Руководство по обслуживанию двигателя Toyota (EN)

ENGINE SERVICE AND REPAIR Course 151 Technician Handbook © 2011 Toyota Motor Sales, U.S.A., Inc. All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc. Revision Date: May 31, 2011 TOYOTA Technical Training

Стр. 1

This page intentionally left blank.

Стр. 2

Table of Contents 151 Engine Service and Repair Engine Service Course Menu ........................................................................................ 3 Section 1: & Repair Internal Combustion Section 1 Topics ................................................................................... 5 Primary Engine Components ................................................................ 7 Other Engine Systems ...................................................................... 7 Cylinder Head Components .................................................................. 8 Cylinder Block Components .................................................................

9 The 4-Stroke Cycle ............................................................................. 10 Engine Operation Intake Stroke ................................................................................... 11 Compression Stroke ........................................................................12 Displacement .............................................................................. 13 Compression Ratio ..................................................................... 14 Ignition Timing ............................................................................ 15 Combustion (Power) Stroke ............................................................

16 Exhaust Stroke ............................................................................... 17 Engine and Block Designs .................................................................. 18 Inline ............................................................................................... 18 V-type ............................................................................................. 18 Horizontally Opposed ..................................................................... 18 Engine Position ................................................................................... 19 Cylinder Identification .........................................................................

19 Engine Serial Number ......................................................................... 20 Engine Decoder .................................................................................. 21 Section 2: Basic Engine Section 2 Topics ................................................................................. 23 Main Components ............................................................................... 24 Components Short Block vs. Long Block ............................................................. 24 Cylinder Block Major Components .....................................................

25 Cylinder Block Designs ....................................................................... 26 Pistons and Connecting Rods ............................................................ 27 Piston Rings ........................................................................................ 28 High vs. Low Tension Rings ........................................................... 28 Piston Ring Grooves ....................................................................... 29 Piston Ring Function ....................................................................... 30 Crankshaft ...........................................................................................

31 Oil Passages ................................................................................... 31 Counterweights ............................................................................... 31 Flywheel .......................................................................................... 31 Crank Pin Position .......................................................................... 32 Crankshaft Main Bearings .............................................................. 33 Balance Shafts .................................................................................... 34 Balance Shaft Timing ......................................................................

35 Cylinder Head ..................................................................................... 36 Valve Train .......................................................................................... 37 Technical Training i

Стр. 3

Table of Contents 151 Engine Service and Repair Camshaft ............................................................................................. 38 Camshaft Operation ........................................................................ 39 Valve Assemblies ................................................................................ 40 Mechanical Lifters and Valve Lash ................................................. 40 Hydraulic Valve Lash Adjuster ........................................................ 40 Timing Chain .......................................................................................

41 Interference Engines ....................................................................... 41 VVT-i ................................................................................................... 42 Timing Belt ...........................................................................................43 Section 3: Tools, Materials Section 3 Topics ................................................................................. 45 Shop Safety ........................................................................................ 46 Engine Lift ...........................................................................................

47 Parts Washers .................................................................................... 48 and Equipment Cylinder Head Cleaning .................................................................. 48 Cylinder Block Cleaning .................................................................. 48 Engine Sealing .....................................................................................49 Seal Installation .............................................................................. 50 FIPG ............................................................................................... 51 Sealing Packing Application ...........................................................

52 Dye Penetrant ..................................................................................... 53 Plastigage ........................................................................................... 54 Thread Cleaning ................................................................................. 55 Vernier Caliper .................................................................................... 56 Reading a Vernier Caliper .............................................................. 57 Micrometer ..........................................................................................

59 Reading a Micrometer .................................................................... 60 Micrometer with Vernier Scale ........................................................ 62 Digital Micrometer ........................................................................... 63 Inside Diameter Gauges ..................................................................... 64 Dial Indicator ....................................................................................... 65 Section 4: Section 4 Topics ................................................................................. 67 Engine Removal Precautions .............................................................

68 Parts Organization and Labeling ........................................................ 69 Fuel Pressure Discharge .................................................................... 70 Fluid Drain ........................................................................................... 71 Hood Removal .................................................................................... 72 Engine Hangers .................................................................................. 73 Engine Lifting ...................................................................................... 74 Engine Stand Mounting ......................................................................

75 Disassembly ........................................................................................ 76 Engine Removal and Disassembly ii Technical Training

Стр. 4