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My 1996 Toyota 3s-fe has no power! Please help.
Hi guys.
I am new to the board, having discovered it recently as I searched for tips on how to rectify a problem with a 1996 Toyota Corona Premio automatic with a 3S-FE 2litre motor (Model E-ST210AEPGK) ex-Japan. We are a group of mechanics who service vehicles for friends and acquaintances as we attempt to raise cash to establish our own fully equipped workshop. (Actually, i’m an accountant by profession, with a bigger interest in vehicle mechanicals)
We received the vehicle with a complaint of "mis-firing" and no power. On driving the vehicle, we noticed that idling engine speed was 500rpm, take-off was very sluggish with a tendency to stall under quick take-off. Once the vehicle was in motion, it would cruise relatively well up to about 100km/h. Gear change from Gear 1 to gear 2 would be very jerky, however the rest of the gear changes were relatively smooth. The car would not have guts/power for overtaking, and would not rev about 4200rpm.
When we received the vehicle, a cylinderhead overhaul had just been done (by other mechanics) due to engine overheating (overheating caused by lack of coolant due a faulty radiator cap). However, the vehicle still had the above-mentioned problems.
We did as follows:
1) Checked HT cables—we would have liked to replace them, but we cannot find replacements at the moment (we are in Harare, Zimbabwe).
2) Checked spark plugs-- replaced with new Bosch twin electrode. There was marginal improvement in performance.
3) We then proceeded to look at the cylinderhead. We saw that the intake valve clearances for cylinders 2 and 3 were too tight (below .24mm). We had the cylinderhead checked and valve clearances were corrected by cylinder head specialists. Valve clearances were redone to exactly .24mm (this was done after tightening camshaft). Camshaft timing was done properly as per marks (this has been checked over and over again), and the camshaft was tensioned. A new cylinderhead gasket was fitted.
After all this, there was a slight improvement in engine response but not enough to release the vehicle to the client. We then checked the fuel regulator and found that it was not operating at all and we replaced it. We checked the fuel pump and realised that it was not pumping optimally, and we replaced it (there was evidence of malicious tampering with fuel pumps)
The vehicle has improved but still not to our satisfaction. The vehicle now idles smoothly, and drives well but still has no guts and struggle to rev beyond 4500rpm. The gear change has also improved, with a smoother change from gear 1 to gear2. The vehicle produces a misfire when trying to do a quick take off. We have observed (using a timing light) that ignition timing is retarded by 15degrees ATDC.
My questions are:
-where did we go wrong? What could be causing this severe lack of power and inability to rev beyond 4500rpm?
-How do we adjust the ignition timing?
-Why would the ignition timing be so far out when we have done everything else correctly?
-Why was the gear change so jerky in the beginning, and why is it now so smooth yet we have not touched the gearbox at all? (This is a question from me, the accountant)
Your help and comments would be greatly appreciated.
Regards
Lemmyb
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