FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 1FZ-F, 1FZ-FE engine equipped in the TOYOTA LAND CRUISER, Applicable modals: FZJ70, 73, 75, 80 series. Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine. Manual Name Pub. No. © 1FZ-F Engine Emission Control Repair ERMOB6E Manual © 1FZ-FE Engine Emission Control Repair ERMOS6E Manual All information in this manual is based on the latest product in- formation at the time of publication. However, specifications and procedures are subject ta change without notice. TOYOTA MOTOR CORPORATION Please Note! This is not an interactive manual.. Goto Pages need to be selected ©2004 TOYOTA MOTOR CORPORATION All rights reserved, This book may not be repra- duced oF copied, in whole or in part, without the written permission of Toyota Motor Corporation, First Printing: ‘Qet, 19, 1992 01-021019-00. Nineteenth Printing: Apr. 1, 2004 19-040d01-05-3IN-2 INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX +H An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you 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 (Precautions) is given that pertains 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 diagnose the problem and find the cause. 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 purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: No.1 Heat insulator Spring (zriate. 731] @——# Gasket S—— pug [49 (609. 357] Tear Kgirer, TbH) : Spectied torque ‘@ Non-reusable partINTRODUCTION — HOW TO USE THIS MANUAL, isd The procedures are presented in a step—by—step forma © The illustration shows what to do and Where to d © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Awl les the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important 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 refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the end of each section, for quick reference.at INTRODUCTION — IDENTIFICATION INFORMATION CAUTIONS, NOTICES, HINTS: © CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. © NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. iv @ HINTS are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair. SI UNIT The UNIT given in this manual are primarily expressed with the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. Example: Torque: 30 N-m (310 kaf-cm, 22 ftbt) IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown.INTRODUCTION — GENERAL REPAIR INSTRUCTIONS Seal Lock Adhesive IN-5 GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the val clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect the negative cable from the battery terminal. (0) If it is necessary to disconnect the battery for inspection 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 strai- ght up without twisting or prying it. (4) Clean the battery terminal posts and cable termi- nals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installa- tion. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. Non—reusable parts (2) Always replace cotter pins, gaskets, O—rings and oil seals etc, with new ones. (b) Non—reusable parts are indicated in the compo- nent illustrations by the “®" symbol. 6. Precoated parts Precoated parts are bolts and nuts, etc. that aro 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.IN-6 INTRODUCTION — GENERAL REPAIR INSTRUCTIONS Fuse Equal Amperage Rating + @ on a 10. i. 12. (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads (c) Precoated parts are indicated in the component illustratiions by the "%” symbol. When necessary. use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 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 proce- dure, A list of SST and SSM can be found at the back of this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. Care must be taken when jacking up and supporting ‘the vehicle. Be sure to lift and support the vehicle at the proper locations. (@) If the vehicle is to be jacked up only at the front ‘or rear end, be sure to block the wheels at the opposite end in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the p arts: {a) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are tou- ched, the IC may be destroyed by static electric- ity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. 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. (b) (ec) ()INTRODUCTION — GENERAL REPAIR INSTRUCTIONS. a (2) When steam cleaning an engine, protect the dis- WRONG coRRECT tributor, air filter, and VCV from water. Z (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (@) When checking continuity at the wire connector, insert the tester probe carefully to prevent termi- t nals from bending. (h) When using a vacuum gauge, never force the snoxee hose onto a connector that is too large. Use a step—down adapter instead. Once the hose has been stretched, it may leak. Example] 13. Tag hoses before disconnecting them: (2) When disconnecting vacuum hoses, use tags to (een identify how they should be reconnected, (b) After completing a job, double check that the @ vacuum hoses are properly connected. A label under the hood shows the proper layout.INTRODUCTION — ABBREVIATIONS USED IN THIS MANUAL. ABBREVIATIONS USED IN THIS MANUAL AAP asv Ar Switching Valve AT ‘Automatic Transmission erbe Betore Top Dead Genter oe CHock Breaker DOHe Double Over Head Gam DP Dash Pot ECU Elactronie Control Unit ESA Electronic Spark Advance x ‘Exhaust (Manifold, Valve) Ee Except rica Fast Idle Cam Breaker FPG | Formed in Ploce Gasket 7 FL Fusible Link 1c 7 Integroated Circuit oe 6 Ignition Ww Intake (Manifold, Valve) 7) Junetion Block io} LeftHand Max. Maximum 7 Min ‘Minin NP Multipurpose. MT ‘Manual Transmission o/s Oversize ‘ovev ‘Outer Vent Control Valve Pov Positive Grankoase Ventilation RH Right Hand ‘ssM Special Service Materials SST Special Service Tools ‘sD Standard Tees Toyota Computer Gontrolied System i Top Dead Center TEMP. Temperatur 1% Throttle Positioner us Undersize vev Vacuum Control Valve vev Vacuum Switching Valve ws with 7 withoutINTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH IN-9 vee el Lae sy tenine | Homa so-| set wna w/ washer bedi aT Grooved rwsnonto or head bolt Ss) Two ie flange bolt Two hexagon bolt anes ves head bott Three fe « wes head bolt aIN-10 INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Spas torque Case Pach Tiexagon oad bot Tixagon fongo bat Nem kgf-cm ft-lbf Nem kgf-cm ftlbt e [4 3 ss asinswt | co Bin e | 125 | is 10 8 “ws 10 «| % | 135 | 38 2018 202k 2 | 125 | a a0 as 535030 wu | 1s | 7% 7805s east we | ois |e 1a80 as e Ee 6 1 6588 Sener | 7878 Cine 8 ts | iss 1802 7888 wo | 125 | 32 330 828 7 12 1.25 59 600 43 65 670 48 | ts) oat 930 or 1001405078 te | 1s | ts 1400 401 Pee s | 4 e samme | 8 50 Bini s | 125 | 1 1 te nots wo | 125 | 39 40028 408 7 12 1.25 nM 730 53 80 810 59 ie | ts | 0 4100 a0 125 1,250 99 te) 18 | a0 1780129 = eee ef 4 0s 10S 28 8 | iz | 2 260 19 228021 a} 2 | tas | se 0 ae 58580 a8 2 | 128 | 9 97% 70 108 1.08078 a | 1s) | ta 1,800 108 tes 1.700123 ws | 15 | 230 2300 168 . eee 2 | 125 | 2 30 22 33g et} 1 | 128 | ot 0a e690 50 12 | 128 | 110 4.0080 120 1,280 99 o | 125 | os 2 378? a | 1 | tz | 7 70 81 7% 70 iz | 125 | 128 1308 1401480108 8 1.25 38 390 28 42 430, a wor} 10 | 125 | 7 © G00 58 se 800 12 | 128 | 140 180108 155 1,600,118 e | 1s | 2 0 7480 nt] i | 128 | a7 a0 we e780 2 | 128 | 186 160 116 175 1.800EG-2 ENGINE — ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 1FZ—FE and 1FZ—F engine is an in—line, 6—cylinder, 4.5 liter DOHC 24 valve engine. 1FZ-FEENGINE — ENGINE MECHANICAL Eee The 1FZ—FE and 1FZ—F engines are an in—line, 6—cylinder engine with the cylinders numbered 1—2~3-4—5—6 from front. The crankshaft is supported by 7 bearings inside the crankcase. These bearings are made of aluminum alloy. The crankshaft is integrated with 12 weights for balance. Oil holes are provided in the crankshaft to supply oil to the connecting rods, bearing, pistons and other components. The firing order is 1—5—3—6—2—4. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and 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 made of special valve spring carbon steel which are capable of following for the full range of engine speeds. The intake camshaft is driven by a timing chain, and a gear on the intake camshaft engages with a gear on the exhaust camshaft to drive it. The cam journal is supported at 7 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and gears is accomplished by oil being supplied through the oiler port in the center of the camshaft. Valve adjusting shims are located above the valve lifters. Pistons are made of high temperature—resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the 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 stianless steel and the No.2 compression ring is made of cast iron. The oil ring is made of a 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. No.1 and No.2 compression rings work to prevent gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chambers. The cylinder block is made of cast iron. It has 6 cylinder which are approximately twice the length of the piston stroke. The top of each cylinder 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 No.1 and No.2 oil pans are bolted onto the bottom of the cylinder block. The No.1 oil pan is an oil reservoir made of combination of aluminum alloy. The No.2 oil pan is an oil reservoir made of combination of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and the oil shifts away from the oil pump suction pipe. Plastic region tightening bolts are used for the cylinder head, main bearing cap and connecting rod.e EG-4 ENGINE — ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 9032-00160 ) oH (09165-16100 Spark Plug Wrench (09201-18010 Valve Stem Guide Remover & Replacer (09202-70010 Valve Spring Comareseor ® 2s 08218-58012 2 ‘Grankshaft Pulley Hoolaing Too! on Too ae RT Gan Sa tea (08213-00020) Body With Bolt <— (08213-00030) Henaie (oeai9-ooobo) ai se a TERIOR “ing Goa ever S —_ OSTISTEOGO 01 Son & Bera Rtas Sanka aro al oo Gen38 MOTT OW Fier Wrench DO2R5=001OT Water Pri Oval Tar StENGINE ~ ENGINE MECHANICAL Ee (09236-15010) Beering Stay Valve stem cit seal (09243-00020 ale Adjusting Serew Wranch (08248-66011 (ovzay—o5310) (08248-06020) Valve Clearance Adjust Tool Sot Valve Lifter Prose Valve Litter Stopper (09316-60010 (09316-00010) (03316-00050) (09930-00021 ‘09608-30012 (os608-o4ez0) (useus—vaubo) Transmission & Transfer Bearing Replaces Replacer Pipe epiacer D* ‘Companion Flange Holding Toot Handle Front Hub Outer Bearing Cup Replacer Crankshaft front ot seal Crankehatttront ol seal Crankshaft pulley Crankshaft rear ci! cos! Spark plug tube aasket Spark plug tube gasket i (09631-20031 i Seal "B Remover Gonseting rod bushing ‘09636-20010 Upper Bal Joint Dust Gover Repacer CGrankshoft timing overEG-6 ENGINE — ENGINE MECHANICAL a) 18816-30010 Oil Prossure Switch Socket Knock sencor Eee, SB See SSS (08960-20017 Universal Puller RECOMMENDED TOOLS (08200-00010 Engine Adjust Kit (09258-00020 Hone Plug Sot Plug for the vasuum Aoee, fuel hase ete, EQUIPMENT Battery specific gravity gauge Caliper gauge ‘CO/HC meter Compression gauge Connecting red aligner Cylinder gauge Dial indicator Dye penetrant Engine tune—up tester Heater ‘Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edgeENGINE — ENGINE MECHANICAL una Sofa Seslsar vara | Thermometer Valve seat cutter Vernior calipers SSM (SPECIAL SERVICE MATERIALS) Pet (08826-00080 Seal packing or equivalent. Over the space between the 7 finder block and timing ein Timing chain cover (06826-00080 Seal packing or eau ‘Semi—creular plus Oitpan Rear oil sear retainer (08833-00070 Adhesive 1324, Plug tube THREE BOND 1324 or equivalent (06833-00080 Achesive 1244, Bvsv THREE BOND 1344, LOGTITE 242 or equivEG-8 ENGINE — ENGINE MECHANICAL TROUBLESHOOTING You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts. Dod == fect ES} see pece ee \ Suspect ea \ Tgition Signs Crewe Temp. Sensor Circuit Throttle Position ‘Sensor Circuit STA Signal Cetwot SV ceut Air Flow Meter Circuit Knock Sensor ‘Oxygen Sensor Cine Coolant Temp. Sensor Circuit Circuit wo) NSW Signal ‘AIC Signal Creu Fuel Pump Cirouit Fuel Pressure |_| Regulator Fue! Lines: Fuel Presse é. Symptom Fa ES Intake Chews [Enaine does not crank B [Sterier suns — engine Goes] {nt erank | 2 5\ho nia combustion [21 3 e No complete combustion |_| 5 2 a | [a0 Engine cranks slowly 2 [Under normal conaition [13 14 z (Cota engine 1 Hot engine 1 Tncorrect fist idle 2 High engine iale speeo 2f4 3 7] se), 3 1 3 7 737 9 fro s + [Low engine idle speed Rough idling 76 Mistire 5 [Hesitation Poor acceleration 2 jBacktire 7 {Mutfer explosion after fro) 5S 7 10 a 14) 13] 18] 18. To} 9 [ii] 12 4" Poor drvability iKeocking n [Soon after starting a 8 4/3 /s {0 ‘after accelerator pedal doprossos /Aftor accelerator pedal released | During AJC operation [When N t0 O shift t Paar fuel econamy [fis } 74] 20 [76 | #5 vie 32) 73 Engine overheat | Engine oversoo! T Excessive oil consumption | Low oil pressure High off pressure ‘Starter keeps running [Battory often discharges L Engine stalt others HINT: When inspecting a wire harness or circuit, the electrical wiring diagrams at the end of repair manual should be roferred to and the ciccuits of related systems also should be checked,EG-9 ENGINE — ENGINE MECHANICAL yo BURL, 4 16 Bunul aaron, 10 12 is 7 a 20ueie9i9 anren 14 16 uojssordwo 9 10 a 7 warshs, wey Butjoo3 paseaiey vaya luons Beig soxeq SUPT Ped 201819)900y waists ¥O3 soangusig 16 8nig >Heds seueig 2609007 ‘oBexe97 uinee, ‘3609099 quejoog ‘2604907 ong ‘Anyeng yong 52 nga 13 8 a 1 18 i 19 1 10 v1 fwoishs ang jong coo Suywado no tinouig Abu Ure 13. =a = [= (e243) a fy Ey rea al kay [eic-54 NaH @neA 91 10kisah ENGINE — ENGINE MECHANICAL See page fa ze [eas cd G1 [cH-10] fec-352] o el Fea ec-138} Connecting Rod Bearing Suspect eree Symptom, Radiator and Radiator Cap Water Pump Vaive Stem Guide Bu: Oli Pump. Crankshaft Bearing Piston Ring Drive Plate Thermostat Drive Belt ECT Sender Fly Wheel Switch Alternator Cylinder Block Engine does not crank ‘Starter runs — engine does} 2 not crank Does not start No initial combustion No complete combustion 7 [Engine cranks slowly 3] 4 ‘Under normal condition W (Cold engine Difficult to start Hot engine Incorrect first idle High engine idle speed ‘Low engine idle speed Poor idling Rough idling 20 | 12 Misfire Hesitation | Poor acceleration Backfire Muffter explosion (after fire) Poor drivability ‘Surging Knocking 2 ole ‘Soon aiter starting ‘Alter accelerator pedal depressed ‘After accelerator pedal released Engine stall During AIC operation (When N to D shift Poor fual economy 10 JEngine overheat 6 10 Ti 3/4 3 Engine overcoo! 2 3 Excessive oll consumption 2 a[4 Others Low oil pressure 2/3 [4 High ofl pressure 1 2 Starter keeps running Battery often discharges 1ENGINE — ENGINE MECHANICAL isabel TUNE-—UP ENGINE COOLANT INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The coolant level should be between the “LOW” and "FULL" lines at low temperature. If low, check for leaks and add coolant up to the ame “FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not EK remove it while the engine and radiator are still hot, as fluid and steam can be blown out under pressure, a (b) There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant should be free from oil If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. ENGINE OIL INSPECTION Recommended Viscosity (SAE) | 1. CHECK OIL QUALITY i Check the oil for deterioration, entry of water, disco- | pes 1 loring or thinning. oI il If oil quality is poor, replace it. cr Oil grade: reer Manor ane ne net ox Sac Inersldaalsg ov teeter sco If it is impossible to got SG or better you may use SF grade Recommended viscosity: Refer to illustration i 2. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and "F” marks on the dipstick. If low, check for leakage and add oil up to the *F” mark.EG-12 SS TY roan ENGINE — ENGINE MECHANICAL BATTERY 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 cell Standard specitic gravity at 20°C (68°F): 1.27 — 1.28 105D31L 1.25 — 1.27 others If not within specifications, charge the battery. 2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES (a) Check that the battery terminals are not loose or corroded. (b) Check the fusible links and fuses for continuity. AIR FILTER INSPECTION AND CLEANING 1. REMOVE AIR FILTER Remove the air cleaner cap and air filter. 2. INSPECT AND CLEAN AIR FILTER ‘A. (Paper type) (a) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. (o) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. B. (Fabric type) (a) Visually check that the element is not excessively dirty damaged or oily. (b) Blow dirt off in the element with compressed air from the inside.EG-13 ENGINE — ENGINE MECHANICAL (c) Submerge the element in the water and agitate it up and down ten or more times. (d) Repeat rinsing in clean water until rise water is clear. (e) Remove excess water by shaking the element or blo- wing with compressed air. NOTICE: Do not beat or drop filter element. (f) Wipe off dust on the air cleaner case interior. 3. REINSTALL AIR FILTER HIGH— TENSION CORDS INSPECTION (See IG section) Moximum resistance: 25 kQ per cord SPARK PLUGS INSPECTION (See IG section) Recommended spark plug: ND K16R—U NGK — BKR5EYA Correct electrode gap: 0.8 mm (0.031 in.)EG-14 ENGINE — ENGINE MECHANICAL | CORRECT WRONG ¥ io Clearance| rove. Water Purp Alternator Idler Pulley caithott 2 — e——~ SSTA A SSTA a mee Lock Bolt ALTERNATOR DRIVE BELT INSPECTION (See CH section) INSPECT DRIVE BELTS (a) Visually check the drive belt for cracks, ciliness or wear. Check that the belt does not touch the bottom of the pulley groove. If necessary, replace the drive belts as a set. Drive belt deflection (w/ 98N (10kaf, 22Ibf)) New belt 11-15 mm (0.43—0.59 in.) Used belt 15~20 mm (0.59-0.79 in.) (b) (Reference) Using SST, measure the belt tension. SST 95506-00020 Drive belt tension(w/ SST): New belt (33-57 kof Used belt 15—35 kgf If the belt tension is not as specified, adjust it. HINT: © "New belt” refers to a belt which has been used less than 6 minutes on a running engine. * "Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. ‘© After installing @ new belt, run the engine for about 5 miutes and recheck the belt tension.ENGINE — ENGINE MECHANICAL Ee te VALVE CLEARANCE INSPECTION AND ~ ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. = 1. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 2, DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS {a) Remove the two mounting bolts of the No.1 and No.2 cord clamps. {b) Disconnect the high ~ tension cords at the rubber boot. Do Not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. (1FZ—FE) REMOVE THROTTLE BODY {a) Disconnect the throttle position sensor connector. {b) Disconnect the ISC valve connector.(e) (a) (e) @ (9) (hy (a) ENGINE — ENGINE MECHANICAL Disconnect the three vacuum hoses. Disconnect the EVAP hose. Disconnect the water hose from the No.2 water by— pass pipe. Remove the four bolts, and disconnect the throttle body from the air intake chamber. Remove the throttle body gasket. Disconnect the No.1 water by—pass hose from the throttle body, and remove the throttle body. REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark “0” of the timing chain cover.£G-17 ENGINE — ENGINE MECHANICAL (b) fa) (b) (c) Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above. le INSPECT VALVE CLEARANCE Check only the valves indicated. * Using a thickness gauge, measure the clearance between the valve lifter and camshaft. © Record the out — of — specification valve clear- ance measurements. They will be used later to determine the required replacement adjusting shim, Valve clearance (Cold): Intake 0.15 — 0.25 mm (0.006 — 0.010 in.) st 0.25 — 0.35 mm (0.010 ~ 0.014 in.) Exhi Turn the crankshaft pulley one revolution (360°) and align the its groove with timing mark “0” of the timing chain cover. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))ENGINE — ENGINE MECHANICAL 7 A fa) (b) ADJUST VALVE CLEARANCE except for Rear valves of No.6 cylinder Remove the adjusting shim. * Turn the crankshaft to position the cam lobe of the camshaft on the the adjusting valve upward. * Position the notch of the valve lifter toward the spark plug side. * Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-66011 (09248-05310, 09248-06020) HINT: © Apply SST (B) at slight angle on the side marked with "11", at the position shown in the illustra- tion * When SST (8) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it shallowly from the outside of the cylinder head, at a slight angle. © Remove the adjusting shim with a small screw- driver and magnetic finger. Determine the replacement adjusting shim size by following the Formula or Charts: * Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve cllearance comes within specified value. Thickness of removed shim Measured valve clearance Thickness of new shim . N=T + (A ~ 0.20 mm (0.008 in.)) Exhaust: N=T + (A = 0.30 mm (0.012 in.) *® = Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0,05 mm (0.0020 in), from 2,50 mm (0.0984 in.) to 3.30 mm (0.1299 in.)ENGINE — ENGINE MECHANICAL (c) (a) fa) (b) (ce) (d) (e) (f) (9) th) EG-19 Install a new adjusting shim. * Place a new adjusting shim on the valve lifter. * Using SST (A), press down the valve lifter and remove SST {B). SST 09248-66011 (09248-05310, 09248-06020) Recheck the valve clearance. Rear valves of No.6 cylinder Remove the distributor. (See IG section) Remove the camshafts. (See step 39 on|pages EG— 49] to[5 1} Remove the adjusting shim with a small screwdriver. Determine the replacement adjusting shim size by following the Formula or Charts: * Using a micrometer, measure the thickness of the removed shim. © Calculate the thickness of a new shim so that the valve cllearance comes within specified value, Thickness of removed shim Measured valve clearance Thickness of new shim N=T + (A — 0.20 mm (0.008 in.) Exhaust: N=T + (A — 0.30 mm (0.012 in.) * Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0,05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). Place a new adjusting shim on the valve lifters, Install the camshafts. (See step 7 on [pages EG—73]t. Recheck the valve clearance. Install the distributor, (See IG section)ENGINE — ENGINE MECHANICAL EG-20 200) a4p Uo poruudus s1o}ou TMs ZL "ON © MAHA UnYs UL pene same aT “WW uy ssauyoIy au anEy SUIS MON “LNIH ZOL LO) ww COS'e aM eseIdoy ("4 EZ LO‘O) WU [er] — ear = eva aro = enirorooez] rosa sore) deon aie oof eee Sere (ezro coe] 21 [(ezi Vo) OsBz |B {4} 0L0'0 — 900'0) wu gz"0 — S1°0 0 Woszrorosee| 91 [oro cose] (9109) eoweseaIo eniea ofe.U) esse = wo ee (oazi'o ooze] st [lesororosce] 9 Saw (owzto) ost’ | vl |(€901°0) COL] G ‘eeetoroove| et Teroror ease] + treet orosoe] 21 [ttororo0s'¢| {| error aoo't| ti |Wwooro) oss] _z ane oa {1g9tt-o) oge'z! OL | (~Réo°o) OOS'z/ OL ‘wero ~ gael oso = Teo swe |aas|_ Se See eon | (ara mec oe peecanean | SUES See RIF ARE ESE SABRE BSCE RERERE eee E EER EE TERER) aan lela BISWAS GIES EE SLs Blt lolol Alb eel Sele SilaleeiLleTEE REEL Sere on (ayequy) yt iP£G-21 ENGINE — ENGINE MECHANICAL Eee Bi “a0e} 04) uo paruudws si0r0us dda otclentecialataat cb nur uy SSOUNOUNR OUP OABY SURE MON “LNIM Or oh imu boare bin eneydols ul 6210 0) il T= aS Oe Orv’ s1 aoues29/9 paunseous aun pus “paljersul a eee 81 WHYS (UI ZOE LO) WHI OOB'Z SUL TEAS ae Tens ew O we (66210) OOE'E| ct | (zt 10) os8'e (M1 bLO'O — 010°0) uH gE"0 — Gz°0 Tego wore wo — Teor acto) 0gz°e| 91 [torr 0) Oz sipjog) eouese0p9 ean ssneuxa ooo were a (sero) oz | et | eaor or Osz Tezro) oove| et [levoro ose Wozro) osoe| zi [trzoro) 06s eed eee e z g (overo) OSbe| pi |eaoro core! v & z t (eto) 0008 | It | {oor Ol OSS z Seas ea (t9tto) os6z] OL [{PB60'O) 00S" ive = sieod oo — TO, ON a "ON sae SsouVML J iyg] SSPE | wus 7 asso HeRH LEO Tee (Cup uw Seay ou TS MON ieee = wba ea =e eatefetereefotatstapstetetsretepsts|epplyre Heat ene Sows ET iss 5/8) 8/8] |8)3)8|8 18) 3) 8|a|s|8|8|2 3)3|2 se EI 5/33 3] 3(8 |e Te IE EIS |e eee IEE eine pnt, elelelele|etele/ele|elelelelejelelealelelele le le Pe lelp le le eieie ele ele ejelee|ele (ele e(e[2|218|8] corm Bae els 5 als |e is[zlela 3 {eile [8 82/2 (88 iS ielz sis lela 2 [3 S15 (812) Ee SUE |e EB Uz/el| ee en (asneyxa| 1OnDe|9g WIYS BunsnipyEG.22 8 tb) (a) (b) (c f (9) {a) ) (d) () ENGINE — ENGINE MECHANICAL REINSTALL CYLINDER HEAD COVER Install the gasket to the cylinder head cover. Install the cylinder head cover with the 13 bolts. (1FZ—FE) INSTALL THROTTLE BODY Connect the No.1 water by—pass hose to the throttle body. Install a new gasket and throttle body with the four bolts. Torque: 21 N-m (210 kgf-cm, 15 ft-Jbt) Connect the water hose to the No.2 water by—pass pipe. Connect the EVAP hose. Connect the three vacuum hoses. Connect the ISC valve connector. Connect the throttle position sensor connector.ENGINE — ENGINE MECHANICAL Ge 10, RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS (a) Connect the high—tension cords. (b) Install the No.1 and No.2 cord clamps with the two. bolts. “EG 11, REINSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts.Eo-24 ENGINE — ENGINE MECHANICAL IGNITION TIMING INSPECTION AND ADJUSTMENT 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER AND TIMING LIGHT OLC) A (1FZ—FE) ragionste Connect the test probe of a tachometer to terminal 1G @ of the check connector. Using SST,connect terminals TE1 and E11 of the check connector SST 09843-18020 B. (IFZ—F) Remove the cap and connect the test probe of a tester to the service connector from the igniter. NOTICE: * NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. * As some tachometer: are net campatibie with thie ignition system, we recommend that you contiem ‘the compatibility of your unit befare use. 3. INSPECT AND ADJUST IGNITION TIMING With the engine idling as specified, use a timing fight to check the timing. Ignition timing: 3° BTDC @idle (w/ Terminals TE1 and £1 connected for 1FZ—FE)EG-25 ENGINE — ENGINE MECHANICAL C RPM conse Tachometer as If necessary, loosen the distributor bolt and turn the distributor to align the marks. Recheck the timing alter tightening the distributor bolt. Torque: 21 N-m (210 kgf-cm, 15 ft-lbf) (1FZ—FE) IDLE SPEED INSPECTION HINT: Initial conditions (See step 1 on[page EG— 33) Idle speed: 650 + 50 rpm (1FZ—F) IDLE SPEED INSPECTION AND ADJUSTMENT 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER 3. INSPECT IDLE SPEED Idle speed: 600 + 50 rpm If not as specified, adjust according to the following procedure: CAUTION: . Always use @ CO meter when adjusting the idle mixture. It is not necessary to adjust with the idie mixture adjusting screw in most vehicles if they are in good condition. + 14.860 meter is not avaliable and it is absolutely necessary to adjust with the idle mixture adjusting Eyre mt stern mand Ge oe EE 2:Q ' Eze ENGINE — ENGINE MECHANICAL A. METHOD WITH CO METER 1. VISUALLY INSPECT CARBURETOR (a) Check for loose screws or a loose mounting to the manifold, (b) Check for wear in the linkage, missing snap rings or excessive looseness in the throttle shaft. Correct any problems found, 2. INITIAL CONDITIONS (a) Air cleaner installed (b) Normal operating coolant temperature (c) Choke fully open (d) All accessories switched off (e) All vacuum lines connected {f) Ignition timing set correctly (a) Transmission in the "N” range (h) Fuel level should be about even with the correct level in the sight glass (i) CO meter operates normally Fuel Level 3. ADJUST IDLE SPEED AND IDLE MIXTURE HINT: Use SST if necessary. SST 09243-00020 (a) Start the engine. aes ol {b) Using a CO meter to measure the CO concentration in the exhaust, turn the idle speed and idle mixture adjusting screws to obtain the specified concentra- tion value at idle speed. Idle speed: wae Soee 600 rom Adjusting ScrewENGINE — ENGINE MECHANICAL oe 2,500 rpm Ne RPM Tachometer scons eumnae 180 Seconds CO Meter Sr 4, (a) (b) (c) INSPECT CO CONCENTRATION Check that the CO meter is properly calibrated. Race the engine at 2,500 rpm for approx. 180 sec- onds before measuring concentration. Insert co Meter testing probe at least 40 cm (1.3 ft) into the tailpipe, during idling. Immediately check the co concentration at Idle. Idle CO concentration: 15 40.5% © If the CO concentration is within specification this adjustment is complete. © If the CO concentration is not within specifica- tion, turn the idle mixture adjusting screw to obtain the specified concentration value. © If the CO concentration cannot be corrected by adjusting the idle mixture, see table below for other possible causes.£G-28 ENGINE — ENGINE MECHANICAL TROUBLESHOOTING co HC Problems Causes Normal High Rough idle Faulty ignition: © Incorrect timing + Fouled, shorted or improperly gapped plugs ‘+ Open or crossed ignition wires * Cracked distributor cap Leaky exhaust valves Leaky cylinder High Rough idle (Fluctuating HC reading) Vacuum leak: * Vacuum hose: © Intake manifold © PCV line * Carburetor base High High Rough idle (Black smoke from exhaust! Restricted air filter . Plugged PCV valve Faulty carburetion: * Faulty choke action + Incorrect float setting + Leaking needle or seat * Leaking power valveEG-29 ENGINE — ENGINE MECHANICAL Idle Mixture Adjusting we Idle Spood Adjusting Screw B. ALTERNATIVE METHOD To be used only if CO moter is not available. 1. VISUALLY INSPECT CARBURETOR (2) Check for loose screws or loose a mounting to the manifold. (b) Check for wear in the linkage, missing snap rings or excessive looseness in the throttle shaft. Correct any problems found. 2. INITIAL CONDITIONS (2) Air cleaner installed (b) Normal operating coolant temperature () Choke fully open {d) All accessories switched off {e) All vacuum lines connected {f) Ignition timing set correctly (g) Transmission in the “N” range 3. ADJUST IDLE SPEED AND IDLE MIXTURE HINT: Use SST if necessary. SST 09243-00020 (2) Start the engine. {b) Set to the maximum speed by turning the idle mixture adjusting screw. (c) Set to the idle mixture speed by turning the idle speed adjusting screw. Idle mixture speed: 650 rpm (a) Before moving to the next step continue adjustments {b) and (¢) until the maximum speed will not rise any further no matter how much the idle mixture adjusting screw is adjusted, {e) Set to the idle speed by screwing in the idle mixture adjusting screw. Idle speed: 600 rpm This is Lean Drop Method for setting idle speed and mixture.EG-30 ENGINE — ENGINE MECHANICAL raise ee Adjusting Screw (1FZ—F) FAST IDLE SPEED INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE. 3. CUT OPERATION OF FAST IDLE CAM BREAKER (FICB) SYSTEM Disconnect the vacuum hoses from the FICB and CB. and plug the hose ends. This shuts off the FICB and CB systems. 4. SET FAST IDLE CAM Lightly race the engine and release the throttle, and check that the fast idle cam is set at the 4th step. 5. INSPECT AND ADJUST FAST IDLE SPEED (a) Check the fast idle speed. Fast idle speed: G.c.c. 800 — 1,000 rpm Others 1,100 — 1,300 rpm If the fast idle speed is not as specified, adjust the fast idle speed by turning the fast idle adjusting screw. Fast idle speed: Gl 900 rpm Others 1,200 rpm (b) Lightly race the engine and release the throttle, and repeat steps 4 and 5. 6. RECONNECT VACUUM HOSES TO FICB AND CBEG-31 ENGINE — ENGINE MECHANICAL j on DP Adjusting Screw (1FZ—F) DASH POT (DP) INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE 3. START ENGINE 4. INSPECT AND ADJUST DASH POT (DP) SETTING SPEED (a) Disconnect the vacuum hose from the DP and plug the hose end. (b) Race the engine to 2,500 rpm for a few seconds, release the throttle and check the DP setting speed Dash pot setting speed: 1,400 — 1,600 rpm If the DP setting speed is not as specified, adjust the setting speed by turning the DP adjusting screw. Dash pot setting speed: 1,500 rpm (c}_ Race the engine to 2,500 rpm for a few seconds, (d) release the throttle and recheck the DP setting speed. Reconnect the vacuum hose to the DP, xeEG-32 ENGINE — ENGINE MECHANICAL TP Adjusting Scrow aes (1FZ—F) THROTTLE POSTIONER (TP) SETTING SPEED INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE 3. START ENGINE 4. INSPECT AND ADJUST THROTTLE POSITIONER (TP) SETTING SPEED (@) Disconnect the vacuum hoses from the gas filter and VSV. (b) Connect the vacuum hose which you have discon- nected from the VSV onto the gas filter. () Check the TP setting speed, TP setting sp 1,150 — 1,250 rpm If the TP setting speed is not as specified, adjust the setting speed by turning the TP adjusting screw. TP setting spee 1.200 rpm (d) Lightly race the engine and release the throttle, and recheck the TP setting speed. (e) Reconnect the vacuum hoses to the proper locations.EG-33 ENGINE ~ ENGINE MECHANICAL 2,500 rpm RPM Tachometer coona7 ewoae 180 Seconds IDLE CO/HC CHECK (1FZ—FE) fa) (b) (e) (a) le) (f) (9) (h) @ HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, ete. should be properly connected. EFI system wiring connectors fully plugged Ignition timing set correctly Transmission in neutral position Tachometer and CO/HC meter calibrated by hand START ENGINE RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS INSERT CO/HC METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm (1.3 ft) DURING IDLING IMMEDIATTELY CHECK GO/HC CONCENTRATION AT IDLE HINT: When performing the test, follow the meas- urement order prescribed by the applicable local reg- ulations. 7 as xLan ENGINE ~ ENGINE MECHANICAL Troubleshooting If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (a) Check oxygen sensor operation Bee page FG—290) (b) See the table below for possible causes, and then inspect and correct the applicable causes if neces- sary. He co Problome Causes High Normal | Rough idle 1. Faulty ignitions: © Incorrect timing ‘+ Fouled, shorted or improperly gapped plugs © Open or crossed high-tension cords = Cracked distributor cap 2. Incorrect valve clearance } 8. Leaky EGR valve | 4, Leaky intake and exhaust valves i 5._Lesky cylinder High Low Rough idle 1. Vacuum leaks: | (Fluctuating HE reading! PCV hose EGR valve Intake manifold ‘Air intake chamber Throttle body ISC valve Brake booster line 2. Lean mixture causing misfire High High Rough ide 1. Restiicted air fiter (Black smoke from exhaust) | 9 . Faulty EFI systems: ‘Faulty pressure regulator Clogged fue! return tine Defective water temp. sensor Faulty ECU Faulty injoctor Faulty throttle position sensor Faulty air flow metENGINE ~ ENGINE MECHANICAL Lica COMPRESSION CHECK HINT: — If there is lack of power, excessive oil co! sumption or poor fuel economy, measure the com- pression pressure. 1, WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature "EG 2. DISCONNECT DISTRIBUTOR CONNECTOR — 3. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 4, DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS {a} Remove the two mounting bolts of the No.1 and No.2 cord clamps. {b) Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. REMOVE SPARK PLUGS Using SST, remove the spark plug. SST 09155-16100£G-36 ENGINE — ENGINE MECHANICAL <7 Compression Gauge 6. fa) (b) (ec) (d) (e) CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle, While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short @ time as possible. Compression pressure: 1,176 kPa (12.0 kaf/em?, 171 psi) or more 1FZ—FE 900 kPa (9.2 kat/em?, 131 psi) or more 1FZ—F (Low octane) 1.030 kPa (10.5 kaf/em’, 149 psi) or more 1FZ—F (Others) Minimum pressure: 883 kPa (9.0 kgf/em*, 128 psi) 1FZ—FE 785 kPa (8.0 kgf/cm*, 114 psi) 1FZ—F Difference between each cylinder: 98 kPa (1.0 kgf/cm’, 14 psi) or less If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylin- der through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. © If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. © If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket, INSTALL SPARK PLUGS Using SST, install the spark plug. SST 09155-16100 Torque: 20 N-m (200 kaf-cm, 14 ftbf)ENGINE — ENGINE MECHANICAL Leeda 8. RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS (a) Reconnect the high—tension cords to the spark plugs. (b) Install the No.1 and No.2 cord clamps with the two bolts. 9. INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts. 10. CONNECT DISTRIBUTOR CONNECTORrere ENGINE — ENGINE MECHANICAL CYLINDER HEAD (1FZ—FE) i COMPONENTS Only for Europe Only for Europe EGR Pipe Z No.3 Cylinder Satara ao | Cover and Modulator ° 7 No.2 Cylinder a a Air Pipe He Cover . e _ eGasket a No.2 Heat Insulator Ta S| No.1 Heat ae bee” = AS Reed Valve Insulate 7206 se 21 210, 78) * EQS No.2 Exhayst Manifold : @. #Gasket SE, #Gasket No.1 Exhaust Manifold 1 Nearer Inter 8 s “ Trot Bony No.2 Engne Water By-Pass “2° Emission eo-Ring—2, Control Woter By-Pass-— Eon Valve Set Pipe a Engine Wire No.1 Water Assembly e0.Ring A, BvPareHowe § ‘Gasket U 21 (reel 18) Gasket nao Weler in Talento Hinge By-Pass Pipe ee Bracket Grom 7 ee Pi | so Fuel Return Pipe “@Gasket O-Ring t 1 water Outlet | istector \ 43 (440, a] Insulator |_Fuel Return Hose Drive Belk Generator . ew \ ar ° Oit Dipstick t oo Filter Se F came ya selene 04 Nem ikgf-om, (tibfi] : Specified torque Ring ee ‘@ Non-reusable part i Dipstick © end Guide Fuel inlet "——— HoseENGINE — ENGINE MECHANICAL bites PCV Valve Cylinder Head Cover 3 ——Gasket S—+ Spark Plug g— Adjusting Shim Tube Gasket @ Valve Lifter ‘Spark Plug 8-—Keeper Camshaft Spring Retainer Boaring Cap Valve Spring Oil Seal Spring Seat Valve Guide Bushing Valve ‘Camshaft Gear Spring ‘st 39 (400, 29) 2nd Turn 90°" 3rd Turn 90° Cylinder Head Water Temp. Sensor Water Temp. Cut Switch Water Temp. Sender Gauge Cylinder Head Gasket Tem (kgfem, (1BH} : Specified torque % Non-reusable part % Precoated part eeEG-40 ENGINE — ENGINE MECHANICAL CYLINDER HEAD REMOVAL (See Components for Removal and Installation) (a) (b) {ce} REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. REMOVE DISTRIBUTOR Remove the two mounting bolts of the No.1 and No.2 cord clamps. Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. Remove the hold—down bolt and distributor.ENGINE — ENGINE MECHANICAL 3. fa) (b) () (d) fe) co) (a) () (ec) EG-41 REMOVE ALTERNATOR Loosen the lock bolt, pivot bolt and adjusting bolt, and remove the drive belts. Disconnect the alternator connector. Remove the nut, and disconnect the alternator wire. Disconnect the wire harness from the clip. Remove the lock bolt, bolt, nut and drive belt adjus- ting bar. Remove the pivot bolt and alternator. REMOVE ALTERNATOR BRACKET Remove the two bolts and alternator bracket. REMOVE WATER OUTLET Disconnect the radiator inlet hose. Disconnect the No.3 water by—pass hose. Remove the two nuts, water outlet and gasket.EG-42 ENGINE — ENGINE MECHANICAL 6. (a) (b) (c) (d) (2) ) (9) (bh) fa) {b) (e) REMOVE THROTTLE BODY Disconnect the throttle position sensor connector. Disconnect the ISC valve connector. Disconnect the three vacuum hoses. Disconnect the EVAP hose. Disconnect the water hose from the No.2 water by— pass pipe, Remove the four bolts, and disconnect the throttle body from the air intake chamber. Remove the throttle body gasket. Disconnect the No.1 water by—pass hose from the throttle body, and remove the throttle body. REMOVE NO.2 WATER BY—PASS PIPE WITH HOSES Disconnect the two vacuum hoses from the PAIR reed valve and No.2 emission control valve set. Disconnect the water hose from the timing chain cover. Remove the three bolts and No.2 water by —pass pipe with hoses.