Toyota 7K Engine Repair Manual PDF

Preview

Summary

J . ' @TOYOTA .. } REPAIR MANUAL Jul., 1995 ;. ·, \ .. • INTRODUCTION .. ··:- ....... .. , ~ '¥ • -:_,.,.., ENGINE ~ d ,..;:/·..:_~,.r;t.: IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM • j; •• .. FOREWORD . '· • This repair manual has been prepared to provide informatio" • ~' ...

Description

J .

@TOYOTA

'

..

}

REPAIR MANUAL Jul., 1995 ;.

·,

\

.. INTRODUCTION ENGINE IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM

•

•

j;

..

••

ｾ＠

..

··:d

....... ..

, ｾ＠ '¥ • -:_,.,..,

,..;:/·ＮＺ｟ｾＬｲ［ｴ＠

FOREWORD

. '·

This repair manual has been prepared to provide informatio" · covering general service repairs for the 7K engine equipped in the TOYOTA TUV .

• ｾＧ＠ •

.'

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 information at the time of publication. However, specifications and procedures are subject to change without notice.

0

TOYOTA MOfOR CORPO{Ul.TION

• •

. •

.

0

©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

" .. -

ｾＭ

,..

IN-1

INTRODUCTION • HOW TO USE THIS MANUAL ·················· IN- 2 IDENTIFICATION INFORMATION ··············· IN- 4 GENERAL REPAIR INSTRUCTIONS ············ IN- 4 ABBREVIATIONS USED IN THIS MANUAL ·••···•••·•·•······•·········•··············· IN- 7 STANDARD BOLT TO ROUE SPECIFICATIONS···································· IN- B

•

ｦｩＧｾ＠

ii.!fJ.:i!!t

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.

GENERAL DESCRIPTION At the beginning of each section, a General Description is given that rertains to all repair operations contained in that section. Read these precautions before starting any repair task.

TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagn.::se the problem and find the causA.

PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains· the purp-ose of each one.

REPAIR PROCEDURES

r

Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Ｍｾ＠

Oil Pump Body

__ ..,

+Cotter Pin

ｾ＠

ｾ＠

ｾ＠ ｾ＠

ｾＮＬ＠

(

ｾ＠

I ｾ＠

Srring Retainor

ｾｊｐ＠

ｾ＠

ｾ＠

ｾＭ

-

I

I

-DriJ.n Rotor-@

Relief Valve Volve Spring

ｾ＠

ｾ＠

I

Oil Pump Covor I I

J

1./

Drive Rotor----J"b.'-

f

) ｾ＠

ＧＭｾ＠

[B·m lkgf·cm, ft·lbf)

+ ｎｯｮｾｲ･ｵｳ｡｢ｬ＠

part

i : Specified torque P2537J

INTRODUCTION

-.

,

The • • •

HOW TO USE THIS MANUAL

procedures are presented in a step-by-step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to do the task and gives other information such as specifications

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.

REFERENCES References have been kept to a minimum. However, when they are required you are £ivan the page to refer to.

SPECIFICATIONS Specifications are presented in bold type throughout the text where needAd. You never have to leave the procedure to look up your specifications. They are also found at the end of each sectio:1, for quick reference .

. CAUTIONS, NOTICES, HINTS: • • •

CAUTIONS are presented in bold type, and indicate ther9 is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to thr components being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently.

11'1-4

INTRODUCTION·- GENERAL REPAIR INSTRUCTIONS

Sf UNIT f

The UNITS given in this manual are primarily expressed according to the SI.UNIT(International System of Unit); and alternately expressed in the metric system and in the Epglbh System. Example: Torque: 30 N·m (31 0 kgf-cm. 22 ft·lbf)

IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown.

GENERAL REPAIR INSTRUCTIONS I

1.

JfOrl-tf

Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in th6 ｡ｰｲｯｩｾｴ＠ order to. facilitate reassembly. ' 3. Observe the fo!lowing: (a) Before doing electrical work. disconnect the negative cable from the battery terminal. (b) If it is necessary to disconnect the battery for in.spection or repair, always disconnect the cable from the negative(-) terminal which is grounded to the vehicle body. . (c) To prevent damagll to the battery terminal post. lcosen tho terminai nut and ｲ｡ｩｳｾ＠ the cablg and valve.

1.

EG-16

ENGINE -

ENGINE MECHANICAL

(c) (d)

Using. needle- nose pliers. remove the B oil seals. Remove the B spring seats. ·HINT: Arrange the valves, v.alve springs, spring seats and· spring· retainers in correct order.

CYLINDER HEAD COMPONENTS INSPECTION. CLEANING AND REPAIR

-..

....

combustion chambers. NOTICE: Be careful not to aeratch the cylinder block contact surface.

'

ENGINE - ENGINE MECHANICAL

l l

t

EG-17

C.

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

D.

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

' '

ｾ＠ ')

ｾ＠

""'"

.'

-

.

., ,•

'

! - ＮＭｾ＠ '

.

3. A.

INSPECT CYLINDER HEAD Inspect for flatness Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder hlock and the manifolds for warpage. Maximum warpage: Cylinder block side: 0.05 mm {0.0020 ln.) Manifold side: 0.10 mm (0.0039 ln.) If warpage is greater than maximum, replace the cylinder head.

B.

Inspect for cracks Using a dye ｰ･ｾｴｲ｡ｮＬ＠ check the combustion chamber, intake ports, exhaust ports and cylinder block side surface for cracks. If cracked, replace the cylinder head.

P2.t961

P2498l

"""'

EG-18

ENGINE -

' .

ENGINE MECHANICAL

4.

CLEAN VALVES

(a) (b)

L!sing a gasket scraper. chip off any carbon from the • valve head. Using a wire brush, thoroughly clean the valvo.

5.

INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a)

Using a caliper gauge, measure the inside diameter of the guide bushing.

j.

'.

Bushing inside diameter: 8.010 - 8.030 mm (0.3154 - 0.3161 in.)

+

(b)

Using a micrometer, measure the diameter of the valve stem. V6lve stem diameter: '

Intake 7.951 - 7.991 mm (0.3130- 0.3146 in.) Exhaust 7.960 - 7.986 mm (0.3134- 0.3144 ln.)

(c)

'''''"

Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Oil clearance:

Standard

Meximum

Intake

Exh!USt

O.OT9 - 0.079 mm

0.024 - 0.075 mm

(0.0007 - 0.0031 ln.)

(0.0009 - 0.0030 ln.)

0.08 mm (0.0031 in.)

- 0.10 mm (0•.0039 ln.)

If the clearance iE greater than maximum, r13plactl ln9 valve and guide bushing.

6.

IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS

'(a! (b)

Using a chisel and hammer, break the valve guide bushings. G•adually heat th·e cylinder head to SO - 1OO"C ;176

- 212"F).

.

' ENGINE - ENGINE MECHANICAL <

"

(b) · Using SST and a hammer. tap out the guide bushing.

I

SST 09201 -1 0000 (09201 -01 080). 09950-70010 (09951-07150)...