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TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL – PDF Download
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Description
TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL
FILE DETAILS:
TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL
LANGUAGE:ENGLISH
PAGES:608
DOWNLOADABLE:YES
FILE TYPE:PDF
TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL
To assist you in finding your way through this manual, the Section Title and major heading are given at the too of every page.
An INDEX is provided on the lat 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 all 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 column to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together.
TABLE OF CONTENTS:
TOY 3SGE 3SGTE 5SFE 3S-GE 3S-GTE 5S-FE ENGINE SERVICE REPAIR MANUAL
CONTENTS........................................................................... 2 INTRODUCTION....................................................................... 3 HOW TO USE THIS MANUAL......................................................... 4 PAGE2.......................................................................... 5 IDENTIFICATION INFORMATION..................................................... 6 GENERAL REPAIR INSTRUCTIONS.................................................... 7 GENERAL REPAIR INSTRUCTIONS 2.................................................. 8 ABBREVIATIONS.................................................................. 9 ENGINE MECHANICAL.................................................................. 10 DESCRIPTION (5S-FE)............................................................ 11 DESCRIPTION (5S-FE)EM.3.................................................... 12 DESCRIPTION (3S-GE AND 3S-GTE)................................................. 13 DESCRIPTION (3S-GE AND 3S-GTE)EM.5......................................... 14 DESCRIPTION (3S-GE AND 3S-GTE)EM.6......................................... 15 TROUBLE SHOOTING............................................................... 16 TROUBLE SHOOTING EM.8...................................................... 17 TROUBLE SHOOTING EM.9...................................................... 18 TROUBLE SHOOTING EM.10..................................................... 19 ENGINE TUNE-UP................................................................. 20 ALTERNATOR DRIVE BELT(5S-FE,3S-GE,3S-GTE)EM12.............................. 21 VALVE CLEARANCES (5S-FE)EM13............................................... 22 VALVE CLEARANCES (3S-GE & 3S-GTE)EM17...................................... 26 IGNITION TIMING (5S-FE)EM22................................................ 31 IGNITION TIMING (3S-GE & 3S-GTE)EM23....................................... 32 IDLE SPEED (5S-FE)EM24..................................................... 33 ACIS INSPECTION (3S-GE)EM25.................................................... 34 T-VIS INSPECTION (3S-GTE)EM26.................................................. 35 IDLE HC/CO CHECK EM27.......................................................... 36 COMPRESSION CHECK EM31......................................................... 40 TIMING BELT (5S-FE)EM33........................................................ 42 TIMING BELT (3S-GE AND 3S-GTE)EM45............................................. 55 CYLINDER HEAD (5S-FE)EM64...................................................... 73 CYLINDER HEAD (3S-GE & 3S-GTE)EM98.............................................107 CYLINDER HEAD (3S-GTE MR2 SPECIFIC)............................................110 CYLINDER BLOCK (5S-FE)EM148....................................................159 CYLINDER BLOCK (3S-GE & 3S-GTE)EM174...........................................185 TURBOCHARGER TC1(INCLUDING MR2 SPECIFIC DESCRIPTION)...............................209 EFI SYSTEM.........................................................................227 SYSTEM DESCRIPTION (5S-FE).....................................................228 SYSTEM DESCRIPTION (3S-GE).....................................................229 SYSTEM DESCRIPTION (3S-GTE)....................................................230 INSPECTION PRECAUTIONS.........................................................232 TROUBLESHOOTING................................................................238 DIAGNOSIS SYSTEM...............................................................254 CANCELLING DIAGNOSTIC CODE (MR2 SPECIFIC)......................................257 DIAGNOSTIC CODES (5S-FE).......................................................258 DIAGNOSTIC CODES (3S-GE).......................................................260 DIAGNOSTIC CODES (3S-GTE)......................................................262 INSPECTION OF DIAGNOSTIC CIRCUIT...............................................264 TROUBLESHOOTING WITH VOLT/OHMMETER.............................................265 LOCATION OF FUSES/FUSIBLE LINKS (MR2 SPECIFIC).............................266 EFI SYSTEM CHECK PROCEDURE (5S-FE w/o ECT) ................................267 EFI SYSTEM CHECK PROCEDURE (5S-FE w/ ECT) .................................282 EFI SYSTEM CHECK PROCEDURE (3S-GE) ........................................298 EFI SYSTEM CHECK PROCEDURE (3S-GTE) .......................................314 FUEL SYSTEM (FUEL PUMP) .......................................................331 ON VEHICLE INSPECTION (5S-FE) .............................................333 ON VEHICLE INSPECTION (3S-GE & 3S-GTE) ....................................336 REMOVAL OF FUEL PUMP ......................................................339 INSTALLATION OF FUEL PUMP..................................................342 REMOVAL OF FUEL PUMP (MR2 SPECIFIC)........................................346 INSTALLATION OF FUEL PUMP (MR2 SPECIFIC)...................................351 FUEL SYSTEM (COLD START INJECTOR (5S-FE)) .....................................353 COLD START INJECTOR (3S-GE)................................................356 COLD START INJECTOR (3S-GTE)...............................................359 FUEL PRESSURE REGULATOR (5S-FE)............................................362 FUEL PRESSURE REGULATOR (3S-GE)............................................364 FUEL PRESSURE REGULATOR (3S-GTE)...........................................366 INJECTORS (5S-FE)..........................................................369 INJECTORS (3S-GE)..........................................................376 INJECTORS (3S-GTE).........................................................385 AIR INDUCTION SYSTEM (AIR FLOW METER (3S-GTE ONLY).............................390 THROTTLE BODY (5S-GE w/o ECT) .............................................392 THROTTLE BODY (5S-GE w/ ECT) ..............................................398 THROTTLE BODY (3S-GE) .....................................................400 THROTTLE BODY (3S-GTE) ....................................................404 IDLE SPEED CONTROL (ISC) VALVE (5S-FE) ....................................409 IDLE SPEED CONTROL (ISC) VALVE (3S-GE) ....................................411 IDLE SPEED CONTROL (ISC) VALVE (3S-GTE) ...................................413 ELECTRONIC CONTROL SYSTEM (LOCATION OF ELECTRONIC CONTROL PARTS) ..............390 LOCATION OF ELECTRONIC CONTROL PARTS (MR2 SPECIFIC) .......................417 EFI MAIN RELAY ............................................................419 CIRCUIT OPENING RELAY .....................................................420 SOLENOID RESISTOR (3S-GTE ONLY) ...........................................421 COLD START INJECTOR TIME SWITCH ...........................................422 WATER TEMPERATURE SENSOR ..................................................423 FUEL PUMP RELAY AND RESISTOR (3S-GTE ONLY) ................................424 INTAKE AIR TEMPERATURE SENSOR (5S-FE & 3S-GE ONLY) ........................425 VACUUM SENSOR (5S-FE & 3S-GE ONLY) (MANIFOLD ABSOLUTE PRESSURE SENSOR) ....426 VARIABLE RESISTOR (3S-GE (w/o TWC) ONLY) ..................................427 ACIS VSV (3S-GE ONLY) .....................................................429 T-VIS VSV (3S-GTE ONLY) ...................................................431 EGR VSV (5S-FE & 3S-GTE ONLY) .............................................433 TURBOCHARGING PRESSURE SENSOR (3S-GTE ONLY) ...............................435 TURBOCHARGING PRESSURE VSV (3S-GTE ONLY) ..................................436 OXYGEN SENSOR (w/ TWC ONLY) ...............................................438 ENGINE (AND ECT) ELECTRONIC CONTROLLED UNIT (ECU) .........................441 VOLTAGE AT ENGINE ECU WIRING CONNECTORS (5S-FE (w/o ECT)) .................442 VOLTAGE AT ENGINE (AND ECT) ECU WIRING CONNECTORS (5S-FE (w/ ECT)) ........443 VOLTAGE AT ENGINE ECU WIRING CONNECTORS (3S-GE) ...........................444 VOLTAGE AT ENGINE ECU WIRING CONNECTORS (3S-GTE) ..........................445 RESISTANCE OF ENGINE ECU WIRING CONNECTORS (5S-FE w/ ECT) .................447 RESISTANCE OF ENGINE ECU WIRING CONNECTORS (3S-GTE) .......................448 FUEL CUT RPM ..............................................................449 FUEL PRESSURE CONTROL SYSTEM (3S-GE ONLY) .................................450 COOLING SYSTEM.....................................................................452 DESCRIPTION....................................................................453 TROUBLESHOOTING................................................................456 CHECK & REPLACEMENT OF ENGINE COOLANT..........................................457 WATER PUMP.....................................................................458 THERMOSTAT.....................................................................463 RADIATOR.......................................................................465 ELECTRIC COOLING FAN...........................................................466 COOLING SYSTEM (EXTRA PAGES MR2 SPECIFIC)..........................................469 DESCRIPTION....................................................................470 TROUBLESHOOTING, ENGINE COOLANT CHECK..........................................472 REPLACEMENT OF ENGINE COOLANT..................................................473 WATER PUMP.....................................................................478 THERMOSTAT.....................................................................482 RADIATOR.......................................................................484 ELECTRIC COOLING FANS (RADIATOR COOLING FANS (w/ A/C)).........................489 ELECTRIC COOLING FANS (RADIATOR COOLING FAN(w/o A/C))..........................496 ENGINE COMPARTMENT COOLING FAN (3S-GE & 3S-GE).................................499 LUBRICATION SYSTEM.................................................................505 DESCRIPTION (5S-FE & 3S-GE)....................................................506 DESCRIPTION (3S-GTE)...........................................................507 TROUBLESHOOTING................................................................509 OIL PRESSURE CHECK.............................................................510 REPLACEMENT OF ENGINE OIL & FILTER.............................................511 OIL PUMP.......................................................................513 OIL COOLER (5S-FE & 3S-GE).....................................................520 OIL COOLER (3S-GTE)............................................................523 OIL COOLER (MR2 SPECIFIC (3S-GTE)).............................................527 OIL NOZZLES (3S-GTE)...........................................................532 IGNITION SYSTEM....................................................................533 PRECAUTIONS, TROUBLESHOOTING...................................................534 IGNITION SYSTEM CIRCUIT........................................................536 ON-VEHICLE INSPECTION..........................................................537 DISTRIBUTOR....................................................................545 STARTING SYSTEM....................................................................547 TROUBLESHOOTING, STARTING SYSTEM CIRCUIT.......................................548 STARTER........................................................................549 CHARGING SYSTEM....................................................................561 TROUBLESHOOTING, CHARGING SYSTEM CIRCUIT.......................................562 ON-VEHICLE INSPECTION..........................................................563 ALTERNATOR.....................................................................566 SERVICE SPECIFICATIONS.............................................................578 ENGINE MECHANICAL (5S-FE)......................................................579 ENGINE MECHANICAL (3S-GE & 3S-GTE).............................................583 TURBOCHARGER SYSTEM............................................................588 EFI SYSTEM (5S-FE).............................................................589 EFI SYSTEM (3S-GE).............................................................592 EFI SYSTEM (3S-GTE)............................................................595 COOLING SYSTEM, LUBRICATION SYSTEM.............................................598 IGNITION, STARTING & CHARGING SYSTEM...........................................599 STANDARD BOLT TORQUE SPECIFICATIONS................................................600 SST AND SSM........................................................................603 SPECIAL SERVICE TOOLS..........................................................604 SPECIAL SERVICE MATERIALS......................................................608
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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