Toyota 7M-GE & 7M-GTE Engine Repair Manual

TOYOb4 ‘. REPAIR MANUAL Downloaded from www.Manualslib.com manuals search engine

COOLtNG SYSTEM m SYSTEM m SVSTEM m SYSTEM m 0 1996 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be re- produced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. Downloaded from www.Manualslib.com manuals search engine

,. a,.. .,.,T Pl9. :-, ,::::;:;: HOW TO USE THIS MANUAL . . . , . , , . . . . . . . . . . . . . IN-2 I IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . IN-4 m GENERAL REPAIR INSTRUCTIONS . . . . . . z., . . . . a. IN-4 . PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER . . . , . , . . . . . . . l . . . . . . IN-6 ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . IN-7 , Downloaded from www.Manualslib.com manuals search engine

IN-2 INTRODUiTlON - How to Use This Manual ._. ._. -,-. .. . HOW TO USE THIS MANUAL To assist you in finding your way through this manual, the Set- tion Title and major heading are given at the top of every page. An INDEX is provided on the 1 st page of each section to guide YOU to the item to be repaired. At the beginning of each section, PRECAUTIONS are given that pertain to al/repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy COI- umn to quickly lead you to the solution. REPAIR PROCEDURES Most repair operations begin with an overview illustration. lt identifies the components and shows how the patiS fit together. Example: Oil Pump Shaft Drive Gear Oil Pump Outlet Pipe Oil Pump Strainer Drive Shaft Relief Valve------Q Oil Pump Cover------& 75 (65 in.-lb, 7.4) -Union Bolt (1 cg-cm (ft-lb, N.m : Specified torque ) Non-reusable part LUO5 Downloaded from www.Manualslib.com manuals search engine

INTROkJCT-iON - How to Use This Manual I IN-3 The procedures are presented in a step-by-ster format: 0 The illustration shows what to do and where to do it. 0 The task heading tells what to do. 0 The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: J / Task heading: _ w at to do tllus tra tion: what to do and where 2. IF NECCESdY, REPLACE DRIVE SH FT BEARING Using SST, replace the No.1 bearing by sing No. 2 bearing as a guide. SST 092 15-00100 (092 15-00120, 09 15-00150, / 092 1500160,092 15-002 10, 09 14-00220) Set part No. \ i Compone t part No. D&/ail text: how to do it (i) Tightecthe No. 3 and No. 7 bearing cap bolt a little at a time and in the sequence shown n the figure. Torque: 500 kg-cm (36 ft-lb, 49 NW) .-Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance and only when necessary, the text below it provides detailed information. Impor:ant specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to go to. SPECIFICATIONS Specifications are presented in bold type the applicable step. You never have to I look up your specifications. All specifica Appendix A, Specifications, for quick WARNINGS, CAUTIONS, N 0 WARNINGS are presented in bold d indicate there is a possibility of injury to you or ot 0 CAUTIONS are also presented in bold possibility of damage to the compone 0 NOTES are separated from the text type. They provide additional infor ciently perform the repair. Downloaded from www.Manualslib.com manuals search engine

IN-4 Identification Information, INTRODUCTION - General Repair Instructions IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the right side of the cylinder block. Seal Lock Adhesive GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. 3. During disassembly, keep parts in order to facilitate reassembly. Observe the following: (a) (b) Before performing electrical work, disconnect ‘the negative (-1 cable from the battery terminal. If it is necessary to disconnect the battery for inspec- tion or repair, always disconnect the cable from the negative (-) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminal posts and cable terminals with a shop rag. Do not scrape them with a file or other abrasive object. (e) (f) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post. Be sure the cover for the positive (+I terminal is pro- perly in place. 4. 5. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts Always replace cotter pins gaskets, O-rings, oil seals, etc. with new ones. (b) Non-reusable parts are indicated in the component illustrations by the “+” symbol. 6. Precoated Parts Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. Downloaded from www.Manualslib.com manuals search engine

INTRODUCTION - General Repair Instructions IN-S (b) Recoating of Precoated Parts (1) Clean off the old adhesive from the threads. (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the threads. (c) Precoated parts are indicated in the component illustrations by the “*” symbol. 7. When necessary, use a sealer or gaskets to prevent leaks. 8. Carefully observe all specifications for bolt torques. Always use a torque wrench. 9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the back of this manual. 10. When replacing fuses, be sure the new fuse is the correct amperage. DO NOT exceed the fuse amp rating or use one of a lower rating. 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels in order to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on the vehicle raised on a jack alone, even for a small job that can be finished quickly. WRONG CORRECT 12. Observe the following precautions to avoid damaging the parts: (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (c) When disconnecting vacuum hoses, pull on the end of the hose, not the middle. (d) When separating electrical connectors, pull on the connector itself, not the wires. Downloaded from www.Manualslib.com manuals search engine

-. EM-1 I ENGINE MECHANICAL ../_ :. F&e. DESCRIPTION . . . ..1........111.......~....~.~ E+ TROUBLESHOOTING . . . . . . . . . . . . . . . . n . mam I. I. ” ENGINE TUNE-UP . . . . . . . . . . . . ..~......~....... COMPRESSION CHECK s e . . . . . . . . . . . . . , . . . . . . . TIMING BELT ,,,..,....................*.*... EM-28 CYLINDER HEAD . . . . . . . . . . . . . . ..*............ EM-37 CYLINDER BLOCK 1”1......1...............,.. EM-66 Downloaded from www.Manualslib.com manuals search engine

EM-2 ENGINE MECHANICAL - Description -. DESCRl.PTlON _ .-. ..‘. /,. : -- +..>r:*. ,, .,. 2 ,-,. j . .:..,. .- The 7M-GE and 7M-GTE engines are an in-line 6-cylinder 3.0 titer DOHC 24 valve engine. i ‘M:G.E. (MA) .. : _ 7M-GE (MS) 7M-GTE Downloaded from www.Manualslib.com manuals search engine

ENGINE MECHANICAL -, Description EM-3 The 7M-GE, 7M-GTE engines are an in-line 6- cylinder engine with the cylinders numbered l-2- 3-4-5-6 from the front. The crankshaft is supported by 7 bearings specified by the inside of the crankcase. These bearings are made of kelmet. .The crankshaft is integrated with 8 weights which are cast along with it for balancing. Oil holes ‘are built into the crankshaft for supplying oil to the connecting rods, pistons and other components. These ignition order is l-5-3-6-2-4 . The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with pent roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. Exhaust and intake valves are equipped with irregular pitch springs with symmetrical ends made of oil tempered silicon chrome steel wire which are capable of following the valves even at ,high engine speeds. Both the exhaust side cam shaft and the. intake side cam shaft are driven by a single timing belt. The cam journal is supported at 7 places between the valve lifters of each cylinder and on the cylinder head of front end. Lubrication of the cam journal and cam is accomplished by oil being sup- plied through the oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve lifters. This permits replacement of the shims without removal of the camshafts. The resin timing belt cover is made in 2 pieces. Pistons are made of highly temperature-resis- tant aluminum alloy, and depressions are built into the piston head to prevent interference with valves. Piston pins are the full-floating type, with the pins fastened to neither the piston boss nor the connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No. 1 compression ring is made of stainless steel and the No. 2 compression ring is made of cast iron. The oil ring is made of a combination of stainless steel. The outer diameter of each piston ring is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. Compression rings No. 1 and No. 2 work to prevent the leakage of gas from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chamber. The cylinder block is made of cast iron. It has 6 cylinders which are approximately 1.6 times the length of the piston stroke. The top of the cylinders is closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition,- the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The .oil pan is bolted onto the botiom of the cylinder block. The oil pan is an oil reservoir made . of pressed steel sheet. A dividing included -inside the oil pan to keep sufficient oil in the bot- tom of the pan even when the vehicle is tilted. This dividing plate also prevent5 the oil from making waves when the vehicle is stopped suddenly and thus shifting the oil away from the oil pump suc- tion pipe. Downloaded from www.Manualslib.com manuals search engine

Toyota 7M-GE & 7M-GTE Engine Repair Manual

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