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This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul.
Engine Course 1 Work Procedures - 1 - Work Procedures Chapter Outline This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul. ã2002 TOYOTA MOTOR CORPORATION. All right reserved. Engine Course 1 Work Procedures - 2 - Outline Outline This section will explain the required work procedures for actually overhauling an engine. The overhaul workflow is conducted in accordance with the following procedures. 1. Remove the engine from the vehicle Remove the engine and transaxle as a unit from the bottom of the vehicle. 2. Disassemble the engine Disassemble the engine into the cylinder head and block.3. Clean and inspect the parts Inspect all the parts after cleaning them. 4. Reassemble the engine Reassemble the cylinder head and block. 5. Install the engine in the vehicle Install the engine and transaxle as a unit in the vehicle. 6. Final inspection Make a final inspection to check assembly condition. (1/1) Removal Engine Outline This section will explain operations from removal of the engine from the vehicle to installation of the engine on the overhaul stand. Remove engine Remove the engine, transaxle, suspension members, etc., as a single unit from under the vehicle. Engine Transaxle Suspension member Drive shaft Engine lifter Steering gear (1/1) REFERENCE: When Removing Engine from Top (FR Vehicles) When removing the engine from the top, remove the engine and transmission as a single unit. The following components need to be removed. (1) Engine hood (2) Radiator (3) Propeller shaft (4) Shift lever When removing the engine, tilt and turn it while it is slung with the chain block to prevent it from interfering with the vehicle body. (1/1) Engine Course 1 Work Procedures - 3 - Removal 1. Take Measures to Prevent Gasoline from Spilling Out (1) Fuel pump connector 2. Remove Battery (1) Battery 3. Drain Coolant (1) Radiator cap (2) Water drain plug (3) Radiator drain plug Engine Course 1 Work Procedures - 4 - 4. Disconnect Connectors and Wire Harness (1) Engine ECU (2) Instrument panel junction block (3) Engine room junction block 5. Remove Vehicle Interior Components (1) Steering intermediate shaft 6. Disconnect Clamps and Hoses (1) Brake booster hose (2) Radiator hose (3) Heater hose (4) Air cleaner hose (5) Air cleaner Engine Course 1 Work Procedures - 5 - 7. Disconnect Fuel Line (1) Fuel line 8. Remove Engine Room Components (1) Shift and select cable (2) Clutch release cylinder (3) A/C compressor (4) Drive belt (5) Engine mounting (6) Accelerator cable 9. Remove Components from Under Vehicle (1) Drive shaft (2) Tie rod end (3) Exhaust pipe (4) Stabilizer Engine Course 1 Work Procedures - 6 - 10. Set Engine Lifter (1) Engine lifter 11. Remove Engine with Transaxle (1) Engine (2) Transaxle (3) Suspension member (4) Drive shaft (5) Engine lifter 12. Disconnect Transaxle (1) Chain block (2) Engine sling device (3) Engine (4) Engine hanger Engine Course 1 Work Procedures - 7 - 13. Remove Clutch and Flywheel (1) Flywheel (2) Clutch disc (3) Clutch cover 14. Install Engine Overhaul Stand (1) Engine (2) Engine overhaul stand 15. Remove Intake and Exhaust Manifold, Alternator, Engine Wire(1) Exhaust manifold heat insulator (2) Exhaust manifold (3) Exhaust manifold gasket (4) Manifold support bracket (5) Intake manifold gasket (6) Intake manifold (7) Alternator (8) Engine wire (1/1) Engine Course 1 Work Procedures - 8 - Disassemble Engine Outline This section will explain the disassembly and inspection of a partial engine*. 1. Disassembly Remove the timing chain and camshaft and disassemble the cylinder head and cylinder block. 2. Inspection Use a measuring instrument to measure the part wear. If the wear exceeds the allowable limit, replace the part with a new one. *Partial engine • An engine with the auxiliary components and intake and exhaust manifold removed. • The largest of the engine supply states. Partial engine Exhaust manifold Intake manifold Auxiliary component (Alternator) (1/1) Disassembly 1. Remove Water Pump Pulley (1) Water pump pulley Engine Course 1 Work Procedures - 9 - 2. Remove Engine Mounting Bracket (1) Engine mounting bracket 3. Remove Crankshaft Pulley (1) Crankshaft pulley 4. Remove Water Pump (1) Water pump (2) Gasket Engine Course 1 Work Procedures - 10 - 5. Remove Timing Chain Cover (1) Cylinder head cover (2) Gasket (3) Timing chain cover 6. Remove Timing Chain (1) Chain tensioner (2) Chain tensioner slipper (3) Chain vibration damper (4) Timing chain 7. Inspect Timing Chain Vernier calipers Timing chain Spring balance Pin Bush [...]... Thickness gauge Engine Course 1 Work Procedures - 6 - 10. Set Engine Lifter (1) Engine lifter 11. Remove Engine with Transaxle (1) Engine (2) Transaxle (3) Suspension member (4) Drive shaft (5) Engine lifter 12. Disconnect Transaxle (1) Chain block (2) Engine sling device (3) Engine (4) Engine hanger Engine Course 1 Work Procedures - 32 - 10. Connect Clamps.. .Engine Course 1 Work Procedures - 26 - 8. Install Timing Chain Cover Timing chain cover Seal packing O-ring 9. Install Crankshaft Pulley (1) Crankshaft pulley 10. Install Water Pump (1) Water pump (2) Gasket Engine Course 1 Work Procedures - 4 - 4. Disconnect Connectors and Wire Harness (1) Engine ECU (2) Instrument panel junction block (3) Engine room... Engine Course 1 Work Procedures - 1 - Work Procedures Chapter Outline This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul. ã2002 TOYOTA MOTOR CORPORATION. All right reserved. Engine Course 1 Work Procedures - 20 -. .. Gear/Sprocket (1) Camshaft timing gear (with VVT-i) (2) Camshaft timing sprocket (without VVT-i) Engine Course 1 Work Procedures - 33 - 13. Fill with Coolant (1) Radiator cap (2) Water drain plug (3) Radiator drain plug 14. Install Battery (1) Battery 15. Final Inspection (1/1) Engine Course 1 Work Procedures - 18 - Reassembly 1. Install Valve Stem Oil Seal 2.... Wire Harness (1) Engine ECU (2) Instrument panel junction block (3) Engine room junction block Engine Course 1 Work Procedures - 2 - Outline Outline This section will explain the required work procedures for actually overhauling an engine. The overhaul workflow is conducted in accordance with the following procedures. 1. Remove the engine from the vehicle Remove the engine and transaxle... lifter Camshaft Plastigage Engine Course 1 Work Procedures - 12 - 11. Remove Cylinder Head (1) Cylinder head 12. Remove Cylinder Head Gasket (1) Cylinder head gasket 13. Remove Oil Pan (1) Drain plug (2) Oil pan No.2 (3) Oil strainer (4) Gasket (5) Oil pan No.1 Engine Course 1 Work Procedures - 8 - Disassemble Engine Outline This section will explain... cleaner hose (5) Air cleaner Engine Course 1 Work Procedures - 28 - 14. Install Cylinder Head Cover Cylinder head cover Gasket (1/1) Installation Engine Outline This section will explain how the overhauled engine is installed in the vehicle and the final inspection is conducted to check for assembly condition. Install engine Install the engine, transaxle, suspension members,... Procedures - 31 - 7. Install Components Under Vehicle (1) Drive shaft (2) Tie rod end (3) Exhaust pipe (4) Stabilizer 8. Install Engine Room Components (1) Shift and select cable (2) Clutch release cylinder (3) A/C compressor (4) Drive belt (5) Engine mounting (6) Accelerator cable 9. Connect Fuel Line (1) Fuel line Engine Course 1 Work Procedures - 19 - Cylinder... Removal Engine Outline This section will explain operations from removal of the engine from the vehicle to installation of the engine on the overhaul stand. Remove engine Remove the engine, transaxle, suspension members, etc., as a single unit from under the vehicle. Engine Transaxle Suspension member Drive shaft Engine lifter Steering gear (1/1) REFERENCE: When Removing Engine. .. removing the engine from the top, remove the engine and transmission as a single unit. The following components need to be removed. (1) Engine hood (2) Radiator (3) Propeller shaft (4) Shift lever When removing the engine, tilt and turn it while it is slung with the chain block to prevent it from interfering with the vehicle body. (1/1) Engine Course 1 Work Procedures - 15 - Inspection . Stabilizer Engine Course 1 Work Procedures - 6 - 10. Set Engine Lifter (1) Engine lifter 11. Remove Engine with Transaxle (1) Engine (2) Transaxle. (5) Engine lifter 12. Disconnect Transaxle (1) Chain block (2) Engine sling device (3) Engine (4) Engine hanger Engine Course 1 Work Procedures -