replace the magnetic switch. · ....
.,
Planetary Shaft and Center Bearing ·-
1. INSPECT PLANETARY SHAFT AND CENTER BEAR- •
ING
(a) Using a micrometer, measure the outer diameter of
the, surface in contact with the center bearing of the
planetary shaft.
Standard shaft diameter:
14.980- 15.000 mm (0.5898- 0.5906 in.)
~ (b) Using a caliper gauge, measure the inside diameter of
the center bearing.
-----------------
Center boadng Inside diameter:
~ST e:i--~ I
"--'- Y-f 15.008 - 15.050 mm (0.5908 - 0.5925 in.)
(c) Subtract the planetary shaft diameter from the bear-
ing inside diameter measurement.
Standard center bearing oil clearance:
0.01 - 0.06 mm (0.0004 - 0.0024 in.)
Maximum cantor bearing oil cloarance:
0.2 mm (0.0078 ln.)
If the clearance is greater than maximum, replace the
planet carrier shaft and center bearing.
2. lF NEC!:SSARY, REPLACE CENTER BEARING
(a) Using SST and .Press, press out the center bearing.
SST 09221-25025 (09221-00090)
~" fy)
(b) Using SST and a press, press in a new center bearing
to the posi.tion shown in the illustration.
SST 09221-25025 (09221-00071)
/•
STARTING. SYSTEM:....· STARTER· ST-9
'' ·(c) Align the hollow of tha internal gear with the protru- ..
sion inside the shock absorber, and remove the inter-
- '' rial gear. ·
••
Hollow
Protrusion
·' SToo-17
STARTER ASSEMBLY
HINT: Use high temperature-resistant grease to lu-
bricate the bearings and sliding parts when assembl-
ing the starter.
1. INSTALL INTERNAL GEAR AND PLANETARY
SHAFT
(a) Apply grease to the internal gear touching the sock
absorber and planetary gears.
· liollow (b) Align the hollow of the internal gear with the protru-
sion inside the shock absorber.
(c) Insert and turn the internal gear 5o that it interlocks
with the shock absorber.
Shock Absorber STC647
(j Planetar~· Shaft (d) Apply turbine oil with additives to thA c&nter bearing.
(e) Apply grease to the plate washer. and install it to the
f
Plate Washer plar.atary shaft
(f) Install the·planetary shaft to the shock absorber.
- )671 (g) Using snap ring plior~. install the plato washer and
snap ring.
Zl~l
: 2. INSTALL STARTER CLUTCH
(a) Apply grease to the bushing and splir.e of the starter
clutch and stop collar.
(b) Place the starter clutch an·d stop collar on the plano·
tary shaft.
sroon
ST-10 STARTJNG.SYSTEM - STARTEtl
(c) Apply. grease to the snap ring, and instal! it to the ..
planetary .shaft gro.ove.
•
(d) Using a vise, compress the snap ring.
ST007J .
(e) Hold the starter clutch, tap the planetary shaft and
install the stop collar onto the Sflap ring with a plastic
-facod hammer.
3. INSTALL PLANETARY GEARS .·
(a) Apply grease to the planetary. gears and flange pin
parts of the planetary shaft.
(b) Install the plate washer and 3 planetary gears.
(c) Align the cutout of the plate With the protrusion insida
the shock absorber, and install the plate.
t 4. INSTALL DRIVE LEVER AND STARTER CLUTCH
: WITH SHOCK ABSORBER
··~. (a) Apply turbine cil with additives to tlie bearing ot 1he
starter housing.
(b) Apply grease to th& drive levor touching the starter
pivot part of the drive levsr.
(c) Install tho drive lever to the starter clutch.
ST07<11 •
(d) Align the protrusion of the shock absorber with the
0utout of the starter hol!sing and install them.
STARTING SYSTEM - STAR.TER ST-11
. ..• 5. INSTALL 2 NEW 0-RJNGS TO FJELD FRAME
... ..
6. PLACE ARMATURE INTO FIELD FRAME
..
7. INSTALL BRUSH HOLDER
iT0727
(a) Place the brush holder in position on ths armature.
RI 88.(
(b) Using a screwdriver. hold the brush spring back. a.1d
·.
connect the brush into tho brush holder. '
i
Connect the 4 ·brushes.
HINT: Check that positive(+) lead wires are not gro-
""" unded.
8. INSTALL COMMUTATOR ENO FRAME
(a) Apply turbine oil with additives to t~e bearing of the
end frame.
(b) Install the end frame with 2 new screws with 0-:--
rings.
NOTICE: To avoid interference between tho brush holder
and tho dust protector, pull tho commutator ~rid frame
away at an angle.
Protrusion 9. INSTALL FIELD FRAME AND ARMATURE
ASSEMBLY
,.;
(a) Align the cutout of the field frame with the protrusion
of the shock absorber.
(b) Install tho field frame and arrnaturo assnmbly with the
2 through bolts.
=
10. INSTALL MAGNETIC SWITCH
I (a) Install the plunger cover to the magnet:c switch.
(b) Ha11g the pltrnpE!r ol tho magn~ti.:: ,~witch to the drive
I levsr from the upper side.
(c) Install ths magnetic switch with the 2 nuts..
(d) Connect the lead wire to th~ terminal, And install the
nut.
(e) Install the magnetic switch cover with the nut.
ST0742 11. INSTALL MAGNETIC SWITCH COVER
STARTER PERFORMANCE TEST
NOTICE: Thaso tests must be dono within 3 to!> seconds
to avoid burning out tho coil:
1. DO PULL-IN TEST
(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear mo·ves outward.
·:··
ST-12 STARTING SYSTEM- STARTER
If the clutch pinion gear does not move, repiace the •
magnetic switch. · -.
2. DO HOLD-IN TEST
With the battery connected as above and with the
clutch pinion gear .:>Ut disconnect the negative (-) •
lead from terminal C.
Di~connect Check that the clutch pinion gear remains out.
"'""' If the clutch pinion gsar returns inward, replace the
magnetic switch.
3. INSPECT CLUTCH PINION GEAR RETURN "
Disconnect the negative (-) le.ad from the switch •
body.
Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return, replace the
!'\lagnetic switch.
4. INSPECT CLUTCH PINION GEAR CLEARANCE
(a) Connect the battery to the magnetic switch as shown.
'---- ------------'-"""="'-1
(b) Move the pinion gear toward ths armature to remove
slack and maasure the ci<Jarance between tha pinion
goar end am! stop co!!a~.
St~and11rd ~lesranee;
7 - ~ m'm (0.04 ·- 0.16 in.)
5. DO NO-LOAD PERFORMANCE TEST •
(a) Connect the field coil lead to terminal C.
Make sure the lead is not grounded.
(b) Connect the battery a·nd ammeter to the starter as
shown.
(c) Check that the starter rotates smoothly and steadily
with the clutch pinion gear moving out.
Check that the ammeter r!3ads the•specified current.
RnAl"':ifiArf r.:m"r"Ant!
STARTING SYSTEM -SERVICE SPECIFICATIONS ST-13
SERVICE SPECIFICATIONS .........
SERVICE DATA
Starter 1RBted voltage and output puwer 12 V 0.8 kW l
No-load characteristics 90 A or less at 11. 5 V
Current
•• Brush len9th rpm 3,000 rpm or more
STD 14.0 mm (0.551 in.)
Minimum 9,0 mm (0.354 in.)
Spring instal:ed load 8.8 - 17.7 N (0.9 ·· l.B kgf, 2.0 - 4.0 lbf)
Ccmmutator
Diameter STD 26 mm (1.10 in.)
Minimum 27 mm ( 1.06 in.)
Undercut dApth STD 0.6 mm (0.024 in.)
Minimum 0.2 mm (0.008 in.)
Circle runout Maximum 0.05 mm (0.0020 in.)
Planetary shaft diametor STD 14.980 - 15.000 mm (0.5898 - 0,5906 in.)
Center bearing
Inside diamoter 15.008 - 15.050 mm (0.5908 ·- 0.5925 in,)
Oil clearance
STD O.GI - 0.08 mm (0.0004 - C.0024 in.)
Maximum 0.2 mm (0.0078 in.)
L____________l_P~i~n~io~n~c~lo~o~,,~n~c~e------------·--------~S~T~D~~I_:-~4~m~m~(0~.04~~-~~0.~1~6~in~.~)------------·----·--
_J
'.
CH-1
,- CHARGING SYSTEM
•
PRECAUTION .......................................... CH- 2
PREPARATION ····························-·······;.. CH- 2'
ON-VEHICLE INSPECTION ..................... CH- 3
ALTERNATOR ............................ _.......... CH- 5
ALTERNATOR REGULATOR,_,_,_,,, ......... CH-13
SERVICE SPECIFICATIONs ........................ CH- 14
'.
I'
i
I
I
I
CH-2 CHARGING SYSTEM - PREPARATION
PRECAU;!ON
1. Check that the battery r.aoles are connected to the correct terminals.
2. Disconnect the battery cables when the battery is given a quick charge.
3. Do not perform tests with a high voltage insulation resistance tester.
4. Never disconnect the battery while the engine is running.
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09286-46011 Injection Pump Spiino Shaft Roto:~r roar bearing
Pullor
09950-60010 Replacer Set Rotor front bearing ..
••
(0995 I -00220) Replacer 22
(09951-00400) Replacer 40
······· ··· ...... ·· ····· · · ··· ·············~··· ···· ········ ............ ·· ·.................... · ... ·· ·
iii9352·~·a6iii'iii···:.;:d~~;~;·
@ill~'~
RECOMMENDED TOOLS L_
09082-00050 TOYOTA Electrical Testor Set.
---------------------------
-EQ-U-IP-MENT Rotor (Slip ring)
Batt&r'f' specific gravity gauge
--Torque wrench
Vernier calipors
•• I
'' CH-3
CHARGING SYSTEM - ON-VEHICLE INSPECTION
... ON- VEHICLE INSPECTION
.'
1. CHECK BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
if insufficient, refill with distilled (or purified) water.
{b) Check the specific gravity of each ceil.
Standard specific gravity:
At 2o·c (sa·FJ:
NS40l: 1.27 - 1.29
CORRECT WRONG Othors: 1.25 - 1.27
If the gravity is less than $pacification, charg~ tho
battery.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals aro not loose or .
corroded.
(b) Check the fusible link and fuses for continuity.
MAOOJS 3. INSPECT DRIVE BELTS
:· - (a) Visually check the drive belt for craeks, oiliness cr
Water Pump wear. Check that the belt does not to:.~ch the bottom
of the pulley groove.
If necessary, replace the driva bel:.
{b) Check the drive belt deflection by pressing on the belt
at the points indicated in the illustration with 98 N {1 0
kgf, 22 lbf) of pressure;
Drive belt deflection:
Allernator New belt: 11 - 15 mm (0.43 - 0.59 in.)
"''"' 1 Used belt: 15 - 20 mm {0.59 - ().79 in.)
If neces.sary, adjust the drive bolt deflection.
HINT:
• "New belt" refers tc a belt which has bGen usod
less than 5 minutes or. a running sngina.
• "Used belt" refers to a bolt which ha$ been used
on a running enginll for 5 minutas or more.
• After installing a new belt, run the engine for
about 5 minutes and recheck the deflection.
4. VISUALLY CHECK ALTERNATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good conclition.
(b) Check that there is no abnormal nois~ from the alter-
nator while the engino is runnin8.
5. INSPECT DISCHARGE WARNING LIGHT SIRCUIT
(a) Turn the ignition switch "ON". Check that the dis-
charge warning light comes on.
(b) Start the engine. Check•that the light goes off.
If the light cloes not operate as specified, troubleshoot
the discharge warning light circuit.
CH-4 CHARGING SYSTEM.- ON-VEHICL:E INSPECTION
· 6, . INSPECT CHARGING CIRCUIT WITHOUT LOAD , .
HINT: If a batteryjalte~nator teste'r is available, con- •
...nect the tester to the charging circuit as per the .
manufacturer's instructions.
Plm / ...._,..__~·,....,
(a) If a tester is not available, connect a voltmeter and
~meter
ammeter to the charging circuit as follows:
CH0008
• ·Disconnect the wire from terminal 8 of the altar-
IQQI17
nator and cc.nnect it to the negative (-) lead of
the ammeter.
• Connect the positive (+) lead of the ammeter to
terminal 8 of the alternator.
• Connect the positive(+) lead of the voltmeter to •
terminal 8" of the alternator.
• Ground the negative(-) lead of the voltmeter. •
(b) . Check the chargi!lg circuit as follows:
With the engine running frorr: idle to 2,000 rpm, ch.eck
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: .. ,·
At20"C(68"F): 13.8 -14.8V
At 60"C (140"F): 13.3- 15.5 V
"If the voltmeter reading is more than standard voltage,
adjust the regulator or replace it.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the
high beam headlights and place th.e heater blower
switch at "HI".
(b) Check the reading on the ainmete~r.
Standard amperage: 30 A or mare
If the ammeier reading is less than standard amper-
age, repair the alternator.
HINT: If the battery is fully charged, the indica·tio;1
will somatiml3s be :!Jss than st<JnJard amperage.
•
..
CH·5
CHARGING SYSTEM ALTERNATOR
.. - ALTERNATOR
'
40A Type CAOSSMEPMOBNLEyNTS FOR D. ISASSEMBLy AND_,,_"
Stator
. Front Bearing Rotor
Onve Elld Frnme
Spacer Coller I
Fan I
Pulley
I ~: ,( Insulator Washer
®® i' .'> Brush Spring
.I
Spacer Coller
Rear End Cover
Rectifier End Frame I
50A Type "" !1:? I "~'""'"'""Fran~ Bearin 9 ~ -Rojtor .I
Drive End F. 1•
• ffime I
Spacer Coller I .
~-'·~ " . _., _,_ I ,-.,:,.
Rear Bearing
,QI ~--~,'t;'). -
TP.rminallnsulator
,-· ' ~
·:::·::::~~:~ --~---
______ ...
Condenser
P2~56 ~R-~ectifier End Frame
P25J57 '.
I N·m (kgf·cm, ft·lbfl Conectamea! Housing
: Specified torque
..,..· ~
CH-6 CHARGING SYSTEM- ALTI::RNATOR
ALTERNATOR DISASSEMBLY -··· •CI-01 .-
·'
1. REMOVE DRIVE END FRAME AND ROTOR
ASSEMBLY FROM STATOR ...
(a) Remove the 3 through screws.
(b) Using a screwdriver. pry the flnd frame and remove it •
together with the rotor.
CAUTION: Do not pry on the coil wires.
•
r-·--------------~·--~-------~ 2. REMOVE PULLEY AND FAN
(a) . Mount the t"otor in a soft jaw vise.
@---j-(11 (b) Remove the nut and these parts:
~--J-(2) (I) Spring washer
(3) (2) Spacer collar
(3) Pul:ey
(4) Fan
(5) Spacer collar
6J ----, 3. REMOVE ROTOR
(a) Using a pn'lss, press ou·t the rotor.
(b) 40A Type:
Remove the spacer ring and snap ring.
(c) 50 A Type:
Remove the spacer ring.
40A Type 4. REMOVE RECTIFIER END FRAME •
A. 40A Type:
(a) Remove the 4 nuts, condenser, cord clip and 2 termi- .•
nal insulators. i
(b) Remove the nut and rear end cover from the rectifier
1
end frame.
(c) Removs the rectifier end frame from the rectifier
holder.
_ _ _ _ _ _ _ _ _ _ _C::.H:..:.:..:.:ARGING SYSTEM- ALTERNATOR CH-7
soA Type l B. 50A Type:
(a). Remove the 4 nuts. condenser and 2 terminal insula-
•'
tors.
...
(b) Remove the rectifier end frame from the rectifier
holder.
(c) Remove the insulator washer from the rectifier holder.
5, REMOVE RECTIFIER HOLDER
H<'ld the rectifier terminal with needie-nose pliers ~~l£:
and unsolder the lead wires.
• CAUTION: Protect the rectifiers trorn heat.
•• 6. 50A Type:
SOA Type REMOVE CONECTAMEAL HOUSING
Using an un·solder, remove the conectameal housing
' from the rectifier holder.
CAUTION: Protect the rectifiers from heat.
No Conlinuily Clocu.,.-•1
ALTERNATOR INSPECTION AND REPAIR
Rotor
1. INSPECT ROTOR rCR OPEN CIRCUIT
Using an ohmmeter, chock that there is continuity ·
between the slip rings.
Standard resistance:
At 2o•c {61l.F): 3.9- 4.1 o
If there is no continuity, replace the rotor.
· z: INSPECT ROTOR FOR GROUND
Using an ohmmeter. check that there is no continuity
between the slip ring and rotor.
If there is continuity, replace ·the rotor.
•
'· .
.-
.CHARGING SYSTEM.- ALTERN ATOR
3. INSPECT SLii= 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 diameter...
Standard diameter:
32.3 - 32.5 mm {1.272 - 1.280 in.)
Minimum diameter:
32.1 mm {1.264 in.)
If the diameter is less than minimum, replace the rotor.
Stator '
1. INSPECT STATOR FOR OPEN CIRCUIT .I
Using an ohmmeter, chsck that there is continuity
between the coil leads. '
, NOTICE: At this time, th& meeting wires should be con-
nected with soldered.
If there is no continuity, replace .the stator.
2. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity
between the coil leads and stator coni.
If th11m i~ r;rmtin11ity, nip11lr.ll thll ~tfll'lr.
Ohmmeter
Q_/
\- I
No cantin-u-!t-y--------------~P~24~939.
L---
I Brushes •
I •'. INSPECT EXPOSED BRUSH LENGTH •
Using a scale. measure the exposed !:irush length.
I Stand~~rd exposed length:
12.5 mm {0.492 ln.)
Minimum exposed length:
I 5.5 mm {0.2171n.)
If the exposed length is less than minimum, replace
the brush.
lF2. 'NECESSARY, REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of a new brush through the spring and
the hole in the brush holder, and insert the spring and
brush into the brush holder.
I. CHARGING SYSTEM- ALTERNATOR CH-9
40A Type fc) Solder the brush wire to the brush holder at specified
exposed length.
-<
.Exposed len;Jth:
-.-. t 2.5 mm (0.492 in.)
..• 50A Type (d) Check that the brush moves smoothly in the brush
holder.
mm {e) Cut off the excess wire.
(f) Apply insulation .paint to the soldered area.
Rectifiers (Rectifier Holder)
.l.c...'.f.i.1.
(a)
INSPECT POSITIVE RECTIFIER .
Using an ohmmeter, connect one tester probe to the
positive (+)terminal and the other to each rectifier
terminal.
(b) Reverse the polarity of the tester probes and repeat
step (a).
(c) Check that one shows continuity and the other shows
no continuity.
If continuity is not as specified, replace the rectifier
Positive i+) holder,
Terminal
Zl66<l7
40A Type 2. INSPECT NEGATIVE RECTIFIER
Negative (a) Using an ohmmeter, connect one tester probe to saC'h
Terminal
SOA Type negative (-) terminal and tha other to each rectifiilr
terminal.
(b) Reverse the polarity of the tester probes and repeat
stop (a). ··
(c) Check that one shows continuity and th" other shows
no continuity.
If continuity is not as specified, replace the rectifier
holder.
Negative (-)
Terrryinal
llfh46
CH-1 0 CHARGING SYSTEM - ALTERNATOR ·•'
7ffii Bearings
5'&1
1. INSPECT FRONT BEARING
Check that the bearing_ is not rough or worn.
2. IF NECESSARY. REPLACE FRONT BEARING
{a) Remove the .3 screws.
{b) Using SST and a press, press out the bearing. .. '
SST 09950-6001 0 (09951 -00220. 09952-0601 0)
(c) Using SST and a press, press in a new bearing.
SST 09950-6001 0 (09951 - 00400)
(d) Install the 3 screws.
3. INSPECT REAR BEARING
Chock that tho bearing is not rough or worn.
4. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST og286-46011
{b) Using a press, press in a new bearing. '
I . ,.
CH.ARGING SYSTEM- ALTERNATOR CH-11
SOA Type ALTERNATOR ASSEMBLY
•' 1. 50A Type:
INSTALL CONECTAMEAL HOUSiNG
... - s·older the conectameal housing to the rectifier hold~r.
40A Type CAUTION: P:·otect t~e rectifiers from heat.
2. INSTALL RECTIFIER HOLDER TO STATOR
Hold the rectifier terminal with needle-pliers while
soldering t~e lead wires.
CAUTION: Protect the rectifiers from heat.
3. INSTALL RECTIFIER END FRAME TO RECTIFIER
HOLDER
A. 40A Type:
(a) Pla~e the 2 insulator washers on the positive studs )f
the 'rectifier holder.
(b) Pla9e the rectifier end fran1e on the rectifier holder.
P2<93J
40A Type (c) Place the rear end cover on the rectifier end frame.
(d) Place the 2 terminal insulators on the positive studs
••
on the rectifier holder.
P249~ (e) Install nut.
.~;;;® Torque: 4.4 N·m (45 kgf.r.m, 39 in•.lbf)
SOA Type ::- -1
(f) Install the cord clip and condenser with the 4 nuts.
r1sJs<~ """ ,_/
J Torquo: 4.4 .N·m (45 kgf.cm, 39 in.·lbf)
P15J5S
..::;I 1'-V---L N (g) Check that the lead wires are not touching the rectifi-
er end frame.
B. 50A Type:
(a) Place the insulator washer on ths positive studs of the
rectifier holder.
(b) Place tho rectifier end frame on the rectifier holcJAr.
(c) Place the 2 terminal insulators on tho positive studs
on the rectifier holder.
(d) Install the condenser with the 4 nuts.
Torque: 4.4 N·m (45 kgf·cm, 39 ;,..Jbf)
(e) Check that the lead wires are not touching the rectifi-
er e!ld frame.
4. INSTALL ROTOR
(a) 40A Typd;
Place the snap nng and spacer ring onta the rotor
shaft.
(b) 50A Type:
Place the spa cor ring onto the rotor shaft.
CH-12 CHARGING SYSTEM- ALTERNATOR
(c) Using a press, press in the rotor.
. ..,'
,,,- 1:.
00311
(51 5. INSTALL FAN AND PULLEY ,.
141 (a) Mount the rotor in S'Jft jaw vise.
131 '••
(h) Install these parts with the nut on the rotor shaft:
(21 (1) Spacer collar l
(2) Fan
(11
(3) Pulley
11&117 (4) Spacer collar
(5) Spring washer
Torque: 61.3 N·m (625 kgf·cm, 45 ft·lbf)
6. INSTALL DRIVE END FRAME ASSEMBLY AND
RECTIFIER END FRAME ASSEMBJ_Y
(a) Bend the rectifier lead wires back to clear the rotor.
(b) Using a curved tool, push tha brushes in as far as they·
will go and hold them in placo by inserting a stiff w'ire
through the accass hole in· the access hole in the
rectifier end frame.
L---------------------~-0~~~
(c) Assemble the drive end frame and the rectifiar arid
frame by inserting the r&ar bflaring on the rotor shaft
into the rectifier end frame.
(d) Install the 3 through screws.
Torque: 5.9 N-m (60 kgf·cm, 52 in..Jbf)
(e) Remove the stiff wire from the access hole.
50A Typo 7. CHECK THAT ROTOR ROTATES SMOOTHLY .•
(a) Che"k that the rotor rotates r<moothly. •
Seal (b) 50A Type:
Seal the access hole.
.'
GHARGING SYSTEM - ALTERN A TOR REGULATOR CH-13 -1
ALTERNATOR REGULATOR .,I'
i·
· tocoeu~"
0
ALTERNATOR REGULATOR INSPECTION
I
1. REMOVE ALTERNATOR REGULATOR AND COVER
2. INSPECT ALTERN A TOR REGULATOR l
A. :nspect point surfaces for seizure and damage 0 ,.
If defective, replace the regulator(
I
. ';
Regulator B. Inspect resistance between terminals
-Re-lay- - - - - - - - - ' - - - 1'1{a) Regulator:
Using an ohmmeter, measure the resistance between
terminals IG and F.
Resistance:
· At rest: 0 Q
Pulled in: Approx. 1 1 Q
{b) Relay: -·
I
•;!•"
Using an ohmmeter, measure the resistance between
terminals E and L.
Resistance:
At rest: 0 0
Pulled i11: Approx. 100 Q
(c) Relay:
Using an ohmmoter. measure tho resistance between
terminals 8 and E.
Resistance: •
At rest: infinity
Pulled In: Approx. 100 Q
{d) Relay:
Using an ohmmeter. measure the resistance bot\veen
terminals 8 and L.
Resistance:
At rest: Infinity .
fulled In: 0 0
{e) Using an ohmmeter, measure the resistance between
terminals N and E.
Resistance: Approx. 23 0
If any of the above checks are not positive, replace the
alternator regulator.
3. REINSTALL ALTERNATOR REGULATOR AND
COVER
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KIJANG 7K Engine Repair Book
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