丰田5A-FE／8A-FE维修手册

[教学研究]丰田5A-FE发动机的整体拆装丰田5A-FE发动机的整体拆装一、实验参考课时:二、实验目的及要求在发动机和总成拆装过程中，通过对实物的观察、分析、讨论、综合检验、装配、排故、考核，使学生进一一步熟悉和巩固发动机模块中所学的构造、诊断和维修等知识，并形成整体概念，熟悉发动机拆装步骤及主要零件的检验方法:通过对发动机的拆装后，起动发动机，使学生有一定的成就感，进一步提高学生学习专业课的积极三、实验设备及工量具1、丰田5A-FE发动机4台;2、丰田5A-FE发动机控制台4套;3、电源1台;4、常用与专用工具4套;5、汽车专用诊断仪2台;6、发动机内窥镜1套;7、各式量具25套。

四、试验内容发动机解体(以丰田5A-FE发动机为例)，解体前认真观察发动机外部各总成、主要零部件的名称、安装位置、连接关系、它们位于哪个机构、哪个系统。

五、实验操作及步骤(一)5A-FE发动机的拆卸1、拆下油底壳的放油螺丝，将发动机内的机油放出;2、拆下各分缸高压线，拆下固定分电器的两颗螺栓，取下分电器总成;3、拆下气门室盖上两条发动机曲轴箱通风管;4、将发电机皮带防护罩拆下;5、将水泵皮带轮的紧固螺栓松开，拆下发电机，取下发电机皮带;6、拆下水泵的皮带轮;7、拆下排气管下方与气缸盖相连的螺母; 8、拆下发动机的机油尺及松开水泵进水口; 9、拆下气门室盖上的螺钉与垫片，取下气门室盖; 10、拆下正时皮带上罩(3号皮带罩); 11、将排气凸轮轴前方的正时齿轮螺母松开;(但暂时不要拆下)12、转动曲轴对一缸上止点记号，检查原有的安装的情况;注意:曲轴皮带轮的记号与正时皮带罩的上止点记号，凸轮轴正时齿轮与排气凸轮轴承盖上的记号。

13、拆下正时皮带下罩(1号皮带罩)的防尘橡胶片;14、松开张紧轮的坚固螺栓，暂时将张紧轮推向前方固定，松开正时皮带;15、拆下进气凸轮轴的第一道轴承盖，转动凸轮轴; 16、用一颗6?20?1的螺栓将进气凸轮上的付斜齿轮与主斜齿轮相连;17、拆下进气与排气凸轮轴的各个轴承盖; 注意:拆卸轴承盖时应注意保持整个凸轮轴的平衡，故同时松开每个轴承盖上的螺栓;拆卸双头螺栓使用10,套筒，棘轮扳手，拆卸单头螺栓则使用10,丁字杆;18、依次取下各个气门挺杆;注意:每一个挺杆都不能够搞乱，各气门挺杆顶端有不同厚度调整气门脚间隙垫片。

丰田8A-FE发动机配气机构的结构与维修(二)
桂健生
【期刊名称】《汽车维护与修理》
【年(卷),期】2004(000)003
【摘要】进、排气凸轮轴的装复要在进气凸轮轴剪式齿轮机构装复后进行。

另外，安装进、排气凸轮轴时要求把它们水平放置，以免损伤气缸盖承受推力的部位。

【总页数】2页(P1-2)
【作者】桂健生
【作者单位】南京汽车制造厂,210037
【正文语种】中文
【中图分类】U4
【相关文献】
1.摩托车二冲程发动机的配气可变机构（一）
2.摩托车二冲程发动机的配气可变机构（二）
3.丰田轿车发动机剪刀式齿轮机构的维修
4.微型汽车462Q汽油发动机
结构及设计特点：（配气机构,传动机构部分）5.发动机配气机构的配气定时研究
与应用
因版权原因，仅展示原文概要，查看原文内容请购买。

110FE–01A65046A65047Front Floor Carpet –FUEL FUEL TANK ASSY11–25992AuthorĂ:DateĂ:2004 COROLLA (RM1037U)Removal & Installation and Disassembly & Reassembly1.REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8)2.REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11–16)3.WORK FOR PREVENTING GASOLINE FROM SPILLING OUT(a)Start the engine.(b)After the engine has stopped on the its own, turn the ignition switch to lock.4.DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY (See page 11–16)5.DISCONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 (See page 11–16)6.REMOVE FUEL TANK VENT TUBE SET PLATE (See page 11–16)7.REMOVE FUEL PUMP ASSEMBLY (See page 11–16)8.REMOVE FUEL SUCTION TUBE SET GASKET9.DRAIN FUEL10.REMOVE FLOOR PANEL BRACE FRONT(a)Remove the 2 nuts and floor panel brace front.11.REMOVE EXHAUST PIPE ASSY FRONT(a)Using a clip remover, remove the clip.(b)Tear off the front floor carpet.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65706A65049A6505011–26–FUEL FUEL TANK ASSY993AuthorĂ:DateĂ:2004 COROLLA (RM1037U)(c)Disconnect the oxygen sensor connector.(d)Remove the 2 exhaust pipe supports.(e)Remove the 4 bolts, 4 compression springs and exhaustpipe.12.REMOVE FUEL TANK PROTECTOR NO.1(a)Remove the 5 bolts and fuel tank protector.13.SEPARATE PARKING BRAKE CABLE ASSY NO.2(a)Remove the 2 installing bolts of the parking brake cable.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65051A65052A66709Nylon Tube Fuel TubeConnector Clip Pipe O–ring Fuel Tube Connector A65054A65055–FUEL FUEL TANK ASSY 11–27994AuthorĂ:DateĂ:2004 COROLLA (RM1037U)14.SEPARATE PARKING BRAKE CABLE ASSY NO.3(a)Remove the 2 installing bolts of the parking brake cable.15.DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY (a)Pinch the fuel tube connector clip, and remove the fuel tube connector clip.(b)Pull out the fuel tank main tube.NOTICE:S Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.S Be careful of dirt like mud because the fuel tube con-nector has an O–ring to seal the fuel tube connector and pipe.S Do not use any tool in this work.S Do not bend or twist the nylon tube by force.S After disconnecting, cover the fuel tube connector with a vinyl bag.S When the fuel tube connector and pipe are stuck,pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.16.DISCONNECT FUEL TANK INLET PIPE FUEL HOSE (a)Disconnect the fuel tank inlet filler pipe hose from the fuel tank.17.DISCONNECT FUEL TANK BREATHER HOSE (a)Disconnect the fuel tank breather hose from the fuel tank.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65056Push Pinch A A PinchA65057A65058A65059Nylon Tube Fuel TubeConnector ClipPipe O–ring Fuel Tube Connector A6506011–28–FUEL FUEL TANK ASSY 995AuthorĂ:DateĂ:2004 COROLLA (RM1037U)18.DISCONNECT FUEL TANK VENT HOSE (a)Disconnect the fuel tank bent hose from the charcoal can-ister.(1)Push the connector deep inside.(2)Pinch portion A.(3)Pull out the connector.19.DISCONNECT VALVE TO FUEL FILLER PIPE HOSE (a)Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.20.DISCONNECT FUEL EMISSION TUBE SUB–ASSY NO.1(a)Pinch the fuel tube connector clip and then pull out the fuel emission tube.NOTICE:S Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.S Be careful of dirt like mud because the fuel tube con-nector has an O–ring to seal the fuel tube connector and pipe.S Do not use any tool in this work.S Do not bend or twist the nylon tube by force.S After disconnecting, cover the fuel tube connector with a vinyl bag.S When the fuel tube connector and pipe are stuck,pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.21.REMOVE FUEL TANK ASSY (a)Set a mission jack to the fuel tank.(b)Remove the 4 bolts, 2 fuel tank bands and fuel tank.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65061A65062A65063A65064A60576Nylon TubeFuel TubeConnector ClipPipe O–ring Fuel TubeConnector –FUEL FUEL TANK ASSY 11–29996AuthorĂ:DateĂ:2004 COROLLA (RM1037U)22.REMOVE FUEL TANK MAIN TUBE SUB–ASSY (a)Remove the fuel tank main tube from the fuel tube clamp and bracket.23.REMOVE FUEL TUBE CLAMP NO.4(a)Remove the bolt and fuel tank clamp.24.REMOVE FUEL TUBE BRACKET (a)Remove the fuel tube bracket from the fuel tank.25.REMOVE FUEL EMISSION TUBE SUB–ASSY NO.1(a)Pinch the fuel tube connector clip and then pull out the fuel emission tube.NOTICE:S Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.S Be careful of dirt like mud because the fuel tube con-nector has an O–ring to seal the fuel tube connector and pipe.S Do not use any tool in this work.S Do not bend or twist the nylon tube by force.S After disconnecting, cover the fuel tube connector with a vinyl bag.S When the fuel tube connector and pipe are stuck,pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65065A65066A65067Clip Remover Gasket A6506811–30–FUEL FUEL TANK ASSY 997AuthorĂ:DateĂ:2004 COROLLA (RM1037U)26.REMOVE FUEL TUBE CLAMP NO.2(a)Remove the fuel tube clamp from the fuel tank.27.REMOVE CHECK VALVE PROTECTOR (a)Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise.28.REMOVE FUEL TANK INLET VALVE ASSY (a)Insert a clip remover between the fuel tank inlet valve and gasket, remove the fuel tank inlet valve by gradually pushing it upward.NOTICE:S Work accurately to maintain the sealing performance of the fuel tank inlet valve, since it is made from resin.It is easy to damage by removing and installing forci-bly.S Be sure to install a new fuel tank inlet valve and gas-ket.29.REMOVE CHECK VALVE GASKET (a)Remove the gasket from the fuel tank inlet valve.汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A65069A65069A65070A65071Apply a light coatof oil–FUEL FUEL TANK ASSY 11–31998AuthorĂ:DateĂ:2004 COROLLA (RM1037U)30.REMOVE FUEL TANK CUSHION NO.1(a)Remove the 7 fuel tank cushions from the fuel tank.31.INSTALL FUEL TANK CUSHION NO.1(a)Install the 7 new fuel tank cushions to the fuel tank.32.INSTALL CHECK VALVE GASKET (a)Install a new gasket to the fuel tank.33.INSTALL FUEL TANK INLET VALVE ASSY (a)Apply a light coat of oil around the fuel tank inlet valve asshown in the illustration, and insert it into the fuel tankwithout force.NOTICE:Be careful not to drop the gasket into the fuel tank.34.INSTALL FUEL EMISSION TUBE SUB–ASSY NO.1(a)Push in the fuel tube connector to the pipe until fuel tube connector makes ”click” sound.NOTICE:S Check if there is any damage or foreign objects on the connected part.S After connecting, check if the fuel tube connector and pipe are securely connected by pullingthem.35.INSTALL FUEL TUBE CLAMP NO.4(a)Install the fuel tube clamp with the bolt.Torque: 6.0 N ⋅m (61 kgf ⋅cm, 53 in.⋅lbf)汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)A51891Tail Pipe Side Gasket –FUEL FUEL TANK ASSY 11–331000AuthorĂ:DateĂ:2004 COROLLA (RM1037U)(c)Install a new gasket on the exhaust pipe (rear side).(d)Install the exhaust pipe with the 4 compression springsand 4 bolts.Torque: 43 N ⋅m (440 kgf ⋅cm, 32 ft ⋅lbf)(e)Install the 2 exhaust pipe supports.(f)Connect the oxygen sensor connector.(g)Install the font floor carpet with a clip.43.INSTALL FLOOR PANEL BRACE FRONT(a)Install the floor panel brace front with the 2 nuts.Torque: 30 N ⋅m (302 kgf ⋅cm, 22 ft ⋅lbf)44.INSTALL FUEL SUCTION TUBE SET GASKET (See page 11–16)45.INSTALL FUEL PUMP ASSEMBLY (See page 11–16)46.INSTALL FUEL TANK VENT TUBE SET PLATE (See page 11–16)47.CONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 (See page 11–16)48.CONNECT FUEL TANK MAIN TUBE SUB–ASSY (See page 11–16)49.CHECK FUEL LEAK (See page 11–1)50.CHECK EXHAUST GAS LEAK51.INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11–16)52.INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8)汽车技师帮技术资料一汽丰田卡罗拉维修维修手册(fuel tank)。

EM18U-01P19776CO/HC Meter-ENGINE MECHANICAL CO/HCEM-1CO/HCINSPECTION HINT:This check is used only to determine whether or not the idle CO/HC complies with regulations.1.INITIAL CONDITIONS (a)Engine coolant at normal operating temperature (b)Air cleaner installed (c)All pipes and hoses of air induction system connected (d)All accessories switched OFF (e)All vacuum lines properly connected (f)SFI system wiring connectors fully plugged (g)Ignition timing set correctly (h)Transmission in neutral position (i)CO/HC meter calibrated by hand 2.START ENGINE 3.RACE ENGINE AT 2,500 RPM FOR APPROX. 180SECONDS 4.INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5.IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT:When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regula-tions.EM-2ENGINE MECHANICAL CO/HC-If the CO/HC concentration does not comply with regulations,troubleshoot according to the table below. Check and correctthe cause if necessary.V08293EM0KB-04A05758Compression GaugeCOMPRESSION INSPECTION HINT:If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.1.WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature.2.REMOVE SPARK PLUGS (See page IG-1)3.CHECK CYLINDER COMPRESSION PRESSURE (a)Insert a compression gauge into the spark plug hole.(b)Fully open the throttle.(c)While cranking the engine, measure the compression pressure.HINT:Always use a fully charged battery to obtain engine revolutions of 250 rpm or more.(d)Repeat steps (a) through (c) for each cylinder.NOTICE:This measurement must be done in as short a time as pression pressure:1,275 kPa (13.0 kgf/cm 2, 185 psi) or more Minimum pressure:981 kPa (10.0 kgf/cm 2, 142 psi)Difference between each cylinder:100 kPa (1.0 kgf/cm 2, 14 psi) or less (e)If the cylinder compression in one or more cylinders is low,pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.L If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage.L If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.4.REINSTALL SPARK PLUGSEM0JU-04S05888Charcoal CanisterVSV for EVAP Tie Rod End Battery Front Exhaust PipeLH Engine Under CoverRH Engine Under CoverCompression SpringL GasketRadiatorUpperSupport M/T A/C Compressor Heated Oxygen Sensor(Bank 1 Sensor 2)Clamp L Gasket Compressor Mounting BracketThrottle Cable (A/T)Drive ShaftRadiatorUpperSupportRadiatorIdler Pulley Bracketw/ A/C and w/ o PSAdjusting StrutPS PumpHood L Non-reusable part AcceleratorCableA/T L Snap Ring Air Cleaner AssemblyL Oil Cooler Hose (A/T)ENGINE UNITCOMPONENTSRH Engine Mounting Insulator MAP sensor Hose Brake Booster Vacuum HoseHeater HoseIdle-Up Air Hose (PS)Rear Engine Mounting BracketFuel InletHoseHole Cover Ground StrapClutch Release CylinderSpeedometer CableStarterSpeedometer Cable Starter Control Cable Control CableGround Strap LH Engine Mounting BracketA/T LH Engine Mounting BracketTransaxle x 3Lx 6Ground Strap Clutch CoverClutch DiscM/TL TransaxleLx 3x 5x 6LEM-54-ENGINE MECHANICAL ENGINE UNITEM0JV-03S05838S05848S05840-ENGINE MECHANICAL ENGINE UNITEM-55REMOVAL1.REMOVE BATTERY 2.REMOVE HOOD3.REMOVE ENGINE UNDER COVERS4.DRAIN ENGINE COOLANT5.DRAIN TRANSAXLE OIL (FLUID)6.DISCONNECT VSV FOR EVAP BRACKET7.REMOVE AIR CLEANER ASSEMBLY WITH AIR INTAKE CONNECTOR8.REMOVE RADIATOR (See page CO-16)9.DISCONNECT ACCELERATOR CABLE 10.DISCONNECT FUEL HOSE Remove the union bolt and gaskets, and disconnect the fuel in-let hose.NOTICE:Catch leaking fuel in a container.11.DISCONNECT HOSES Disconnect these hoses:L Brake booster vacuum hose L MAP sensor hose L Heater hoses 12.DISCONNECT SPEEDOMETER CABLE FROM TRANSAXLE 13.w/ PS:DISCONNECT IDLE-UP AIR HOSES FROM AIR CONTROL VALVE 14.DISCONNECT ENGINE WIRE HARNESS Disconnect these connectors and wires:L Oxygen sensor connector L Oil pressure switch connector L Engine coolant temperature sender gauge connector L Engine coolant temperature sensor connector L Camshaft position sensor connector L Fan engine coolant temperature switch connector L A/T only:Lock-up solenoid connector L A/T only:S06150M/T onlyP20565M/TA132 LA/TA242 LA/T EM-56-ENGINE MECHANICAL ENGINE UNITLM/T only:Backup light switch connector L A/T only:No.2 vehicle speed sensor connector L Ground strap L Throttle position sensor connector L IAC valve connector L Injector connectors L Crankshaft position sensor connector L Knock sensor connector L Starter connector and wire L Generator connector and wire 15.M/T only:REMOVE CLUTCH RELEASE CYLINDER WITHOUT DISCONNECTING TUBE (a)Remove the 3 bolts, release cylinder and tube from the transaxle.(b)Disconnect the ground strap.16.M/T:DISCONNECT CONTROL CABLE(S) FROM TRANS-AXLE (a)Remove the clip and plate washer.(b)Remove the retainer from the cable.17.A/T:DISCONNECT CONTROL CABLE(S) FROM TRANS-AXLE (a)Remove the clip and plate washer.(b)Remove the 2 bolts from the LH engine mounting bracket.P20577P20292P20164P20246-ENGINE MECHANICAL ENGINE UNITEM-5718.w/ PS:REMOVE PS PUMP WITHOUT DISCONNECTING HOSES (a)Loosen the 2 bolts, and remove the PS drive belt.(b)Remove the 2 bolts, and disconnect the PS pump from the engine.HINT:Put aside the PS pump, and suspend it.19.w/ A/C:REMOVE A/C COMPRESSOR (a)Disconnect the compressor connector.(b)Remove the 4 compressor mounting bolts.HINT:Put aside the compressor, and suspend it.20.REMOVE FRONT EXHAUST PIPE (a)Disconnect the heated oxygen sensor.(b)Remove the 2 bolts, compression springs and disconnect the exhaust pipe.(c)Remove the bolts and rear clamp.(d)Disconnect the 2 rings and remove the front exhaust pipe.21.REMOVE DRIVE SHAFTS (See page SA-17)22.REMOVE ENGINE WITH TRANSAXLE FROM VEHICLE (a)Install the No.1 engine hanger in the correct direction.Part No.:No.1 engine hanger 12281-11031Bolt 91642-80825(b)Attach the engine sling device to the engine hangers.(c)Remove the rear engine mounting insulator through bolt.(d)Remove charcoal canister (See page EM-12).P20153Ground StrapP20285M/TP20002A132L A/TZ14321A242L A/TLift EM-58-ENGINE MECHANICAL ENGINE UNIT(e)Remove the bolt and disconnect the ground strap.(f)Remove the through bolt, 2 bolts, nut and RH engine mounting insulator.(g)Remove the bolt and disconnect the ground strap.(h)Remove the 5 bolts and LH engine mounting bracket.(i)Lift the engine out of the vehicle slowly and carefully.HINT:Clear the battery carrier support while lowering the transaxle.(j)Place the engine with the transaxle onto the stand.P20167P20161P20245A/T only-ENGINE MECHANICAL ENGINE UNITEM-5923.w/PS:REMOVE PS PUMP ADJUSTING STRUT Remove the 2 bolts and PS pump adjusting strut.24.w/A/C:REMOVE A/C COMPRESSOR MOUNTING BRACKET Remove the 4 bolts and compressor mounting bracket.25.A/T only:REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS (a)Remove the engine rear end plate hole cover.(b)Turn the crankshaft to gain access to each bolt.(c)Hold the crankshaft pulley bolt with a wrench.(d)Remove the 6 bolts.26.REMOVE STARTER (See page ST-4 and ST-18)27.SEPARATE ENGINE AND TRANSAXLEEM0JW-03P20245A/T only P20161P20167Lower EM-60-ENGINE MECHANICAL ENGINE UNITINSTALLATION1.ASSEMBLE ENGINE AND TRANSAXLE M/T: (See page MX-3)A132L A/T: (See page AX-26)A242L A/T: (See page AX-30)2.INSTALL STARTER (See page ST-15 and ST-32)3.A/T only:INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS (a)First, install the gray bolt and then 5 bolts.(b)Tighten the bolts evenly.Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)(c)Install the engine rear end plate hole cover.4.w/A/C:INSTALL A/C COMPRESSOR MOUNTING BRACKET Install the compressor mounting bracket with the 4 bolts.Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)5.w/PS:INSTALL PS PUMP ADJUSTING STRUT Install the PS pump adjusting strut with the 2 bolts.Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)6.INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a)Attach the engine sling device to the engine hangers.(b)Lower the engine into the engine compartment.Tilt the transaxle downward, lower the engine and clear the LH engine mounting.NOTICE:Be careful not to hit the PS gear housing, park/neutral posi-P20246P00352P20285 M/TA132L A/TA242L A/T -ENGINE MECHANICAL ENGINE UNITEM-61(c)Keep the engine level, and align RH and LH enginemountings with the body bracket.(d)Attach the RH engine mounting insulator to the mountingbracket and body, and temporarily install the through bolt,2 bolts and nut.(e)Install the LH engine mounting bracket to the transaxleand mounting insulator with the 5 bolts. T orque the bolts.Torque:Bracket to transaxle (bolt head: NT)64 N·m (650 kgf·cm, 47 ft·lbf)Bracket to insulator (bolt head: 7T)49 N·m (490 kgf·cm, 35 ft·lbf)(f)Connect the ground strap with the bolt.Torque: 49 N·m (490 kgf·cm, 35 ft·lbf)P20336P00356P20164EM-62-ENGINE MECHANICAL ENGINE UNIT(g)Install and torque the rear engine mounting insulator through bolt.Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)(h)Remove the engine sling device from the engine.(i)Torque the 2 bolts, nut and through bolt of the RH mount-ing insulator.Torque:Bolt and nut 64 N·m (650 kgf·cm, 47 ft·lbf)Through bolt 73 N·m (740 kgf·cm, 54 ft·lbf)(j)Connect the ground strap with the bolt.(k)Install charcoal canister.(See page EM-17)7.INSTALL DRIVE SHAFTS (See page SA-17)8.INSTALL FRONT EXHAUST PIPE (a)Connect the 2 rings to the front exhaust pipe.(b)Place a new gasket on the exhaust pipe.(c)Connect the exhaust pipe to the exhaust manifold with 2compression springs and 2 bolts.Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)(d)Install the exhaust pipe to the tail pipe with the clamp.Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)(e)Install the heated oxygen sensor.Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)HINT:L Before installing the heated oxygen sensor, twist the sen-sor wire counterclockwise 3 and 1/2 turns.L After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.P20292P20577P20565 M/TP21044 A132L A/TA242L A/T -ENGINE MECHANICAL ENGINE UNITEM-639.w/ A/C:INSTALL A/C COMPRESSOR(a)Install the A/C compressor to the bracket with the 4 bolts.Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)(b)Connect A/C compressor connector.10.w/ PS:INSTALL PS PUMP(a)Install the PS pump and drive belt with the 2 bolts.(b)Adjust the drive belt tension.(See page SR-3)11.M/T:CONNECT CONTROL CABLE(S) TO TRANSAXLE(a)Install the retainer to the cable.(b)Connect the linkage with the plate washer and clip.12.A/T:CONNECT CONTROL CABLE(S) TO TRANSAXLE(a)Install the support bracket to the LH engine mountingbracket with the 2 bolts.(b)Connect the linkage with the plate washer and clip.S06150M/T onlyS05840EM-64-ENGINE MECHANICAL ENGINE UNIT13.M/T only:INSTALL CLUTCH RELEASE CYLINDER Install the release cylinder, tube and ground strap with the 3bolts.Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)14.CONNECT ENGINE WIRE HARNESS Connect these connectors and wires:L Oxygen sensor connector L Oil pressure switch connector L Engine coolant temperature sender gauge connector L Engine coolant temperature sensor connector L Camshaft position sensor connector L Fan engine coolant temperature switch connector L A/T only:Lock-up solenoid connector L A/T only:Park/Neutral position switch connector L M/T only:Backup light switch connector L A/T only:No.2 vehicle speed sensor connector L Ground strap L Throttle position sensor connector L IAC valve connector L Injector connectors L Crankshaft position sensor connector L Knock sensor connector L Starter connector and wire L Generator connector and wire 15.w/ PS:CONNECT IDLE-UP AIR HOSES TO AIR CONTROL VALVE 16.CONNECT SPEEDOMETER CABLE 17.CONNECT HOSES Connect these hoses:(1)Brake booster vacuum hose (2)MAP sensor hose (3)Heater hosesS05838-ENGINE MECHANICAL ENGINE UNIT18.CONNECT FUEL HOSEConnect the fuel inlet hose with the union bolt and 2 new gas-kets.Torque: 29.5 N·m (300 kgf·cm, 22 ft·lbf)19.CONNECT ACCELERATOR CABLE, AND ADJUST IT20.INSTALL RADIATOR(See page CO-22)21.INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-TAKE CONNECTOR22.FILL WITH TRANSAXLE OIL (FLUID)23.FILL WITH ENGINE COOLANT24.INSTALL ENGINE UNDER COVERS25.INSTALL HOOD26.START ENGINE AND CHECK FOR LEAKS27.PERFORM ENGINE ADJUSTMENT28.PERFORM ROAD TESTCheck for abnormal noise, shock, slippage, correct shift pointsand smooth operation.29.RECHECK ENGINE COOLANT AND ENGINE OIL LEV-ELSEM0JS-01P20490P20482SSTP20564Cut Position TapeP20563SST -ENGINE MECHANICAL CYLINDER BLOCKREPLACEMENT1.REPLACE CRANKSHAFT FRONT OIL SEAL HINT:There are 2 methods to replace the oil seal which are as follows:If oil pump is removed from cylinder block (a)Using a screwdriver, pry out the oil seal.(b)Using SST and a hammer, tap in a new oil seal until its sur-face is flush with the oil pump case edge.SST 09309-37010(c)Apply MP grease to the oil seal lip.If oil pump is installed to the cylinder block (d)Using a knife, cut off the oil seal lip.(e)Using a screwdriver, pry out the oil seal.NOTICE:Be careful not to damage the crankshaft.Tape the screwdriver tip.(f)Apply MP grease to a new oil seal lip.(g)Using SST and a hammer, tap in the oil seal until its sur-face is flush with the oil pump case edge.SST 09309-370102.REPLACE CRANKSHAFT REAR OIL SEAL HINT:There are 2 methods to replace the oil seal which are as follows:If rear oil retainer is removed from cylinder block (a)Using a screwdriver and hammer, tap out the oil seal.S07242SST SSTN00264Tape Cut PositionS07243SSTSST EM-82-ENGINE MECHANICAL CYLINDER BLOCK(b)Using SST and a hammer, tap in a new oil seal until its sur-face is flush with the rear oil seal edge.SST 09223-15030, 09550-10012 (09552-10010)(c)Apply MP grease to the oil seal lip.If rear oil seal retainer is installed to cylinder block (d)Using a knife, cut off the oil seal lip.(e)Using a screwdriver, pry out the oil seal.NOTICE:Be careful not to damage the crankshaft.Tape the screwdriver tip.(f)Apply MP grease to a new oil seal lip.(g)Using SST and a hammer, tap in the oil seal until its sur-face is flush with the rear oil seal retainer edge.SST 09223-15030, 09550-10012 (09552-10010)EM0JT-01P20471Front Mark(Cavity)Front Mark (Protrusion)Z08055SST Piston PinSST SST SSTSSTSST SST P205491R2R-ENGINE MECHANICAL CYLINDER BLOCKEM-83REASSEMBLYHINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all slid-ing and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.1.ASSEMBLE PISTON AND CONNECTING ROD (a)Coat the piston pin and pin holes of the piston with engine oil.(b)Align the cavity on the piston with the protrusion on the connecting rod.(c)Using SST, press in the piston pin.SST 09221-25026 (09221-00020, 09221-00030,09221-00130, 09221-00140, 09221-00150)(d)After installing the piston pin, check that when the con-necting rod is aligned with the center of the piston the space between the piston and each end of the piston pin are equal on the left and right sides.HINT:If the piston pin is off-center due to insufficient insertion pres-sure on the piston pin, place a washer at the position indicated by L in the illustration for (c). Then, while checking that the space is equal at the ends of the piston pin on the left and right sides, press in the washer.2.INSTALL PISTON RINGS (a)Install the oil ring expander and 2 side rails by hand.(b)Using a piston ring expander, install the 2 compression rings with the code mark facing upward.Code Mark:P20867FrontExpanderNo.2CompressionRingUpper Side Rail Front Mark (Cavity)No.1Compression Ring Lower Side Rail EM3477EM9416P20550EM-84-ENGINE MECHANICAL CYLINDER BLOCK(c)Position the piston rings so that the ring ends are as shown.NOTICE:Do not align the end gaps.3.INSTALL BEARINGS (a)Align the bearing claw with the groove of the connecting rod or connecting cap.(b)Install the bearings in the connecting rod and connecting rod cap.4.INSTALL MAIN BEARINGS (a)Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.NOTICE:Install the bearing with the oil hole in the cylinder block.(b)Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.HINT:A number is marked on each main bearing cap to indicate the illustration position.5.INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position with the oil grooves facing outward.6.PLACE CRANKSHAFT ON CYLINDER BLOCKP20551P20530FrontZ1429112345678910EM3480Front Mark(Cavity)Front Push-ENGINE MECHANICAL CYLINDER BLOCKEM-857.INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS (a)Install the 2 thrust washers on the No.3 bearing cap with the oil grooves facing outward.(b)Install the 5 main bearing caps in their proper locations.HINT:Each bearing cap has a number and front mark.(c)Apply a light coat of engine oil on the threads and under the heads of the main bearing caps.(d)Install and uniformly tighten the 10 bolts of the main bear-ing caps, in several passes, in the sequence shown.Torque: 58 N·m (580 kgf·cm, 42 ft·lbf)(e)Check that the crankshaft turns smoothly.(f)Check the crankshaft thrust clearance.(See page EM-68)8.INSTALL PISTON AND CONNECTING ROD ASSEMBLIES (a)Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.(b)Using a piston ring compressor, push the correctly num-bered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.EM3481Front Mark(Protrusion)Front EM3448P20475Seal Packing A’B’A BA - A’B - B’EM-86-ENGINE MECHANICAL CYLINDER BLOCK9.INSTALL CONNECTING ROD CAPS (a)Match the numbered connecting rod cap with the num-bered connecting rod.(b)Install the connecting rod cap with the front mark facing forward.(c)Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.(d)Install and alternately tighten the nuts of the connecting rod cap in several passes.Torque: 40 N·m (400 kgf·cm, 29 ft·lbf)(e)Check that the crankshaft turns smoothly.(f)Check the connecting rod thrust clearance.(See page EM-68)10.INSTALL REAR OIL SEAL RETAINER (a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the rear oil seal retainer and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket sur-faces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.(b)Apply seal packing to the rear oil seal retainer as shown in the illustration.Seal packing:Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 2 - 3 mm (0.08- 0.12 in.) opening. Parts must be assembled within 5 minutes of ap-plication. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and rein-stall cap.(c)Install the oil seal retainer with the 4 bolts.Torque: 7.5 N·m (75 kgf·cm, 65 in.·lbf)P2047612 mmHexagon WrenchP00496AdhesiveP20479SST P20750SST-ENGINE MECHANICAL CYLINDER BLOCK EM-8711.INSTALL OIL FILTER UNION Using a 12 mm hexagon wrench, install the oil filter union.Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)12.INSTALL OIL PUMP AND PRESSURE REGULATOR VALVE 13.INSTALL OIL PRESSURE SWITCH (a)Clean the switch threads and cylinder block switch holes of any sealer, oil or foreign materials.Remove any oil with kerosene or gasoline.(b)Apply adhesive to 2 or 3 threads of the switch end.Adhesive:Part No. 08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent (c)Using SST, install the oil pressure switch.SST 09816-30010Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)14.INSTALL OIL FILTER (See page LU-1)15.INSTALL RH ENGINE MOUNTING BRACKET Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)16.INSTALL KNOCK SENSOR Using SST, install the knock sensor.SST 09816-30010Torque: 45 N·m (450 kgf·cm, 33 ft·lbf)P20545EM9412EM7333EM941012345617.INSTALL GENERATOR BRACKET Torque: 24 N·m (240 kgf·cm, 18 ft·lbf)18.INSTALL WATER PUMP WITH WATER INLET PIPE 19.INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-JUSTING BAR 20.INSTALL CYLINDER HEAD 21.INSTALL TIMING BELT AND PULLEYS 22.REMOVE ENGINE STAND 23.INSTALL REAR END PLATE Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)24.M/T:INSTALL FLYWHEEL (a)Apply adhesive to 2 or 3 threads of new mounting bolt end.Adhesive:Part No. 08833-00070, THREE BOND 1324 or equivalent (b)Install the flywheel on the crankshaft.(c)Install and uniformly tighten the mounting bolts, in several passes, in the sequence shown.Torque: 90 N·m (900 kgf·cm, 65 ft·lbf)25.A/T:INSTALL DRIVE PLATE (See step 24)26.M/T:INSTALL CLUTCH DISC AND COVEREM0JR-01P00393Z07983P00390FrontINSPECTION1.CLEAN CYLINDER BLOCK (a)Remove gasket ing a gasket scraper, remove all the gasket material from the top surface of the cylinder block.(b)Clean cylinder ing a soft brush and solvent, thoroughly clean the cylin-der block.2.INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage.Maximum warpage: 0.05 mm (0.0020 in.)If warpage is greater than maximum, replace the cylinder block.3.INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches.If deep scratches are present, replace the cylinder block.4.INSPECT CYLINDER BORE DIAMETER HINT:There are 3 sizes of the standard cylinder bore diameter,marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top of the cylinder block.P20484Front ThrustDirectionAxialDirection10 mm(0.39 in.)10 mm(0.39 in.)A B C P20491P20541-ENGINE MECHANICAL CYLINDER BLOCK EM-77Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.Standard diameter:Maximum diameter:74.23 mm (2.9224 in.)If the diameter is greater than maximum, replace the cylinder block.5.REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,grind the top of the cylinder.6.CLEAN PISTON (a)Using a gasket scraper, remove the carbon from the pis-ton top.(b)Using a groove cleaning tool or broken ring, clean the ring grooves.P20539P20561Mark 1, 2 or 3Front mark (Cavity)P2047423 mm (0.91 in.)Mark 1, 2 or 3FrontFront mark (Cavity)Mark 1, 2 or 3EM-78-ENGINE MECHANICAL CYLINDER BLOCK(c)Using a soft brush and solvent, thoroughly clean the pis-ton.NOTICE:Do not damage the piston.7.INSPECT PISTON OIL CLEARANCE HINT:There are 3 sizes of the standard piston diameter, marked ”1”,”2” and ”3” accordingly. The mark is stamped on the piston top.(a)Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23 mm (0.91 in.) from the piston head.Piston diameter:(b)Measure the cylinder bore diameter in the thrust direc-tions. (See step 4)(c)Subtract the piston diameter measurement from the cylin-der bore diameter measurement.Standard oil clearance:0.09 - 0.11 mm (0.0035 - 0.0043 in.)Maximum oil clearance:0.13 mm (0.0051 in.)If the oil clearance is greater than maximum, replace all 4 pis-tons. If necessary, replace the cylinder block.HINT:(Use new cylinder block):Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.P20540P20527Top of Cylinder Block110 mm (4.33 in.,)EM7639-ENGINE MECHANICAL CYLINDER BLOCKEM-798.INSPECT PISTON RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new pis-ton ring and the wall of the ring groove.Ring groove clearance:If the oil clearance is greater than maximum, replace the piston.9.INSPECT PISTON RING END GAP (a)Insert the piston ring into the cylinder bore.(b)Using a piston, push the piston ring a little beyond the bot-tom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.(c)Using a feeler gauge, measure the end gap.Standard end gap:Maximum end gap:If the end gap is greater than maximum, replace the piston ring.If necessary, replace the cylinder block.10.INSPECT CONNECTING RODS Using a rod aligner, check the connecting rod alignment.L Check for out-of-alignment.Maximum out-of-alignment:0.03 mm (0.0012 in.) per 100 mm (3.94 in.)If out-of-alignment is greater than maximum, replace the con-necting rod assembly.N00302 EM3208N00295L Check for twistMaximum twist:0.05 mm (0.0020 in.) per 100 mm (3.94 in.)If twist is greater than maximum, replace the connecting rod as-sembly.HINT:If replacing the connection rods, replace the same number of connecting rod bearings as that of new connecting rod caps.11.INSPECT CRANKSHAFT FOR RUNOUT(a)Place the crankshaft on V-blocks.(b)Using a dial indicator, measure the circle runout at thecenter journal.Maximum circle runout: 0.06 mm (0.0024 in.)If the circle runout is greater than maximum, replace the crank-shaft.12.INSPECT MAIN JOURNALS AND CRANK PINS(a)Using a micrometer, measure the diameter of each mainjournal and crank pin.Main journal diameter:Crank pin diameter:If the diameter is not as specified, check the oil clearance (See steps 3 and 6 in cylinder block disassembly). If necessary, grind or replace the crankshaft.(b)Check each main journal and crank pin for taper and out-of-round as shown.Maximum taper:0.08 mm (0.0031 in.)Maximum out-of-round:0.07 mm (0.0028 in.)If the taper and out-of-round is greater than maximum, replace the crankshaft.13.IF NECESSARY, GRIND AND HONE MAINJOURNALS AND/OR CRANK PINS(a)Grind and hone the main journals and/or crank pins to thefinished undersized diameter (See procedure in step 2).(b)Install new main journal and/or crank pin undersizedbearings.EM0JQ-04EM9411EM9412P20480SSTP20478SST12 mmHexagonWrench DISASSEMBLY1.M/T:REMOVE CLUTCH COVER AND DISC 2.REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)3.REMOVE REAR END PLATE 4.INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 5.REMOVE TIMING BELT AND PULLEYS 6.REMOVE CYLINDER HEAD 7.REMOVE OIL DIPSTICK GUIDE AND GENERATOR ADJUSTING BAR 8.REMOVE WATER PUMP WITH WATER INLET PIPE 9.REMOVE GENERATOR BRACKET 10.REMOVE KNOCK SENSOR Using SST, remove the knock sensor.SST 09816-3001011.REMOVE RH ENGINE MOUNTING BRACKET 12.REMOVE OIL FILTER 13.REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch.SST 09816-3001014.REMOVE OIL PUMP AND PRESSURE REGULATOR VALVE 15.REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union.。

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丰田卡罗拉 1ZR-FE 发动机维修手册故障诊断手册2丰田卡罗拉 1ZR-FE 发动机维修手册故障诊断手册2第一章引言1.1 文档目的本手册旨在提供丰田卡罗拉1ZR-FE发动机的维修指导和故障诊断方法。

1.2 适用范围本手册适用于丰田卡罗拉车型搭载1ZR-FE发动机的维修和故障诊断。

第二章技术规范2.1 发动机信息在本章节中，提供1ZR-FE发动机的基本参数、技术规格和特征。

2.2 发动机构造本章节详细介绍1ZR-FE发动机的构造和主要组成部件，包括气缸、活塞、曲轴等。

2.3 燃油系统在本章节中，提供1ZR-FE发动机燃油系统的详细介绍和相应的维修步骤。

包括燃油喷射器、燃油泵等。

2.4 点火系统本章节介绍1ZR-FE发动机的点火系统构造和工作原理，以及维修和故障诊断方法。

2.5 冷却系统在本章节中，提供1ZR-FE发动机冷却系统的维修和故障诊断指导，包括水泵、散热器等。

第三章维修步骤3.1 维修准备工作本章节介绍进行发动机维修所需的准备工作，包括工具和安全注意事项。

3.2 维修步骤在本章节中，提供1ZR-FE发动机常见故障的维修步骤和维修注意事项，包括拆卸零件、更换部件等。

第四章故障诊断4.1 故障码读取本章节介绍如何读取1ZR-FE发动机的故障码，并提供相应的故障解释和修复建议。

4.2 常见故障诊断在本章节中，1ZR-FE发动机常见故障的症状、原因和诊断方法，以及相应的维修建议。

第五章附件本文档涉及的附件包括：- 1ZR-FE发动机技术规格表- 1ZR-FE发动机电气连接图附录A 法律名词及注释本文所涉及的法律名词及注释包括但不限于：- 汽车排放标准：指根据国家或地区的法律法规，对汽车尾气排放进行限制的标准。

- 污染控制设备：指用于降低或控制汽车尾气排放污染物的设备，如废气净化器等。

丰田车系5A-FE 直列四缸1.5L 16气门DOHC 威驰9、8 68/6000 124/32008A-FE 直列四缸1.3L 16气门DOHC 威驰9、3 64/6000 110/3200 丰田5A FE发动机目前国内天津一汽04年至05年1ZZ-FE 直列四缸1.8L 16气门DOHC、DIS(含铅汽油) 花冠9、5 94/6000 162/44003ZZ-FE 直列四缸1.6L 16气门DOHC、VVT-i、DIS(无铅汽油) 10、5 81/6000 146/44001NZ-FE 直列四缸1.5L 16气门DOHC、VVT-i、DIS(无铅汽油) 威驰花冠2NZ-FE 直列四缸1.3L 16气门DOHC、DIS(含铅汽油) 威驰花冠1MZ-FE V型6缸3.0L 24气门DOHC, 10、5 188/5200 203/4400 佳美94年后1AZ-FE 直列四缸2.0L 16气门DOHC、VVT-i、DIS、ETCS-I 凯美瑞、 RA V4 9、8 108/6000 190/60002AZ-FE 直列四缸2.4L 16气门DOHC、VVT-i、DIS、ETCS-I 凯美瑞大霸王 RA V4 9、8 123/6000 224/40002TR-FE 直列4缸 2.7L 双凸轮轴16气门(VVT-i) 霸道、海狮1GR-FE V型六缸4.0L 霸道、兰德酷路泽(第七代陆地巡洋舰)2GR-FE V型六缸3.5L 24气门DOHC、双VVT-i、DIS、ACIS、ETCS-i 新款凯美瑞10、8 204/6200 346/4700/3GR-FE V型六缸3.0L 24气门DOHC、双VVT-i、DIS 2005款皇冠、锐志10、5 170/6200 300/4400 5GR-FE V型六缸2.5L 24气门DOHC、双VVT-i、DIS 锐志10、0 145/6200 242/44001FZ-FE 直列六缸4.5L 陆地巡洋舰(第六代)2UZ-FE V型八缸4.7L 兰德酷路泽(第七代陆地巡洋舰)1NZ-FXE 1.5升4缸直列双凸轮轴16气门普锐斯1ZR-FE 1.6L DOHC 16气门Dual-VVT-I 卡罗拉10、2 92kW/6000 157/42002ZR-FE 1.8L DOHC 16气门Dual-VVT-I 卡罗拉10、0 98kW/6100 174/40002ZR-FAE 1.8L DOHC 16气门Dual-VVT-I Valvematic 卡罗拉10、0 110kW/6100 179/40003ZR-FE 2.0L DOHC 16气门Dual-VVT-I 10、0 105kW/5600 194/3900 Dual-VVT-I3ZR-FAE 2.0L DOHC 16气门Dual-VVT-I Valvematic 116kW/6200 195/4400 2007年4ZR-FE 1.6L 96、7kW Dual-VVT-i4Zr就是丰田08年最新研发的发动机,ZR系列就是丰田最新研究发动机之一。

丰田5A发动机与8A发动机区别简单认识这两款发动机机械结构基本一样：水冷式4冲程4缸16气门电喷式汽油机，闭环多点电控燃油喷射。

所不同的是排量：丰田5A排量：1498ml，丰田8A排量：1342ml。

动力输出方面，丰田5A排量比8A大，功率扭矩自然较高：丰田5A最大功率：68千瓦，最大扭矩：124Nm/3200rpm（3200转每分时达最大扭矩124牛顿米）丰田8A最大功率：63千瓦/6000转/分，最大扭矩：110牛顿米/5200转/分需说明的是，尽管数据差别不大，但5A出现最大扭矩的转速比8A低很多，表现出来就是低转下动力性比8A好，更符合国人驾驶习惯。

原来的8A和5A发动机，现在采用的是丰田公司的VVT-i发动机。

VVT-i 是一种智能正时可变气门控制系统，作为丰田公司的经典之作，是当今汽车界表较先进的发动机技术之一。

与其他类似技术相比，该系统可连续调节气门正时，实现充沛的扭矩，并且通过控制进气门开启时机，从而降低燃油消耗。

导入VVT-i 发动机后，威驰90km/h等速油耗，1.5L AT小于等于5.6L/100km，1.5L MT小于等于5.8L/100km，省油率达10％以上。

其另一优势是在实现低油耗的同时，创造了更加优异的动力性。

数据显示，威驰1.5L MT VVT-i发动机的扭矩达到130Nm/4400rpm，功率75kW/6000rpm，均优于原先的5A发动机。

（2SZ-FE & 3SZ-FE）新款威驰的VVT-i发动机是否适合04款以前的威驰使用？老的威驰用的丰田8A\5A的发动机，后来该款了，去年的威驰上就是SZ系列发动机了，老的8A被力帆拿去用了效果也不错。

今年即将上市的新款威驰用的乃是最新的丰田双VVT-I发动机，排放更环保更节油！你要是威驰换发动机肯定是车管部门不允许的，因为你的登记证和行驶证上都有车子的发动机号的，改变了绝对过不了年审！故---还不如新买一个！vvt-i可变气门正时系统VVT—i.系统是丰田公司的智能可变气门正时系统的英文缩写。

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