14_Engine_Mechanical.pdf

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14–1
ENGINE MECHANICAL
–
ENGINE ASSEMBLY (2AZ–FE)
ENGINE ASSEMBLY (2AZ–FE)
INSPECTION
1.
1404R–02
INSPECT COOLANT (See page 16–20 )
2.
INSPECT ENGINE OIL
3.
INSPECT BATTERY
Standard specific gravity: 1.25 – 1.29 at 20
C (68
F)
4.
INSPECT AIR CLEANER FILTER ELEMENT SUB–ASSY
5.
INSPECT SPARK PLUG
(See page 18–1 )
6.
INSPECT V–RIBBED BELT
7.
INSPECT IGNITION TIMING
(a)
Warm up engine.
(b)
When using hand–held tester.
(1) Connect the hand–held tester to the DLC3.
Ignition timing: 8 – 12
BTDC
HINT:
Please refer to the hand–held tester operator’s manual for fur-
ther details.
(c)
When not using hand–held tester.
(1)
Using SST, connect terminals 13 (TC) and 4 (CG)
of DLC3.
TC
SST
09843–18040
NOTICE:
Be sure not to connect incorrectly. It causes breakage
of the engine.
Turn OFF all electrical systems.
Operate the inspection when the cooling fan motor is
turned OFF.
(2)
CG
A51075
Remove the cylinder head cover No.2.
(3)
Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:
Use a timing light which can detect the first signal.
After checking, be sure to tape the wire harness.
(4) Inspect ignition timing at idle.
Ignition timing: 8 – 12
BTDC
NOTICE:
When checking the ignition timing, the transmission is at
neutral position.
HINT:
After engine rpm is kept at 1,000 – 1,300 r/min. for 5 seconds,
check that it returns idle speed.
A52004
2002 CAMRY REPAIR MANUAL (RM881U)
Author:
Date:
1523
807413051.010.png
14–2
ENGINE MECHANICAL
–
ENGINE ASSEMBLY (2AZ–FE)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 – 15
BTDC
(7) Confirm that ignition timing moves to advanced
angle side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand–held tester.
(1) Connect the hand–held tester to the DLC3.
Idle speed:
A/T 610 – 710 r/min.
M/T 650 – 750 r/min.
NOTICE:
Check idle speed with cooling fan OFF.
Switch off all accessories and air conditioning.
HINT:
Please refer to the hand–held tester operator’s manual for fur-
ther details.
(c)
When not using hand–held tester.
(1) Using SST, connect tachometer test prove to termi-
nal 9 (TAC) of DLC3.
SST 09843–18040
(2) Check the idle speed.
Idle speed:
A/T 610 – 710 r/min.
M/T 650 – 750 r/min.
TAC
A52006
9.
INSPECT COMPRESSION
(a)
Warm up and stop engine.
(b)
Disconnect the injector connectors.
(c)
Remove ignition coils.
(d)
Remove spark plugs.
(e)
Inspect cylinder compression pressure.
(1)
Insert a compression gauge into the spark plug
hole.
(2)
Fully open the throttle.
A01037
2002 CAMRY REPAIR MANUAL (RM881U)
Author:
Date:
1524
807413051.011.png
14–3
ENGINE MECHANICAL
–
ENGINE ASSEMBLY (2AZ–FE)
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1.360 MPa (13.9 kgf/cm 2 , 198 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm 2 , 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm 2 , 14 psi)
NOTICE:
Always use a fully charged battery to obtain engine
speed of 250 rpm or more.
Check other cylinder’s compression pressure in the
same way.
This measurement must be done in as short a time as
possible.
(4)
If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:
If adding oil increases the compression, it is likely that the
piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating
improperly, or there may be leakage past the gasket.
10.
INSPECT CO/HC
(a)
Start the engine.
(b)
Race engine at 2,500 r/min for approx. 180 seconds.
(c)
Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling.
(d)
Immediately check CO/HC concentration at idle and/or 2,500 r/min.
HINT:
Complete the measuring within 3 minutes.
When doing the 2 mode (idle and 2,500 r/min.) test, these measuring orders are prescribed by the ap-
plicable local regulations.
(e)
If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1)
Check heated oxygen sensor operation. (See page 12–1 )
(2)
See the table below for possible causes, and then inspect and correct the applicable causes if
necessary.
2002 CAMRY REPAIR MANUAL (RM881U)
Author:
Date:
1525
14–4
ENGINE MECHANICAL
–
ENGINE ASSEMBLY (2AZ–FE)
CO
HC
Problems
Causes
1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
Normal
High
Rough idle
1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
ISC valve
Brake booster line
2. Lean mixture causing misfire
Rough idle
(Fluctuating HC reading)
Low
High
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:
Faulty pressure regulator
Defective water temperature sensor
DEFECTIVE Air–flow meter
Faulty ECU
Faulty injectors
Faulty throttle position sensor
Rough idle
(Black smoke from exhaust)
High
High
2002 CAMRY REPAIR MANUAL (RM881U)
Author:
Date:
1526
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14–5
ENGINE MECHANICAL
–
FAN AND GENERATOR V BELT (2AZ–FE)
FAN AND GENERATOR V BELT (2AZ–FE)
REPLACEMENT
1.
1405U–02
REMOVE FRONT WHEEL RH
2.
REMOVE FRONT FENDER APRON SEAL RH
3.
REMOVE ENGINE COVER SUB–ASSY NO.1
4.
REMOVE ENGINE MOVING CONTROL ROD
W/BRACKET
(a)
Remove the 3 bolts and engine mounting control rod w/
bracket.
A59888
5.
REMOVE ENGINE MOUNTING STAY NO.2 RH
6.
REMOVE ENGINE MOUNTING BRACKET NO.2 RH
7.
REMOVE FAN AND GENERATOR V BELT
SST
(a)
Slowly turn the drive belt tensioner clockwise in more than
3 seconds, and remove the drive bolt by using SST.
SST
09249–63010
A62240
8.
INSTALL FAN AND GENERATOR V BELT
SST
(a)
Slowly turn the drive belt tensioner clockwise in more than
3 seconds, and install the drive bolt by using SST.
SST
09249–63010
A62240
9.
INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 N
m (531 kgf
cm, 38 ft
lbf)
V
V
V
2002 CAMRY REPAIR MANUAL (RM881U)
Author:
Date:
1527
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