Hyundai 20G-7 Service Manual Download

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7-9

POWER CIRCUIT

HORN

CS-11

CS-12

GEAR SELECTOR

COMBI SWITCH

38SQ(B)

BATTERY

12V

MASTER SW

OPTION

START MOTOR

CN-45

B+

120

ALTERNATOR

CN-74

B+

4-FWD

5-REV

3-C

5-C

7-Lo

8-Hi

4-HO

1-TLH

2-TRH

9-C

6-ILL

3-HO

DUMMY

FUSE BOX

(CABIN)

CN-17

CN-1

R/COMBI RH

CL-16

R/COMBI LH

CL-15

BRAKE SW

CD-4

CN-25

200

390

380

38SQ(B)

38SQ(R)

120

SP2

120

SP1

120

CS-2

START KEY

120

4
3

4 BR

- ACC

1 R1

4 BR

- ACC

4 BR

- ACC

2 R2

- ST

B 3

START RELAY

TURN LAMP

10A

ILL/HEAD LAMP

15A

HORN/STOP LAMP

TRAVEL

-
CLUSTER

WORK/BEACON LAMP

FOR CABIN
OPSS

-A

10A

15A

10A

CLUSTER

9
10

CN-36

1
2

OPSS BUZZER

CN-113

200

CR-11

FLASHER UNIT

CN-57

212

1
2
3
4
5
6
7
8

FUEL GAUGE
-

EARTH(GAUGE)

E/G TEMP GAUGE

B+

ANTI-RESTART

CN-55

OPSS UNIT

200

IGN

SEAT S/W

REV S/W

FWD S/W

TRAVEL CUT

RELAY2

GND

OPS-LAMP
BUZZER(-)

BRAKE S/W

RELAY3
BATT(+)

PARK'G S/W

1
2
3
4
5
6
7
8
9

10
11
12
13
14

200

390

210

CN-4

CLUSTER

200
210

212

332

200

380

TO JEHIN
HARNESS

390

BI-FUEL SELECT

20L7EL03

Summary of Contents for 20G-7

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Page 4: ...https www facebook com groups ManualesDigitalesJC e mail manualesdigitalesjc gmail com Tlfs Whatsapp 58 424 858 47 28 ...

Page 5: ...okmarks to help quickly access each section of the manual Click on the Bookmarks tab located on the left and click on the plus sign to expand the desired section Alternatively click on the minus sign to contract a section Once a section is expanded you may click on a Section or Group to go directly to that page Another method of quickly accessing each page in the manual is going to the Table of Co...

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Page 7: ...ECTION 3 POWER TRAIN SYSTEM This section explains the structure of the transmission as well as control valve and drive axle SECTION 4 BRAKE SYSTEM This section explains the brake piping each component and operation SECTION 5 STEERING SYSTEM This section explains the structure of the steering unit priority valve trail axle as well as steering circuit and operation SECTION 6 HYDRAULIC SYSTEM This se...

Page 8: ...tion before you start any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item R...

Page 9: ...nt one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118 0 157 0 ...

Page 10: ...3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 9...

Page 11: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 ...

Page 12: ...0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2...

Page 13: ...280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 233...

Page 14: ...2 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 8...

Page 15: ... and Function 4 1 Group 2 Operational Checks and Troubleshooting 4 8 Group 3 Tests and Adjustments 4 10 SECTION 5 STEERING SYSTEM Group 1 Structure and Function 5 1 Group 2 Operational Checks and Troubleshooting 5 12 Group 3 Disassembly and Assembly 5 14 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function 6 1 Group 2 Operational Checks and Troubleshooting 6 19 Group 3 Disassembly and Assembl...

Page 16: ...SECTION 8 MAST Group 1 Structure 8 1 Group 2 Operational Checks and Troubleshooting 8 5 Group 3 Adjustment 8 8 Group 4 Removal and Installation 8 11 ...

Page 17: ...SECTION 1 GENERAL Group 1 Safety hints 1 1 Group 2 Specifications 1 5 Group 3 Periodic replacement 1 14 ...

Page 18: ...fighting equipment Wear well fitting helmet safety shoes and working clothes When drilling grinding or hammering always wear protective goggles Always do up safety clothes properly so that they do not catch on protruding parts of machines Do not wear oily clothes When checking always release battery plug Flames should never be used instead of lamps Never use a naked flame to check leaks or the lev...

Page 19: ...fighting equipment Wear well fitting helmet safety shoes and working clothes When drilling grinding or hammering always wear protective goggles Always do up safety clothes properly so that they do not catch on protruding parts of machines Do not wear oily clothes When checking always release battery plug Flames should never be used instead of lamps Never use a naked flame to check leaks or the lev...

Page 20: ...nce and fall Hand a caution sign in the operator s compartment For example Do not start or Maintenance in progress This will prevent anyone from starting or moving the machine by mistake It is extremely dangerous to try to check the fan belt tension while he engine is running When inspecting the engine is running parts or near such parts always stop the engine first Before checking or servicing ac...

Page 21: ... you have special instructions to the contrary maintenance should always be carried out with the engine stopped If maintenance is carried out with the engine running there must be two men present one sitting in the operator s seat and the other one performing the maintenance In such a case never touch any moving part Always remember that the hydraulic oil circuit is under pressure When feeding or ...

Page 22: ... signs of excessive metal particles or other foreign materials When removing parts containing O ring gaskets or seals clean the mounting surface and replace with new sealing parts After injecting grease always wipe off the oil grease that was forced out Do not handle electrical equipment while wearing wet places as this can cause electric shock During maintenance do not allow any unauthorized pers...

Page 23: ...rest 7 Carriage 8 Forks 9 Tilt cylinder 10 Front wheel 11 Bonnet 12 Rear wheel 13 Counterweight 14 Seat 15 LPG tank 16 Clamp 17 Overhead guard 18 Rear combination lamp 19 Turn signal lamp 20 Head lamp 21 Sub bonnet 11 12 2 6 5 1 7 9 8 10 19 18 17 16 15 14 13 3 4 20 21 25L7OM57 1 GENERAL LOCATIONS ...

Page 24: ...18 1700 1005 980 Capacity Load center Weight Unloaded Model Unit 20L 7 20G 7 25L 7 25G 7 30L 7 30G 7 Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load L W T Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 2000 500 3476 3300 155 610 580 450 500 1050 100 45 6 10 4485 2175 20 6 27 6 2252 2500 3766 610 550 24 2300 3000 ...

Page 25: ...15 2370 1110 905 910 Capacity Load center Weight Unloaded Model Unit 20LC 7 20GC 7 25LC 7 25GC 7 30LC 7 30GC 7 Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load L W T Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 2000 500 3413 3300 115 610 580 450 500 1050 100 45 6 10 4485 2135 18 6 30 9 2038 2500 3753 610 550 26 ...

Page 26: ...nder bore X stroke Piston displacement Compression ratio Rated gross horse power Maximum gross torque at rpm Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption Starting motor Alternator Battery Fan belt deflection Unit mm in cc cu in ps rpm kgf m rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HYUNDAI beta 4 cycle vertical Water cooled 4 cy...

Page 27: ...38 1 Front wheel drive type fixed location 6 5 1 Ring pinion gear type Single 2 2 Double 4 2 Single 7 0 12 12PR 21 7 15 Double 6 0 15 10PR Single 28 9 15 14PR 21 8 15 Double 6 0 15 10PR 6 0 9 10PR 16 6 10 1 2 6 5 10 12PR 16 6 10 1 2 Front wheel Wet disk brake Ratchet band brake type Hydro static power steering 79 to both right and left angle respectively Travel Parking Type Steering angle S STEERI...

Page 28: ... 5 58 8 5 40 10 18 2 215 33 2 5 0 5 6 2 8 9 17 4 18 1 3 6 50 10 50 10 29 3 6 54 452 69 420 61 289 72 130 14 1555 239 18 1 3 6 44 8 kgf m lbf ft Hydraulic system Power train system NO 1 2 3 4 5 6 7 8 9 10 11 12 Item Size Engine Others Engine mounting bolt nut Radiator mounting bolt nut Torque converter mounting bolt MCV mounting bolt nut Steering unit mounting bolt Transmission mounting bolt nut Dr...

Page 29: ...12 6 19 7 29 8 39 8 60 71 114 121 167 182 247 254 343 356 482 476 709 615 832 1223 1655 1808 2242 lbf ft 8T 10T F Fine thread 2 Bolt size M 8 1 0 M10 1 25 M12 1 25 M14 1 5 M16 1 5 M18 1 5 M20 1 5 M22 1 5 M24 2 0 M30 2 0 M36 3 0 kgf m 2 17 3 37 4 46 6 66 7 78 11 58 13 3 18 1 19 9 26 9 28 6 43 6 40 0 54 0 52 7 71 3 67 9 91 9 137 185 192 260 lbf ft 15 7 24 3 32 3 48 2 76 3 83 7 96 2 130 144 194 207 3...

Page 30: ...130 152 253 P PIPE AND HOSE ORFS TYPE Thread size 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16 12 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 152 253 2 2 3 FITTING Thread size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 152 253 4 4 ...

Page 31: ...Torque converter transmission Axle Hydraulic tank Fuel tank Fitting Grease nipple Brake reservoir tank Radiator Engine oil Hydraulic oil LPG Brake oil Grease Antifreeze Water 50 50 3 9 1 0 20 4 10 14 0 32 10 50 20 68 30 86 40 104 ATF Engine oil Gear oil 8 5 2 2 STD 24 5 6 5 OPT 30 8 0 0 5 0 13 17 4 5 ISO VG32 SAE 10W 30 API SL class or better ATF DEXRON III Mobil Fluid 424 LPG Azola ZS10 Hydraulic...

Page 32: ...s replace with new parts within the prescribed period of replacement Or earlier if trouble is found Note that periodic replacement has nothing to do with guarantee service Description Period of replacement Master cylinder and wheel cylinder caps dust seals Brake hose or tube Brake reservoir tank and tube Power steering hose Stop lamp switch Oil pressure type Fuel hose Rubber parts of power steerin...

Page 33: ...SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure 2 1 Group 2 Removal and Installation of Unit 2 2 ...

Page 34: ...r 5 Control valve 6 Fork 7 Front wheel 8 Drive axle 9 Hydraulic pump 10 Transmission 11 Torque converter 12 Engine 13 Air cleaner 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Tail pipe 19 Radiator 20 Muffler 21 LPG tank 22 Overhead guard 23 Seat 24 Control lever 25 Steering wheel 25L7OM23 ...

Page 35: ...wheel 8 Drive axle 9 Hydraulic pump 10 Transmission 11 Torque converter 12 Engine 13 Air cleaner 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Tail pipe 19 Radiator 20 Muffler 21 LPG tank 22 Overhead guard 23 Seat 24 Control lever 25 Steering wheel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25L7OM23 ...

Page 36: ...stall following units as explained in the flow chart Backrest Knob Carriage Center notch Fork Pin Spring Backrest If necessary Remove bolts securing backrest to fork carriage Lift backrest straight up and remove it from carriage 2 Backrest Bolt Carriage 20D7RE02 20D7RE03 C Carriage With the mast vertical raise the carriage high enough to place blocks under the load forks This is done to create sla...

Page 37: ... the front of the carriage Carriage Lift chain Mast Block 20D7RE06 Slowly raise inner mast upright until mast clears top of fork carriage Move carriage to work area and lower the mast Make sure that carriage remains on floor and does not bind while mast is being raised Inspect all parts for wear or damage Replace all worn or damaged parts Inner mast Carriage Lift chain 20D7RE07 ...

Page 38: ...t cylinder Loosen hexagonal bolts and remove washers securing the lift cylinders to inner mast Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding Make sure that the lift cylinder be tightened firmly for safety Loosen and remove hexagon nuts and clamp securing cylinder to outer mast Using an overhead hoist slowly raise the inner mast high enough to ...

Page 39: ...ast support cap Attach a crane to the stay at the top of the outer mast and raise enough to sustain jacked up machine This operation is carried out from under the machine so use a pit or if there is no pit jack up the machine and loosen with impact wrench Remove the mounting bolts from the cap then slowly raise the outer mast 7 8 Outer mast Tilt cylinder Pin Mounting bolt Mast support cap Bushing ...

Page 40: ... 0 04in INSTALLATION After assembling mast components totally without piping connections install mast assembly to the equipment Installation procedure for each of mast component is the reverse of the removal procedure Mast support cap Check the mast support cap and spring pin for wear Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle...

Page 41: ...2 7 Mast Refer to the chapter 1 MAST Page 2 2 1 2 POWER TRAIN ASSEMBLY REMOVAL 1 D503RE04 ...

Page 42: ...onnect the brake piping from the brake housing of drive axle 2 Brake pipe Brake valve Drive axle Parking brake cable Disconnect parking brake cable from the transmission 3 Transmission Parking brake cable 20D7RE12 20D7RE13 ...

Page 43: ...the hose 6 D Drive axle Attach a crane to the tilt cylinder notches on the dashboard and raise the machine Loosen hexagonal bolts 1 connection drive axle to the transmission Put the block under the drive axle and support under the drive axle with a truck Remove drive axle mount bolts 2 from the frame and then slowly pull out the truck with drive axle to the front Remove drive shaft assy from trans...

Page 44: ...rter Remove the cover on top face of the torque converter housing then remove the 8 mounting bolts installed on the engine flywheel To rotate the flywheel remove 1 mounting bolt then insert a turning tool in the mounting hole One man must turn the engine fan by hand while the other turns the flywheel 7 Using a moving truck slowly pull out transmission assembly to the front Frame Crane Truck 20D7RE...

Page 45: ... be careful of the following points Tightening torque Bolt 1 5 5 8 3kgf m 39 8 60lbf ft Bolt 2 2 7 4 1kgf m 19 5 29 7lbf ft Bolt 3 5 5 8 3kgf m 39 8 60lbf ft Bolt 4 53 72kgf m 383 521lbf ft Bolt 5 7 5kgf m 54 2lbf ft 1 2 2 2 Bolt 2 Bolt 3 Bolt 4 Bolt 1 Bolt 5 20L7RE21 ...

Page 46: ...nt axle inside the frame then remove the engine assembly REMOVAL Overhead guard Remove the wiring for rear combination lamp working lamp head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet 1 1 D503RE25 20L7RE22 ...

Page 47: ...ngine water temperature gauges Cables for meters buttons and accelerator pedal Hoses to fuel tank and air cleaner Exhaust pipe Radiator hose Open the drain valve of the radiator and drain the cooling water then remove the radiator hose 2 3 4 Engine Engine 20L7RE23 20L7RE24 Mounting bolt Attach a crane to the engine hook and raise then remove mounting bolts Raise the engine slightly slide towards t...

Page 48: ...everse order of removal but be careful of the following points Tighten the engine mounting bolts and nuts Tighten the engine mounting bracket bolts Do not remove the bolts unless necessary Loctite is coated over the threads of bolt So once the bolts were removed coat them with loctite 243 when installing Before installing the bolts loctite in the holes should be removed by a tap Tightening torque ...

Page 49: ...t with a crane Remove the mounting bolts raise slightly and move it slowly to rear side Weight of counterweight standard 1 1 20L7RE27 20L 7 20G 7 25L 7 25G 7 30L 7 30G 7 1100kg 2430lb 1390kg 3060lb 1740kg 3840lb 1030kg 2270lb 1370kg 3020lb 1750kg 3860lb 20LC 7 20GC 7 25LC 7 25GC 7 30LC 7 30GC 7 ...

Page 50: ...aring and oil seal 2 Mounting bolt Hub Hub nut Hub cap Tire assy 20L 25L 30L 7 20G 25G 30G 7 20LC 25LC 30LC 7 20GC 25GC 30GC 7 Rear wheel Castle nut Cap Taper roller bearing Oil seal Split pin 20L7RE28 Hose 3 20D7RE29 Mounting bolt Put a block under the steering axle support on a truck an raise the frame with a crane Remove the mounting bolts installing to the frame and pull out to the rear There ...

Page 51: ...SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation 3 1 Group 2 Troubleshooting 3 21 Group 3 Disassembly and Assembly 3 25 ...

Page 52: ...3 1 GROUP 1 STRUCTURE AND OPERATION SECTION 3 POWER TRAIN SYSTEM 20L7PT26 1 POWER TRAIN DIAGRAM STRUCTURE 1 Engine 2 Transmission 3 Drive shaft 4 Drive axle 5 Brake 1 ...

Page 53: ...3 1 GROUP 1 STRUCTURE AND OPERATION SECTION 3 POWER TRAIN SYSTEM 1 2 3 4 5 20L7PT26 1 POWER TRAIN DIAGRAM STRUCTURE 1 Engine 2 Transmission 3 Drive shaft 4 Drive axle 5 Brake 1 ...

Page 54: ...ift 1 1 Electrical single lever type kick down system 2 444 1 2 538 1 Front wheel drive type fixed location 6 5 1 Ring pinion gear type Single 2 2 Double 4 2 Single 7 0 12 12PR 21 7 15 Double 6 0 15 10PR Single 28 9 15 14PR 21 8 15 Double 6 0 15 10PR 6 0 9 10PR 16 6 10 1 2 6 5 10 12PR 16 6 10 1 2 Front wheel Wet disk brake Ratchet band brake type Hydro static power steering 79 to both right and le...

Page 55: ...3 9 Bolt 10 Torque converter housing cover 11 Temperature sensor 12 Inner oil strainer 13 Oil strainer spring 14 O ring 15 Oil strainer plug 16 Torque converter housing 1 Bolt 2 Plate 3 Flexible plate 4 Torque converter assembly 5 Bolt 6 O ring 7 Oil level gauge 8 Oil level gauge guide ...

Page 56: ... housing forms the oil path for the oil pump it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside 2 TORQUE CONVERTER HYDRAULIC CIRCUIT 3 Main relief valve B To control valve Gear pump Torque converter assy Inlet port Inlet pressure detector port Outlet port Outlet pressure detector port C F T P S G I To coole...

Page 57: ... 15 20D7PT28 1 Control valve 2 Torque converter 3 Turbine shaft 4 Impeller shaft 5 Stator 6 Forward clutch gear 7 Oil pump 8 Reverse clutch gear 9 Output gear 10 Temperature sensor 11 Oil input path 12 Parking drum 13 Forward clutch 14 Input shaft 15 Reverse clutch ...

Page 58: ...When the truck starts running or goes to the uphill a torque converter transmits a torque increased against engine torque to power transmission system of the transport When the truck runs at regular speed without increase speed high torque is not required and output torque is gradually reduced Since the engine and transmission are connected through the fluid return vibrations and shocks from the d...

Page 59: ...3 7 OPERATING MODES Forward INPUT OUTPUT 4 1 INPUT OUTPUT 20D7PT29 20D7PT30 Reverse 2 ...

Page 60: ...cated on the spacer side It is in charge of the function of clutching internal oil of the transmission through control valve and the function of sucking oil for oil supply of the torque converter and lubrication function of a clutch Oil pump choose gear pump supplies oil in control valve and torque converter through the oil path between a spacer and a transmission case The relief valve located on ...

Page 61: ...lter 2 Oil filter bolt 3 Bolt 4 Pipe 5 Washer 6 Control valve 7 Plug 8 Cam shaft 9 Parking brake connector Large 10 Parking brake connector Small 11 Band brake 12 Air breather 13 O ring 14 Nut 15 Parking brake control shaft 16 Bolt 17 Oil seal 1 18 Parking bracket 19 Bolt 20 Bolt 21 Snap ring 22 Parking lever 23 Oil seal 24 Parking return spring 25 Stoper pin ...

Page 62: ...he solenoid valve At this time the solenoid valve is in charge of the important function of transmitting oil pressure for forward and reverse through an electric signal by the forward and reverse selection lever of the truck Oil pressure chosen for forward or reverse by the solenoid valve is transmitted to the forward clutch through the formed oil path between transmission case or the reverse clut...

Page 63: ...cting port Reverse clutch pressure detecting port From cooler To cooler Change of direction function charge Inching function charge 20D7PT08 7 1 Stoper 2 O ring 3 Spring 4 Plug 5 Bolt 6 Spring 7 Piston 8 Plug 9 Plug 10 O ring 11 Spring 12 Nut 13 Stoper 14 Plug 15 Piston 16 Valve 17 Spring 18 Stoper 1 20 Plug 21 Washer 22 Nipple 23 Spring 24 Valve 25 O ring 26 Plate 27 Washer 28 Bolt 29 Valve 30 Sp...

Page 64: ...tput from the torque converter is adjusted below 7kgf cm2 100psi The oil in charge of increasing torque in the torque converter flows from the torque converter enters the radiator after refrigerated it is in charge of clutch lubrication through the lubrication oil path of the clutch shaft The pressure detecting valve and built in accumulator provide a soft plugging when changing gears The pressure...

Page 65: ... valve the flux flowed by the oil pump flows into forward clutch pack in 9 14 2kgf cm2 128 202psi of pressure through the oil path of transmission inside This oil make plugging of clutch pack by giving pressure at the piston of clutch pack At this time the drum gear of clutch pack is always revolving while connected with the turbine shaft of torque converter According to be plugging the clutch gea...

Page 66: ...5 Friction plate 6 Plate 7 Spacer 8 Seal ring 9 Snap ring 10 Needle bearing 11 Thrust needle bearing 12 Thrust washer 13 Spring 14 Snap ring 15 Seal ring 16 Spring cover 17 Taper roller bearing 18 Taper roller bearing 19 Needle bearing 20 Bush 21 Forward drum gear 22 Snap ring 23 Thrust washer 24 O ring 25 Parking drum 26 Snap ring 27 AV Seal 28 Side plate 29 Ring ...

Page 67: ...wed by the oil pump flows into the oil path of reverse shaft in 9 14 2kgf cm2 128 202psi of pressure through the oil path of transmission outside This oil make plugging of reverse clutch pack by giving pressure at the piston of clutch pack At this time the reverse drum gear is revolving against forward drum gear with engaging forward drum gear According as the clutch is plugging the reverse clutch...

Page 68: ...4 Piston ring 5 Friction plate 6 Plate 7 Spacer 8 Seal ring 9 Rivet 10 O ring 11 Snap ring 12 Needle bearing 13 Thrust needle bearing 14 Thrust washer 15 Clutch spring 16 Snap ring 17 Seal ring 18 Spring cover 19 Taper roller bearing 20 Taper roller bearing 21 Reverse drum gear 22 Snap ring 23 Thrust washer 24 O ring 25 AV Seal 26 Side plate ...

Page 69: ...ugging the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear If a driver selects reverse the reverse clutch gets plugging the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear 1 10 2 1 4 2 3 20D7PT14 1 Output gear 2 Taper roller bearing 3 Oil seal 4 Output gear cover Structure 2 ...

Page 70: ... Oil level gage 1 2 3 4 4 5 6 6 20D7PT16 STRUCTURE 2 The drive axle is connected with the transmission output gear and universal joint The power transferred by the universal joint is connected to the pinion shaft of drive axle the pinion shaft delivers the power to the differential device through the ring gear The power transferred to the differential gear is delivered to final drive through the a...

Page 71: ... connected with an axle shaft and a spline the power transferred to differential device is delivered to final drive through the axle shaft 1 3 17 17 2 25 5 25 17 16 4 7 6 15 3 23 19 20 21 22 8 9 10 18 23 1 12 14 11 13 23 24 20D7PT18 Structure 2 1 Carrier case 2 Spiral ring gear 3 Pinion shaft 4 Carrier cap 5 Differential device 6 Cap bolt 7 Washer 8 Shim 9 Shim 10 Shim 11 Universal joint flange 12...

Page 72: ...the power to the final drive If the load concerning in the left and right of the final drive is different the shock is transferred to the drive axle the differential gear in the differential device runs the power transferred to the differential device adjusts the delivering rate to the left and right axle shaft Consequently it guarantees for safety of drivers 1 4 3 4 9 5 7 4 3 2 1 8 6 20D7PT19 Str...

Page 73: ... malfunctioning Air sucked in Water intruding into transmission case Bearing worn or seizing Gauge malfunctioning Clutch dragging Bearing worn or seized Check oil level Add or drain oil as necessary After draining oil from oil tank and tra nsmission check and replace interfe ring parts Check engine stalling speed If necessary replace Check the inlet side joint or pipe If necessary retighten joint ...

Page 74: ... Check joints and pipes If necessary retighten joint or repla ce packing Check and replace Check oil pressure If necessary rep lace pump Check spring tension If necessary replace Disassemble check and repair or re place Disassemble check measure and re place Check stalling speed Increased engine load will cause ex cessive drop of stalling speed Check oil temperature rise If any replace free wheel ...

Page 75: ...defects and replace P Probable cause Remedy 5 Power is not transmitted 1 Torque converter 2 Transmission Clutch plate damaged Low oil level Oil pump driving system faulty Shaft broken Lack of oil pressure Low oil level Inching valve and link lever improper ly positioned Forward reverse spool and link lever improperly positioned Clutch fails to disengage 1 Clutch case piston ring defective 2 Main s...

Page 76: ...rack Disassemble and check for wear of seal lips and mating sliding surfaces pump boss coupling etc Replace oil seal pump boss coupl ing etc Check and retighten or replace pack ing Check and repair or replace gasket Check and retighten or gasket Check and replace cracked part Foreign matter intruding into oil pass age to clutch Shaft spline worn Disassemble check and repair or replace Disassemble ...

Page 77: ... 25 GROUP 3 DISASSEMBLY AND ASSEMBLY 1 TRANSMISSION DISASSEMBLY 1 Transmission assembly set 20D7TM001 20D7TM002 20D7TM003 20D7TM004 Disconnect torque converter Extract PTO shaft Remove control valve bolt ...

Page 78: ...3 26 Extract control valve 20D7TM005 20D7TM006 20D7TM007 20D7TM008 Extract oil filter Remove snap ring 20D7TM009 Remove parking lever ...

Page 79: ...3 27 Remove snap ring 20D7TM010 20D7TM011 20D7TM012 20D7TM013 Remove bolt Remove out wheel bolt Remove bolt on the back side of filter 20D7TM014 Remove bolt ...

Page 80: ...3 28 Connect disassembly bolt 20D7TM015 20D7TM016 20D7TM017 20D7TM018 Disassemble torque converter housing Disassemble spacer After disassemble 20D7TM019 Disassemble output gear assembly set ...

Page 81: ...3 29 Disassemble connection 20D7TM020 20D7TM021 20D7TM022 20D7TM023 Extract band brake Disassemble forward clutch gear Disassemble reverse clutch gear 20D7TM024 After disassemble ...

Page 82: ...sembly 2 Before assemble taper plug spread loctite 577 Assemble the upper part taper plug of hydraulic pipe 20D7TM025 20D7TM026 20D7TM027 20D7TM028 Assemble installation part taper plug of control valve Assemble space installation part Assemble the left taper plug 1 ...

Page 83: ... seal Spread loctite 592 on the out wheel of oil seal Spread grease on inside wheel of oil seal 20D7TM030 20D7TM031 Pressurize oil seal A Assembly of filter assembly bolt Spread sealant on oil seal Spread loctite 277 on filter assembly bolt 20D7TM032 20D7TM033 Confirm assembly and torque Tightening torque 3 5 4 5 kgf m 25 33 lbf ft ...

Page 84: ... bearing out wheel R part Installation part of reverse clutch gear 20D7TM034 20D7TM035 20D7TM036 20D7TM037 Pressurize O part of bearing out wheel O part Installation part of output gear assembly Pressurize F part of bearing out wheel F part Installation part of forward clutch gear Assemble adjustment shaft 2 ...

Page 85: ...ng make sure whether or not it is close Spread grease in taper roller bearing A Assembly of forward reverse clutch pack Confirm seal ring of reverse clutch Spread grease on seal ring of clutch pack 20D7TM040 20D7TM041 Spread oil on seal ring of reverse clutch 20D7TM042 Assemble reverse clutch at transmission ...

Page 86: ... forward clutch 20D7TM044 20D7TM045 Assemble forward clutch at transmission After finishing assembly make sure whether or not revolution of forward reverse clutch pack is good A Assembly of parking brake system Fix small connection in PBB 20D7TM046 20D7TM047 Set in parking drum ...

Page 87: ...0D7TM049 Spread grease on cam shaft Fix large connection in cam shaft Fit large connection in PBB 20D7TM050 20D7TM051 Assemble an eccentric shaft in PBB A Assembly of output gear assembly Assembly output gear 20D7TM052 ...

Page 88: ...ly Assembly of oil pump Assemble O ring of charging pump Spread grease at O ring surface 20D7TM054 20D7TM055 20D7TM056 20D7TM057 Spread sealant on charging pump Spread loctite 5127 at stator shaft lower in oil pump Spread sealant on the whole surface Fix charging pump in spacer 3 ...

Page 89: ...y and torque Tightening torque 3 5 4 0 kgf m 25 29 lbf ft A Assembly of inlet and outlet of pressure adjustment valve in torque converter and pressure checking port Fix steel ball in spacer 20D7TM060 20D7TM061 Fix spring 20D7TM062 Spread sealant on plug and O ring Spread loctite 277 at plug and bolt ...

Page 90: ... 25 33 lbf ft A Assembly of bearing cup After measuring the transmission case spacer and each clutch pack and estimating a proper amount of shim Insert a proper amount of shim before assembling bearing cup Make sure whether or not it is close with the lower of bearing cup Pressurize F part of bearing out wheel 20D7TM066 20D7TM067 Pressurize R part of bearing out wheel ...

Page 91: ...g sub assembly Assembly of temperature sensor and O ring Spread loctite 577 on temperature sensor 20D7TM069 20D7TM070 20D7TM071 20D7TM072 Confirm assembly and torque Tightening torque 3 0 4 0 kgf m 22 29 lbf ft Assemble O ring and spread grease Fix spring in strainer 4 Oil strainer assembly ...

Page 92: ...torque converter housing Temporarily assemble plug 20D7TM075 Confirm torque Tightening torque 8 10 kgf m 58 72 lbf ft A Assembly of sub assembly Assembly of transmission case and spacer sub assembly Spread oil 20D7TM076 20D7TM077 Fix O ring 5 ...

Page 93: ...M078 20D7TM079 Spread loctite 5127 on transmission case Pressurize lock pin Assemble space 20D7TM080 20D7TM081 Confirm gear revolution condition T Torque converter assembly Spread loctite 5127 on space 20D7TM082 ...

Page 94: ...n to tear O ring of torque converter and oil pump 20D7TM084 Fit torque converter housing in space 20D7TM085 Spread loctite 277 on bolt Temporarily assemble bolt 20D7TM086 20D7TM087 Confirm torque Tightening torque 5 5 6 5 kgf m 40 47 lbf ft ...

Page 95: ...tening of transmission case bolt Revolve 90 20D7TM088 20D7TM089 Spread sealant on socket bolt 6 20D7TM090 Temporarily assemble at transmission case 20D7TM091 Confirm torque Spread sealant on hexagon bolt Spread loctite 277 on bolt 20D7TM092 ...

Page 96: ... kgf m 40 47 lbf ft O Oil filter assembly Temporarily assemble filter 20D7TM094 20D7TM095 Confirm fastening Tightening torque 0 8 1 2 kgf m 5 8 8 7 lbf ft P Parking brake part assembly Assemble snap ring 20D7TM096 20D7TM097 Spread loctite 277 on support pin ...

Page 97: ...98 Temporarily assemble support pin 20D7TM099 Confirm torque Tightening torque 2 0 3 0 kgf m 14 22 lbf ft Fix parking lever 20D7TM100 Assemble snap ring 20D7TM101 20D7TM102 Fix spring and spread loctite 277 on bolt ...

Page 98: ...usting parking brake Spread loctite 592 Adjustment shaft Nut Position eccentric shaft as figure Pipe offering oil path of reverse clutch assembly Prepare reverse pipe 20D7TM105 Tighten the adjustment shaft and loosen the shaft a 3 4 revolution Tightening torque 0 65kgf m 4 7lbf ft Tighten the nut Tightening torque 3kgf m 221lbf ft 20D7PT33 ...

Page 99: ...emporarily assemble oil pressure pipe and seal washer at the same time 20D7TM108 Spread sealant on nipple plug Temporarily assemble oil pressure pipe and seal washer at the same time 20D7TM109 Confirm torque Tightening torque 3 5 4 0 kgf m 25 29 lbf ft 20D7TM110 ...

Page 100: ...92 on the out wheel of oil seal 20D7TM111 20D7TM112 Pressurize oil seal 20D7TM113 Spread grease on inside wheel of oil seal Control valve assembly As assembling use guide pin at two spot Fix guide pin 20D7TM114 20D7TM115 Assemble control valve assembly ...

Page 101: ...rque 3 4 kgf m 22 29 lbf ft A Air breather and oil level gauge guide pipe assembly Air breather Assemble air breather Spread loctite 577 on air breather 20D7TM117 20D7TM118 Spread sealant on oil level gauge guide Spread loctite 608 on pipe 20D7TM119 Pressurize guide ...

Page 102: ...3 50 2 DRIVE AXLE DISASSEMBLY 1 Drive axle 20D7AXLE001 20D7AXLE002 20D7AXLE003 20D7AXLE004 Remove the bolt of axle shaft Extract the left axle shaft Extract the right axle shaft ...

Page 103: ...3 51 Remove the bolt of plate nut 20D7AXLE005 20D7AXLE006 20D7AXLE007 20D7AXLE008 Extract the nut Extract the plate Extract the hub bearing 20D7AXLE009 Extract the hub ...

Page 104: ...2 Remove the bolt of flange shaft 20D7AXLE010 20D7AXLE011 20D7AXLE012 20D7AXLE013 Extract the flange shaft Disassemble the piston brake Disassemble the carrier assembly 20D7AXLE014 Fix the carrier assembly ...

Page 105: ... carrier cap 20D7AXLE015 20D7AXLE016 20D7AXLE017 20D7AXLE018 Extract the carrier cap Remove the left adjusting cap of bearing cup Remove the right adjusting cap of bearing cup 20D7AXLE019 Disassemble the differential assembly ...

Page 106: ...rrier ASSEMBLY Assembly of carrier assembly Differential device assembly 2 1 Assemble spider and the differential pinion 20D7AXLE021 20D7AXLE022 20D7AXLE023 Assemble the washer and the differential gear Assemble the spider and the differential ...

Page 107: ...her and the differential gear Assemble the differential case 20D7AXLE025 20D7AXLE026 20D7AXLE027 20D7AXLE028 Fix the bolt Confirm the differential gear backlash Adjust backlash of differential gear within 0 015mm Assemble the ring gear ...

Page 108: ... 2 Fix the carrier case 20D7AXLE030 20D7AXLE031 20D7AXLE032 Measure a gap A for deciding an amount of shim with feeler gauge Determine shim X X A Mounting distance MD of pinion gear Ex 1 A 0 5 MD value 0 2 X 0 5 0 2 0 7mm Ex 2 A 0 5 MD value 0 2 X 0 5 0 2 0 3mm Select the shim and assemble 20D7AXLE033 Pressurize the bearing cup ...

Page 109: ...3 57 Pressurize the bearing cone into the pinion shaft 20D7AXLE034 20D7AXLE035 20D7AXLE036 20D7AXLE037 Fix the pinion shaft Set the ball Fix the fixing jig 20D7AXLE038 Fix the ball ...

Page 110: ...3 58 Revolve the carrier case in 180 20D7AXLE039 20D7AXLE040 20D7AXLE041 20D7AXLE042 Fix the spacer Shim measuring gauge 1 insert Shim measuring gauge 2 insert 20D7AXLE043 Put the shim measuring block ...

Page 111: ...mine shim X X B End play 0 03 0 06 Ex 1 B 0 5 X 0 5 0 03 0 06 0 47 0 44mm 20D7AXLE044 20D7AXLE045 20D7AXLE046 20D7AXLE047 Remove the pinion shaft Assemble the bearing cup Assemble and fit the pinion 20D7AXLE048 Assemble the shim ...

Page 112: ...mbly of carrier sub assembly Pressurize the oil seal 20D7AXLE050 20D7AXLE051 20D7AXLE052 Fix the U joint flange Assemble U joint flange in preload 0 01 0 19 kgf m Fix the O ring 20D7AXLE053 Temporarily assemble the nut Spread loctite 242 on nut ...

Page 113: ...ening torque 16 2 19 1 kgf m 117 138 lbf ft 20D7AXLE054 20D7AXLE055 Calking 40 20D7PT34 20D7AXLE057 Confirm the preload Perform the calking Assemble the differential sub in case Paint marking Both sides 20D7PT35 Fix the steel ball ...

Page 114: ... 20D7AXLE059 20D7AXLE060 Fasten the torque Spread loctite 277 on bolt Tightening torque 26 8 32 kgf m 194 231 lbf ft A Adjust backlash Assemble the RING BRG ADJUST 20D7AXLE062 20D7AXLE063 Adjust the RING BRG ADJUST 20D7AXLE064 Measure backlash ...

Page 115: ...f backlash is wrong carry out adjusting work Adjust the left right of RING BRG ADJUST by one and one clip Fit position Assemble cotter pin 60 4 0 7 5 4 0 7 5 60 40 40 Heel Toe Toe Heel Drive side Forward Coast side Reverse 20D7PT37 After assembling adjust pattern of the gear and pinion shaft as figure If pattern is not adjusted take a measure as measuring backlash again and then reassemble ...

Page 116: ... 20D7AXLE071 Spread sealant on the installation surface of carrier Fix assembly guide bar 20D7AXLE072 Fit carrier at drive axle housing Spread loctite 5127 on drive axle housing Spread loctite 277 on the spring washer bolt 20D7AXLE073 A Assembly of carrier assembly ...

Page 117: ...f m 43 51 lbf ft Fix large quad ring into brake 20D7AXLE075 20D7AXLE076 20D7AXLE077 Fix small quad ring into brake When assembling quad ring pay attent to chopping Spread oil on the piston 20D7AXLE078 Fix piston into drive axle housing T TRAVELING BRAKE SYSTEM ASSEMBLY Piston assembly 2 ...

Page 118: ...0 20D7AXLE081 20D7AXLE082 Assemble close to drive axle housing Pressurize lock pin Measure projection degree of piston Manage projection degree of piston in 0 6 0 9mm Pressurize oil seal into flange 20D7AXLE083 F Friction plate and plate assembly ...

Page 119: ...20D7AXLE085 Assemble snap ring at socket Fix socket gear into flange shaft 20D7AXLE086 Fix plate into socket gear Fix friction plate into socket gear 20D7AXLE087 20D7AXLE088 Fix friction plate and confirm the direction ...

Page 120: ... socket Measure stepped pulley between flange and plate and record Manage stepped pulley of flange 0 6 0 9mm Select flange shaft 20D7AXLE091 20D7AXLE092 20D7AXLE093 Spread loctite 5127 Spread on the whole surface of flange shaft F Flange shaft assembly ...

Page 121: ...axle housing Spread loctite 242 on bolt 20D7AXLE095 20D7AXLE096 Fasten bolt Tightening torque 9 11 5 kgf m 65 83 lbf ft Pressurize bolt 20D7AXLE097 20D7AXLE098 Put a bearing cup on the upper and lower of hub H Hub assembly Hub sub assembly 3 ...

Page 122: ...0D7AXLE099 Pressurize bearing cup 20D7AXLE100 Spread grease on the bearing of flange Fix bearing into hub 20D7AXLE101 20D7AXLE102 Spread grease in the oil seal 20D7AXLE103 Spread sealant on the outside of oil ...

Page 123: ... Fix bearing into hub 20D7AXLE106 20D7AXLE107 Spread grease on hub 20D7AXLE104 Pressurize oil seal 20D7AXLE105 Spread grease on the bearing of axle Spread grease on the flange shaft 20D7AXLE108 Hub assembly ...

Page 124: ...3 72 20D7AXLE109 20D7AXLE110 Fix hub Fix plate 20D7AXLE111 Fix nut Fasten torque and loosen Tightening torque 21 25 kgf m 152 181 lbf ft 20D7AXLE112 20D7AXLE113 Adjust preload 0 6 0 8 kgf m ...

Page 125: ...position of plate nut and hole 20D7AXLE115 Spread loctite 277 20D7AXLE116 Confirm torque Tightening torque 0 8 1 2 kgf m 5 8 11 lbf ft Spread loctite 5127 on axle shaft 20D7AXLE117 20D7AXLE118 Fix into hub A Axle shaft assembly ...

Page 126: ...Tightening torque 6 7 kgf m 43 51 lbf ft Fasten torque 20D7AXLE121 Assemble the air breather into LH 20D7AXLE122 20D7AXLE123 Assemble the air breather into RH Spread loctite 577 on the air breather Tightening torque LH RH 1 5 2 kgf m 11 14 lbf ft T The rest part assembly ...

Page 127: ...3 75 20D7AXLE124 Assemble hanger bolt 20D7AXLE125 Fix dipstick Loctite 577 Assemble the magnetic plug Spread loctite 577 on plug 20D7PT36 ...

Page 128: ...SECTION 4 BRAKE SYSTEM Group 1 Structure and function 4 1 Group 2 Operational checks and troubleshooting 4 8 Group 3 Tests and adjustments 4 10 ...

Page 129: ...ction plate and a plate So when the transportation travels it is possible to brake The parking brake works by the hand brake installed on parking drum which is linked to the output shaft of the forward clutch 4 1 GROUP 1 STRUCTURE AND FUNCTION SECTION 4 BRAKE SYSTEM 1 OUTLINE 1 2 Item Type Parking lever stroke Cable stroke Ratchet internal expanding mechanical type 12 1 11 5mm Specification Item T...

Page 130: ...ction plate and a plate So when the transportation travels it is possible to brake The parking brake works by the hand brake installed on parking drum which is linked to the output shaft of the forward clutch 4 1 GROUP 1 STRUCTURE AND FUNCTION SECTION 4 BRAKE SYSTEM 1 OUTLINE 1 2 Item Type Parking lever stroke Cable stroke Ratchet internal expanding mechanical type 12 1 11 5mm Specification Item T...

Page 131: ...4 2 3 BRAKE PEDAL AND PIPING STRUCTURE Drive axle 1 2 3 4 Transmission T M control valve 20D7BS01 1 Brake pedal 2 Parking lever assembly 3 Reservoir tank assembly 4 Brake master cylinder 1 ...

Page 132: ...e the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force By treading the pedal further the brake is applied 4 INCHING PEDAL AND LINKAGE 160mm Floor plate 342 5 5mm Control valve 33mm 1 3in Inching spool T M Idle stroke 1 3mm 20L7BS02 ...

Page 133: ...structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area Because it is possible to use the brake semi permanently there is no need to replace or change the lining as drum type brake do Major components are 6 plates 5 5 friction plates 6 piston brake 4 and brake housing Braking force is applied by restricting the drivie force from drive shaft and ...

Page 134: ...ousing 3 Push rod 4 Bellows 5 Master piston 6 Lock washer 7 Piston ball 8 Piston ring 9 Servo piston 10 Servo spring 11 Seal 12 Seal 13 Seal 14 Seal 15 Relief piston 16 Shim 17 Relief spring 18 Relief plug 19 O ring 20 O ring 21 Check ball 22 O ring 23 Check spring 24 Cage 25 Air bent 26 Check plug 27 O ring 28 Bolt 1 20D7BS03 ...

Page 135: ...o spring 10 servo piston 9 and master piston 5 2 1 5 9 10 2 20D7BS05 Remove relief plug 18 with O ring 19 relief spring 17 shim 16 and relief piston 15 3 Front housing 15 16 17 18 19 20D7BS06 Remove O ring 20 check plug 26 with O ring 27 cage 24 check spring 23 check ball 21 and O ring 22 4 Rear housing 27 26 24 22 23 21 20 20D7BS07 ...

Page 136: ...her with mineral or with hydraulic oil according to their use destination All single parts are to be checked for damage and replaced if required Assembly is in opposite order to disassembly Seal kit XKAU 00176 Use only brake fluid Azola ZS10 into the compensation reservoirs 1 2 3 4 3 ...

Page 137: ...at low speed and check braking effect of parking brake B BRAKE PIPING Check pipes hoses and joints for damage oil leakage or interference Operate brake pedal and check operating force when pedal in depressed Check also change in operating force and change in position of pedal when pedal is kept depressed GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1 OPERATIONAL CHECKS 1 1 2 2 1 2 2 1 D35AtA19 ...

Page 138: ... Brake valve return port clogged Hydraulic system clogged Wheel bearing out of adjustment Adjust Replace Clean Clean Adjust or replace 2 2 TROUBLESHOOTING Brake chirps Brake trailing Piston fails to return Disk worn Disk surface roughened See above Brake trailing Replace Replace Repair by polishing or replace Brake squeaks Disk surface roughened Disk worn Excessively large friction between disk pl...

Page 139: ...a vessel filled with hydraulic oil Loosen air vent plug by turning it 3 4 with a wrench Depress brake pedal to drain oil mixed with air bubbles from plug hole Depress brake pedal until no air bubbles come out of air vent plug hole After completion of air bleeding securely tighten air vent plug Install cap on plug 1 2 3 4 5 6 7 Air vent plug Vessel Vinyl tube 20D7BS09 2 ADJUSTMENT OF PEDAL BRAKE PE...

Page 140: ...ng stroke 0mm 20L7BS11 Lever stroke 12 1 o Rachet Parking cable Micro switch Nut 20D7BS08 Micro switch for parking brake if equipped After assembling parking brake and parking cable put the parking brake lever released Loosen the nut for parking brake plate to play up and down Move up the plate so that the stopper can be contacted with the pin and then reassemble nut Micro switch stroke when parki...

Page 141: ...SECTION 5 STEERING SYSTEM Group 1 Structure and Function 5 1 Group 2 Operational Checks and Troubleshooting 5 12 Group 3 Disassembly and Assembly 5 14 ...

Page 142: ... unit through the steering column The required oil flow is sensed by the function of the control section of the unit and pressurized oil delivered from the hydraulic pump is fed to the steering cylinder The force produced by the steering cylinder moves the knuckle of steering tires through the intermediate link The axle body is unit structure having steering knuckles installed to its both ends by ...

Page 143: ...ering force given to the steering wheel enters the steering unit through the steering column The required oil flow is sensed by the function of the control section of the unit and pressurized oil delivered from the hydraulic pump is fed to the steering cylinder The force produced by the steering cylinder moves the knuckle of steering tires through the intermediate link The axle body is unit struct...

Page 144: ...5 2 2 HYDRAULIC CIRCUIT 3 T LS L R P 4 7 10 MCV EF CF LS T M 9 0MPa 8 1 20L7SS02 1 Gear pump with priority valve 3 Steering unit 4 Steering cylinder 7 Suction strainer 8 Return filter 10 Hydraulic tank ...

Page 145: ...3 NEUTRAL 1 The steering wheel is not being operated so control spool G does not move The oil from hydraulic gear pump 1 moves the priority valve spool D to the left Oil flow into LS port to the hydraulic tank 10 So the pump flow is routed to the main control valve ...

Page 146: ... direction At this time the oil discharged from the pump flows into the spool G within the steering unit 3 through the spool D of priority valve in gear pump 1 and flows to the gerotor H Oil flow from the gerotor H flows back into the spool G where it is directed out of the left work port L Oil returned from cylinder returns to hydraulic tank 10 When the above operation is completed the machine tu...

Page 147: ... direction At this time the oil discharged from the pump flows into the spool G within the steering unit 3 through the spool D of priority valve in gear pump 1 and flows to the gerotor H Oil flow from the gerotor H flows back into the spool G where it is directed out of the right work port R Oil returned from cylinder returns to hydraulic tank 10 When the above operation is completed the machine t...

Page 148: ...Retaining ring 3 Cap seal 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Center spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive 17 End cap 18 Gland bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 25 P port check valve 25 1 Plug 25 2 Poppet 25 3 Spring seat 25 4 Spring ...

Page 149: ...run by oil pressure and the sleeve is caused to run through the drive shaft and cross pin Therefore when the spool is turned the spool turns by the same value in such a manner that it follows the motion of the spool Steering motion can be accomplished when this operation is performed in a continuous state If the hoses of the steering system are incorrectly connected the steering wheel can turn ver...

Page 150: ... nipple 11 Oil seal 12 Taper roller bearing 13 Split pin 14 Nut 15 Washer 16 Plate 17 Hub 18 Hub bolt 19 Hub nut 20 Hub cap 21 Steering link 22 Steering cylinder 23 SPH plain bearing 24 Steer link pin 25 Plain washer 26 Grease nipple 27 Lock plate 28 Bolt 29 Hex nut 30 Hex bolt 31 Trunnion block 32 Bushing 33 Thrust washer 34 Pin 35 Spring washer 36 Hardened washer 37 Upper cover 38 Lower cover 39...

Page 151: ...r bearing 7 Plain washer 8 Split pin 9 Castle nut 10 Hub cap 11 Oil seal 12 Grease nipple 13 Retaining ring 14 King pin washer 15 Needle bearing 16 Thrust bearing 17 Shim 0 13t 18 Shim 0 25t 19 Clevis pin 20 Thrust washer 21 Bearing 22 Plain washer 23 Split pin 24 Clevis pin 25 Special bolt 26 Spring washer 27 Hex bolt 28 Hex nut 29 Lock plate 30 Hex bolt 31 Steering cylinder 32 Link 33 Grease nip...

Page 152: ... 5 66 5 kgf m 358 481 lbf ft 2 20D7SS08 20L 25L 30L 7 20G 25G 30G 7 1 Type Structure of knuckle Toe in Camber Caster King pin angle Max steering angle of wheels Inside Outside Tread Unit degree degree degree degree degree mm in Elliott type 0 0 0 0 78 9 56 6 980 38 6 Center pin support single shaft ...

Page 153: ... 481 lbf ft 20L7SS08 20LC 25LC 30LC 7 20GC 25GC 30GC 7 2 Type Structure of knuckle Toe in Camber Caster King pin angle Max steering angle of wheels Inside Outside Tread Unit degree degree degree degree degree mm in Elliott type 0 0 0 0 72 7 50 1 910 35 8 Center pin support single shaft ...

Page 154: ...n 0 0 5 rear axle is bent Ask assistant to drive machine at minimum turning radius Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius If minimum turning radius is not within 100mm 4in of specified value adjust turning angle stopper bolt Min turning radius Outside 20L 7 20G 7 25L 7 25G 7 30L 7 30G 7 2252mm 89in 2300mm 91in 2393mm 94in 2 2 TROUBLESHOOTING Pr...

Page 155: ... Insufficient or variable oil flow Flow control valve orifice clogged Clean Insufficient or variable dischar ge pressure Piping Pipe from tank to pipe dented or clogged Repair or replace Steering cylinder head leakage Piston rod Packing foreign material Piston rod damage Rod seal damage and distortion Chrome gilding damage Replace Grind surface with oil stone Replace Grind Steering cylinder head t...

Page 156: ...06 1 Dust seal 2 Retaining ring 3 Cap seal 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Center spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive 17 End cap 18 Gland bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 25 P port check valve 25 1 Plug 25 2 Poppet 25 3 Spring seat 25 4 Spring ...

Page 157: ...TOOLS Holding tool 5 15 2 1 Assembly tool for O ring and kin ring 2 Assembly tool for lip seal 3 Assembly tool for cardan shaft 4 5 69 1 5 69 2 5 69 3 5 69 4 ...

Page 158: ...crewdriver 2mm screwdriver 13mm ring spanner 6 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 6 5 70 1 5 70 2 D353SE23 TIGHTENING TORQUE L Left port R Right port T Tank P Pump 3 Port L R T P Mounting bolt Size 3 4 UNF 16 3 4 UNF 16 3 4 UNF 16 3 4 UNF 16 M10 1 5 Torque kgf m lbf ft 13 94 13 94 13 94 13 94 5 0 1 0 36 7 2 ...

Page 159: ...the steering unit in the holding tool Screw out the screws in the end cover 6 off plus one special screw 4 1 Remove the end cover sideways 2 Lift the gearwheel set With spacer if fitted off the unit Take out the two O rings 3 Remove cardan shaft 4 5 72 1 5 72 2 5 72 3 5 72 4 ...

Page 160: ...emove O ring 7 5 73 1 5 73 2 5 73 3 Take care to keep the cross pin in the sleeve and spool horizontal The pin can be seen through the open end of the spool Press the spool inwards and the sleeve ring bearing races and thrust bearing will be pushed out of the housing together 8 5 73 4 ...

Page 161: ...Use the special screw from the end cover 10 A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the neutral position springs See drawing If the mark is not visible remember to leave a mark of your own on sleeve and spool before the neutral position springs are disassembled 5 74 1 5 74 2 5 74 3 Carefully press the spool out of the sleeve 11 5 74 4 ...

Page 162: ...in the spool 12 Remove dust seal and O ring 13 Disassembling the pressure relief valve Screw out the plug using an 8mm hexagon socket spanner Remove seal washers 14 5 75 1 5 75 2 D353SE10 Unscrew the setting screw using an 8mm hexagon socket spanner 15 D353SE11 ...

Page 163: ...5 21 Shake out spring and piston The valve seat is bonded into the housing and cannot be removed 16 The pressure relief valve is now disassem bled 17 D353SE12 D353SE13 ...

Page 164: ...h spring slots Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool 5 1 Place the two flat neutral position springs in the slot Place the curved springs between the flat ones and press them into place see assembly pattern 2 Line up the spring set 3 5 76 1 5 76 2 5 76 4 Guide the spool into the sleeve Make sure that spool ...

Page 165: ...utral position springs into place in the sleeve 5 Line up the springs and center them 6 Guide the ring down over the sleeve The ring should be able to rotate free of the springs 7 5 77 2 5 77 3 5 77 4 Fit the cross pin into the spool sleeve 8 5 78 1 ...

Page 166: ...ttern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve Installation instruction for O ring Turn the steering unit until the bore is horizontal Guide the outer part of the assembly tool into the bore for the spool sleeve 10 5 78 2 5 78 3 5 78 4 ...

Page 167: ...them on the tool 11 Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom 12 Press and turn the O ring into position in the housing 13 5 79 1 5 79 2 5 79 3 5 79 4 ...

Page 168: ...l with hydraulic oil and place it on the assembly tool 15 Guide the assembly tool right to the bottom 16 Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the inner part in the bore 14 5 80 1 5 80 2 5 80 3 5 80 4 ...

Page 169: ...nit until the bore is vertical again Put the check valve ball into the hole indicated by the arrow 20 Press and turn the lip seal into place in the housing 17 With a light turning movement guide the spool and sleeve into the bore Fit the spool set holding the cross pin horizontal 18 5 81 1 5 81 2 5 81 3 5 81 4 ...

Page 170: ... shaft down into the bore so that the slot is parallel with the connection flange 24 Screw the threaded bush lightly into the check valve bore The top of the bush must lie just below the surface of the housing 21 Grease the O ring with mineral oil approx viscosity 500 cSt at 20C 22 5 82 1 5 82 2 5 82 3 5 82 4 ...

Page 171: ... the seven through holes match the holes in the housing 27 Fit the spacer if any 28 Place the cardan shaft as shown so that it is held in position by the mounting fork 25 Grease the two O rings with mineral oil approx viscosity 500 cSt at 20 C and place them in the two grooves in the gear rim Fit the gearwheel and rim on the cardan shaft 26 5 83 1 5 83 2 5 83 3 5 83 4 ...

Page 172: ...ghten all the screws and the rolled pin Tightening torque 3 0 0 6kgf m 21 7 4 3lbf ft 31 Place the dust seal ring in the housing 32 Place the end cover in position 29 Fit the special screw with washer and place it in the hole shown 30 5 84 1 5 84 2 5 84 3 5 84 4 ...

Page 173: ...5 31 Fit the dust seal ring in the housing 33 Press the plastic plugs into the connection ports Do not use a hammer 34 5 85 1 5 85 2 ...

Page 174: ...R STRUCTURE 1 2 4 3 5 9 6 7 8 10 4 9 10 5 6 7 8 12 12 11 3 D255SS11 1 Tube assembly 2 Rod 3 Gland 4 DU bushing 5 Rod seal 6 Back up ring 7 Dust wiper 8 Snap ring 9 O ring 10 O ring 11 Piston seal 12 Pin bush 1 20L 25L 30L 7 1 ...

Page 175: ...5 33 20LC 25LC 30LC 7 2 8 7 9 6 5 3 4 1 7 8 5 L255SS11 1 Tube assembly 2 Rod assembly 3 Piston seal 4 Wear ring 5 Gland 6 Bushing 7 U packing 8 Dust wiper 9 O ring 2 ...

Page 176: ...heck item Remedy Criteria Clearance between piston cylinder tube Clearance between cylinder rod bushing Seals O ring Cylinder rod Cylinder tube Replace piston seal Replace bushing Replace Replace Replace 0 064 0 137 0 0025 0 0054 0 024 0 112 0 0009 0 0044 Damage Dents Biting Standard size Repair limit 0 180 0 0070 0 120 0 0049 3 3 mm in ASSEMBLY Install a new piston seal the groove on the piston B...

Page 177: ...eed calking again never using previous calking position 6 D353SE31 Move the piston rod back and forth several times for the full distance of its stroke This helps to seat the ring and seals before applying full hydraulic pressure to the cylinder Install cylinder into steering axle While idling the engine with the rear wheels off the ground operate the steering wheel left and right alternately Then...

Page 178: ...g ring 9 Collar 10 Grease nipple 11 Oil seal 12 Taper roller bearing 13 Split pin 14 Nut 15 Washer 16 Plate 17 Hub 18 Hub bolt 19 Hub nut 20 Hub cap 21 Steering link 22 Steering cylinder 23 SPH plain bearing 24 Steer link pin 25 Plain washer 26 Grease nipple 27 Lock plate 28 Bolt 29 Hex nut 30 Hex bolt 31 Trunnion block 32 Bushing 33 Thrust washer 34 Pin 35 Spring washer 36 Hardened washer 37 Uppe...

Page 179: ...r bearing 7 Plain washer 8 Split pin 9 Castle nut 10 Hub cap 11 Oil seal 12 Grease nipple 13 Retaining ring 14 King pin washer 15 Needle bearing 16 Thrust bearing 17 Shim 0 13t 18 Shim 0 25t 19 Clevis pin 20 Thrust washer 21 Bearing 22 Plain washer 23 Split pin 24 Clevis pin 25 Special bolt 26 Spring washer 27 Hex bolt 28 Hex nut 29 Lock plate 30 Hex bolt 31 Steering cylinder 32 Link 33 Grease nip...

Page 180: ... Shaft Replace Adjust with shims Replace OD of king pin OD of steering cylinder pin Knuckle A1 A2 D1 D2 D3 OD of pin Vertical play ID of bushing OD of shaft ID of bushing 55 2 2 55 2 2 35 1 4 20 0 8 20 0 8 20 0 8 54 5 2 1 55 5 2 2 34 5 1 4 19 5 0 8 19 5 0 8 20 5 0 8 OD Outer diameter ID Inner diameter 2 20L 25L 30L 7 20G 25G 30G 7 1 ...

Page 181: ...ith shims Replace OD of king pin OD of steering cylinder pin Knuckle A1 A2 D1 D2 D3 OD of pin Vertical play ID of bushing OD of shaft ID of bushing 50 2 0 50 2 0 35 1 4 17 0 7 17 0 7 17 0 7 49 5 1 9 50 5 2 0 34 5 1 4 16 5 0 6 16 5 0 6 0 2 0 008 17 5 0 7 OD Outer diameter ID Inner diameter 2 20LC 25LC 30LC 7 20GC 25GC 30GC 7 2 ...

Page 182: ... together with the roller bearing Be very careful because just before the hub comes off tapered roller bearing will fall out After hub is removed take off the inner race of roller bearing Pull out oil seal Don t use same oil seal twice Repeat the same procedure for the other side Moreover when disassembling is completed part the slotted nut in the knuckle to protect the threaded portion Hub cap Sp...

Page 183: ...ull out oil seal Don t use same oil seal twice Repeat the same procedure for the other side Moreover when disassembling is completed part the castle nut in the knuckle to protect the threaded portion Knuckle Oil seal Bearing Wheel hub Bearing L255SS13 L255SS14 20LC 25LC 30LC 7 20GC 25GC 30GC 7 2 37 39 5 25 13 4 3 24 6 6 35 20D7SS11 Loosen special bolt 4 and spring washer 35 Remove hexagon bolt 39 ...

Page 184: ...without damaging the knuckle 2 Pull out the needle bearing 17 If defect is observed in needle bearing 17 pull it out by using extractor Remove the split pin 25 and the clevis pin 26 Then remove the knuckle 2 Repeat the same procedure for the other side 35 26 2 18 28 27 24 25 19 20 14 15 16 13 17 36 13 17 13 16 15 14 1 L255SS15 ...

Page 185: ...ol Be sure that the fixed ring of the bearing is placed in position facing the knuckle 3 Hub Mount oil seal 11 and inner race of tapered roller bearing 12 on the knuckle The bearing should be well greased before assembling Install the outer race of the bearing 46 in the wheel center and assemble to the knuckle Tighten nut 14 and lock with split pin 48 In locking with split pin locate the hole for ...

Page 186: ...r bearing 7 on the knuckle 2 The bearing should be well greased before assembling Install the outer race of the bearing 8 in the wheel center and assemble to the knuckle Tighten with castle nut 11 and locked with split pin 10 In locking with split pin locate the hole for the split pin by turning the nut back 1 6 of a turn Adjust the preload of bearing Mount the hub cap 12 Bearing should be well gr...

Page 187: ...SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function 6 1 Group 2 Operational Checks and Troubleshooting 6 19 Group 3 Disassembly and Assembly 6 23 ...

Page 188: ...STEM 1 HYDRAULIC CIRCUIT Non OPSS and non boosted brake 20L7HS01 1 Gear pump with priority valve 2 Main control valve 3 Steering unit 4 Steering cylinder 5 Lift cylinder 6 Tilt cylinder 7 Suction strainer 8 Return filter 9 Down safety valve 10 Hydraulic tank ...

Page 189: ... 8 10 2 6 5 9 L R P 4 3 T LS EF CF LS T M 9 0MPa 1 T 1A 2B 2A 3B 3A 4B 4A LIFT TILT AUX1 AUX2 G P 22 0MPa 16 5MPa 20L7HS01 1 Gear pump with priority valve 2 Main control valve 3 Steering unit 4 Steering cylinder 5 Lift cylinder 6 Tilt cylinder 7 Suction strainer 8 Return filter 9 Down safety valve 10 Hydraulic tank ...

Page 190: ...B 2A 3B 3A 4B 4A LIFT TILT AUX1 AUX2 1A G P T 6 5 1 9 10 12 3 7 11 8 2 4 20L7HS02 1 Hydraulic gear pump 2 Dual flow divider 3 Main control valve 4 Brake valve 5 Steering unit 6 Steering cylinder 7 Lift cylinder 8 Tilt cylinder 9 Suction strainer 10 Return filter 11 Down safety valve 12 Hydraulic tank ...

Page 191: ... When the lift control lever is pulled back the spool on the first block moves to lift position The oil from hydraulic gear pump 1 flows into main control valve 2 and then goes to the large chamber of lift cylinder 5 by pushing the load check valve of the spool The oil from the small chamber of lift cylinder 5 returns to hydraulic oil tank 10 at the same time When this happens the fork goes up ...

Page 192: ...16 5MPa 20L7HS04 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 2 When the lift control lever is pushed forward the spool on the first block moves to lower position The work port 1A and the small and the large chamber of lift cylinder are connected to the return passage so the fork will be lowered due to its own weight ...

Page 193: ...the tilt control lever is pushed forward the spool on the second block is moved to tilt forward position The oil from hydraulic gear pump 1 flows into main control valve 2 and then goes to the large chamber of tilt cylinder 6 by pushing the load check valve of the spool The oil at the small chamber of tilt cylinder 6 returns to hydraulic tank 10 at the same time When this happens the mast tilt for...

Page 194: ... the tilt control lever is pulled back the spool on the second block is moved to tilt backward position The oil from hydraulic gear pump 1 flows into main control valve 2 and then goes to the small chamber of tilt cylinder 6 by pushing the load check valve of the spool The oil at the large chamber of tilt cylinder 6 returns to hydraulic tank 10 at the same time When this happens the mast tilts bac...

Page 195: ...ooster brake 3 4 5 12 2 7 9 10 11 1 13 14 6 8 15 16 20D7HS14 1 Housing 2 Body 3 Rear cover 4 Bushing 5 O ring 6 Pin 7 Drive gear 8 Idle gear 9 Side plate 10 O ring 11 Back up ring 12 Side plate 13 Oil seal 14 Snap ring 15 Bolt 16 Washer 1 ...

Page 196: ... 22 17 20 19 18 20L7HS07 1 Housing 2 Body 3 Priority valve body 4 Bushing 5 O ring 6 Pin 7 Drive gear 8 Idle gear 9 Side plate 10 O ring 11 Back up ring 12 Side plate 13 Oil seal 14 Snap ring 15 Bolt 16 Washer 17 Plug 18 O ring 19 Orifice plug 20 Spool 21 Spring 22 Plug 23 O ring 24 Adjust screw 25 O ring 26 Bolt plug 27 Poppet 28 Relief spring 29 Plug 30 O ring ...

Page 197: ...k assy 4 Aux2 block assy 5 T cover 6 Gauge plug assy 7 Long bolt 8 Hydrostat plug 9 O ring 10 Hydrostat spring 11 Hydrostat sleeve 12 Relief piston 13 Nut 14 Relief plug 15 O ring 16 Relief spring 17 Pilot poppet 18 Plug 19 O ring 20 O ring 21 O ring 22 O ring 23 O ring retainer 24 Plug 25 Steel ball 26 Load sensor spring 27 Load sensor spring 28 O ring 29 System relief seat 30 Secondary relief se...

Page 198: ...8 17 30 8 9 10 29 11 Relief valve piston Relief valve piston T 2 1 20D7HS08 8 Hydrostat plug 9 O ring 10 Hydrostat spring 11 Hydrostat sleeve 12 Relief piston 13 Nut 14 Relief plug 16 Relief spring 17 Pilot poppet 28 O ring 29 System relief seat 30 Secondary relief seat ...

Page 199: ...lve To neutral passage P To aux block 1 To neutral passage 20L7HS15 Oil flows from P pump port to reservoir T by pushing hydrostat spool 1 Before the center bypass line closed hydrostat spool is keep opening so pump port P and tank port T are always connected in operation to minimize heat generation ...

Page 200: ... to the right and the neutral passage is closed The oil supplied from the pump pushes up the load check valve and flow into lift cylinder port 1A The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage The return oil from cylinder flows into the tank 20D7HS09 ...

Page 201: ...n the lift control lever is pushed forward the spool moves to the left and the neutral passage is closed The spool moves to the lift lower position opening up the neutral passage to tank and 1A T In lift lower position the fork drops due to its own weight ...

Page 202: ...es to the left and the neutral passage is closed The oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port 2B The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage The return oil from cylinder port 2A flows into the tank through the hole of the tilt lock spool ...

Page 203: ...ight and the neutral passage is closed The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port 2A The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage The return oil from cylinder port 2B flows into the tank via the low pressure passage ...

Page 204: ...osen lock nut Set adjusting bar to desired pressure setting Tighten lock nut Retest in similar manner as above Adjust bar Lock nut Relief plug Relief spring O ring Pilot poppet Seat T P Main relief valve 220 bar 5 1 20L7hs08 O Operation Pressurized oil over the relief pressure pushes pilot poppet and flows to tank passage therefore the system pressure keeps under the adjusted relief pressure 2 T R...

Page 205: ...Guide 13 DU bushing 14 Spacer 15 O ring 5 TILT CYLINDER 7 23 18 19 11 10 13 12 17 15 14 8 1 3 4 6 5 2 20 21 22 16 9 20L7HS19 1 Tube assembly 2 Rod 3 Piston 4 Glyd ring 5 Wear ring 6 O ring 7 Hexagon nut 8 Gland 9 Bushing 10 U packing 11 Back up ring 12 Dust wiper 13 Stop ring 14 O ring 15 Back up ring 16 O ring 17 Washer 18 Eye 19 Bushing 20 Hexagon bolt 21 Spring washer 22 Lock nut 23 Grease nipp...

Page 206: ...DER 7 4 5 8 6 3 2 1 13 14 9 10 11 12 20L7HS20 1 Tube assembly 2 Rod 3 Piston 4 Piston seal 5 Wear ring 6 Check valve 7 Retaining ring 8 Set screw 9 Gland 10 U packing 11 Dust wiper 12 Retaining ring 13 O ring 14 Back up ring ...

Page 207: ... move down and amount mast tilts forward C Check condition Hydraulic oil Normal operating temp Mast substantially vertical Rated capacity load Hydraulic drift Down Downward movement of forks Within 100mm 3 9in Forward Extension of tilt cylinder Within 5 If the hydraulic drift is more than the specified value replace the control valve or cylinder packing Check that clearance between tilt cylinder b...

Page 208: ...restriction of oil flow on pump suction side Relief valve fails to keep specified pressure Poor sealing inside cylinder High hydraulic oil viscosity Mast fails to move smoothly Oil leaks from lift control valve spool Oil leaks from tilt control valve spool Excessive restriction of oil flow pump suction side Gear or bearing in hydraulic pump defective Foreign matter jammed between sp ool and valve ...

Page 209: ...for proper size Fill reservoir to proper level Drain reservoir and refill with clean oil Set to correct pressure Drain reservoir and fill with proper viscosity Fill reservoir to proper level Tighten fittings check condition of line Drain reservoir fill with non foaming oil Replace shaft seal Replace drive shaft and seal C Cause Remedy HYDRAULIC GEAR PUMP 2 MAIN RELIEF VALVE 3 Problem Can t get pre...

Page 210: ...iped O ring damaged Scores on inner surface of tube Unallowable score on the inner surface of tube Foreign matters in piston seal Excessive clearance between cylinder tube and wear ring Insufficient lubrication of anchor pin or worn bushing and pin Bent tilt cylinder rod Replace packing Smooth rod surface with an oil stone Replace dust seal Replace rod Replace O ring Smooth rod surface with an oil...

Page 211: ...ore continu ing Remove port plugs and drain oil from pump Use a permanent marker pen to mark a line across the mounting flange gear housing and end cover This will assure proper reassembly and rotation of pump Remove key from drive shaft if applicable 1 2 3 4 PUMP 01 PUMP 02 Clamp mounting flange in a protected jaw vise with pump shaft facing down Loosen the four metric hexagon head bolts Remove p...

Page 212: ...P 04 Carefully remove gear housing and place on work bench Make sure the rear bearing block remains on the drive and idler shafts 9 PUMP 05 Remove rear bearing block from drive and idler shafts 10 PUMP 06 Remove idler shaft from bearing block 11 ...

Page 213: ... item 12 PUMP 08 Remove the front bearing block 13 PUMP 09 Turn mounting flange over with shaft seal up and remove the retaining ring with proper snap ring pliers 14 PUMP 10 Remove the oil seal from mounting flange be careful not to mar or scratch the seal bore Remove the dowel pins from the gear housing Do not lose pins 15 16 ...

Page 214: ... teeth check keyed drive shaft for broken or chipped keyway No marks or grooves on shaft in seal area some discoloration of shaft is allowable Inspect both the drive gear shaft and idler gear shafts at the bearing points and seal area for rough surfaces and excessive wear 1 2 3 2 PUMP 12 PUMP 13 Inspect gear face for scoring or excessive wear If the face edge of gear teeth are sharp they will mill...

Page 215: ...normal for the surface inside the gear housing to show a clean wipe on the inside surface on the intake side There should not be excessive wear or deep scratches and gouges General information It is important that the relationship of the mounting flange bearing blocks and gear housing is correct Failure to properly assemble this pump will result with little or no flow at rated pressure This pump i...

Page 216: ...ck bearing blocks on a clean surface with the E seal grooves facing up Apply a light coating of petroleum jelly in the grooves Also coat the E seal and backup with the petroleum jelly this will help keep the seals in place during assembly 3 PUMP 18 Place the E seals flat side outward into the grooves in both bearing blocks Follow by carefully placing the backup ring flat side outward in the groove...

Page 217: ...g block Apply a light coat of clean oil to the face of the drive and idler gears 9 PUMP 21 Pick up the rear bearing block with seal side up and with open end of the E seal facing the intake side of the pump place over the drive and idler gear shafts Install two dowel pins in the holes in the mounting flange or two long dowel pins through gear housing if pump is a multiple section pump 10 11 PUMP 2...

Page 218: ... are in alignment The surface of the rear bearing block should be slightly below the face of the gear housing If the bearing block sits higher then the rear face of the gear housing then the E seal or O ring have shifted out of the groove If this is the case remove the gear housing and check for proper seal installation 13 14 PUMP 24 Install the two remaining dowel pins in the rear of the gear hou...

Page 219: ...the bolts Tighten torque 3 0 4 0kgf m 22 29lbf ft Remove pump from vise Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution If the drive shaft binds disassemble the pump and check for assembly problems then reassemble the pump 17 18 19 ...

Page 220: ...olt 1 to separate the valve section Divide the valve body 2 3 Remove dust cap 3 and bolt 2 from the valve body Remove attachment spool 4 from the valve body 4 1 Aux2 Aux1 Tilt Lift T cover 1 20D7MCV01 20D7MCV02 20D7MCV03 20D7MCV04 2 3 4 ...

Page 221: ...alve body 7 9 8 Remove lift spool 7 from the valve body Remove lock poppet 8 from the valve body Remove normal close solenoid valve 9 Opt from the valve body Remove plug 12 and spring 11 Remove hydrostate 10 12 11 10 5 5 6 5 20D7MCV05 20D7MCV06 20D7MCV07 20D7MCV08 6 7 8 9 10 11 ...

Page 222: ...6 34 Remove relief plugs 15 springs 14 and poppets 13 13 14 15 20D7MCV09 12 Remove normal open solenoid valve 16 Opt from the valve body 16 20D7MCV10 13 ...

Page 223: ... 13 12 14 15 2 3 5 4 6 1 11 7 A B Down safety valve A B D255HS24 1 Tube assy 2 Rod assy 3 Piston 4 Piston seal 5 Back up ring 6 Wear ring 7 Retaining ring 8 Gland 9 Dust wiper 10 Rod seal 11 O ring 12 Guide 13 Du bushing 14 Spacer 15 O ring ...

Page 224: ...e guide can be removed 2 3 Guide 1 ASSEMBLY Soak the piston ring in hydraulic oil at a temperature of 40 to 50 C expand the inside diameter and assemble on the piston Install a piston seal Bend the edge of the guide and rotate it to install the guide completely 4 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearance between piston ring tube 0 072 0 288 0 0...

Page 225: ...15 20L7HS27 1 Tube assembly 2 Rod 3 Piston 4 Glyd ring 5 Wear ring 6 O ring 7 Nylon nut 8 Rod cover 9 Bushing 10 U packing 11 Back up ring 12 Dust wiper 13 Stop ring 14 O ring 15 Back up ring 16 O ring 17 Washer 18 Eye 19 Bushing 20 Hexagon bolt 21 Spring washer 22 Lock nut 23 Grease nipple ...

Page 226: ... cylinder head from cylinder tube When doing this wind tape round the threaded part of the rod and be careful not to damage the dust seal and rod seal inside cylinder head 2 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearance between rod head bushing pin 0 072 0 288 0 003 0 011 0 10 0 35 0 004 0 014 0 5 0 020 0 6 0 024 Replace bushing Replace bushing CHE...

Page 227: ...SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location 7 1 Group 2 Electrical Circuit 7 2 Group 3 Component Specification 7 12 Group 4 Connector Destination 7 13 Group 5 Troubleshooting 7 15 ...

Page 228: ...YSTEM 1 Flasher lamp 2 Work lamp 3 Combination switch 4 Horn assembly 5 Combination lamp 6 Back buzzer 7 Forward reverse lever 8 Operating panel 9 Start switch 10 Horn button 11 Switch assembly 12 Fuse box 13 OPSS unit 14 Flasher unit 15 Battery 20L7EL02 ...

Page 229: ... C 5 2 6 7 8 9 10 11 12 13 14 15 1 Flasher lamp 2 Work lamp 3 Combination switch 4 Horn assembly 5 Combination lamp 6 Back buzzer 7 Forward reverse lever 8 Operating panel 9 Start switch 10 Horn button 11 Switch assembly 12 Fuse box 13 OPSS unit 14 Flasher unit 15 Battery 20L7EL02 ...

Page 230: ... 65 MAIN EARTH CN 122 F SOL 352 420 CN 123 R SOL 354 422 354 420 352 DO 1 422 420 CN 6 354 G3 FUEL SYSTEM INTERFACE 170 456 452 448 430 320 170 456 452 448 430 320 380 446 458 450 460 336 352 420 120 G3 380 446 458 450 460 336 352 420 120 G3 G1 TO JEHIN HAR TO JEHIN HAR VSW E G TEMP SENSOR E G OIL PS CHARGE F PUMP RELAY ENGINE CHECK STARTER COMMAND FUEL SELECTOR LPG CUTOFF1 LPG CUTOFF2 5V RTN FPP1...

Page 231: ...7 3 FUEL SYSTEM CIRCUIT TIER 3 LPG 20L7EL07 ...

Page 232: ...7 4 FUEL SYSTEM CIRCUIT TIER 3 BI FUEL 20L7EL06 ...

Page 233: ...7 5 FUEL SYSTEM CIRCUIT NON CERT LPG 20L7EL08 ...

Page 234: ...7 6 FUEL SYSTEM CIRCUIT NON CERT BI FUEL 20L7EL09 ...

Page 235: ...7 7 MEMORANDUM ...

Page 236: ... battery terminal OPERATING FLOW Battery Start motor CN 45 B I conn CN 1 12 13 14 Start switch CS 2 3 Fuse box CN 36 No 1 Cab CN 7 1 OPSS buzzer CN 113 2 OPSS unit CN 55 12 I conn CN 1 4 Horn CN 25 2 Brake switch CD 4 No 2 Flasher unit CR 11 2 No 3 Cluster CN 57 4 1 CHECK POINT 2 Engine OFF Key switch OFF Voltage 10 13V Check point GND Battery GND Fuse No 1 GND Start key ...

Page 237: ...P2 120 120 120 SP1 120 CS 2 START KEY 120 4 3 2 1 0 I 0 I H 4 BR ACC 1 R1 4 BR ACC 4 BR ACC 2 R2 ST B 3 5A START RELAY TURN LAMP 10A ILL HEAD LAMP 15A HORN STOP LAMP TRAVEL CLUSTER WORK BEACON LAMP FOR CABIN OPSS 5A A A 5A 10A 15A 5A 10A CLUSTER 5A 1 2 3 4 5 6 7 8 9 10 11 12 CN 36 1 2 OPSS BUZZER CN 113 200 B L E 2 1 3 G CR 11 FLASHER UNIT CN 57 212 1 2 3 4 5 6 7 8 IG FUEL GAUGE EARTH GAUGE E G TE...

Page 238: ...t key switch is in ON position Start switch ON CS 2 4 Fuse box No 5 I conn CN 1 19 Fuel system interface CN 6 1 When start key switch is START position Start switch START CS 2 2 Fuse box CN 36 4 Neutral relay CR 5 4 2 I conn CN 1 21 Fuel system interface CN 6 7 1 1 2 CHECK POINT 2 Engine Running Key switch ON Voltage 10 14 5V Check point GND Battery B GND Fuse box No 5 GND Start key GND Neutral re...

Page 239: ...MP 15A HORN STOP LAMP TRAVEL CLUSTER WORK BEACON LAMP FOR CABIN OPSS 5A A A 5A 10A 15A 5A 10A CLUSTER 5A 1 2 3 4 5 6 7 8 9 10 11 12 CN 36 3 170 180 19 20 21 22 23 24 25 26 27 28 320 RELAY NEUTRAL CR 5 320 220 1 2 3 4 3 1 2 4 220 170 CN 6 FUEL SYSTEM INTERFACE VSW E G TEMP SENSOR E G OIL PS CHARGE F PUMP RELAY ENGINE CHECK STARTER COMMAND FUEL SELECTOR LPG CUTOFF1 LPG CUTOFF2 5V RTN FPP1 VREF 5V IV...

Page 240: ...h Hazard switch Start switch OPSS unit Relay 4P Relay 5P Qty 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 Specification CCA 550 20HR 60AH CMF 60 223 168 220 12V 55W 12V 3 4W 2 12V 21W T S 12V 10W Back 12V 5W Tail 12V 21W Stop 12V 55W 85 10 C M 23W 23W 2 3W 2 12V 20A Relay 12V 21W 21W 2 3W Flasher 130W Harzard 12V 90 5dB 60 10C M 12V MAX 3 5A 105 120dB Remark 180A 12V 16A 12V 16A 12V 24V 15 28A 12V 24V MAX 0 5A...

Page 241: ...nit Cluster Back buzzer OPSS buzzer Forward solenoid Reverse solenoid Accel pedal Start switch Gear selector switch Combination switch Parking switch Rear work switch Hazard switch Cut off switch Seat switch Head lamp Beacon lamp Combination lamp LH Combination lamp RH Rear working lamp Neutral relay Flasher unit Head lamp relay Warning relay Fuel lamp relay Attach cut relay 1743059 2 MG610331 MG6...

Page 242: ...DEUTSCH KET AMP 2 2 2 1 Fuel level sensor Brake switch Air cleaner switch T M temp switch MG610043 ST730057 2 172320 2 DT04 2P E005 Connector number Type Destination Connector part No Female Male No of pin Sensor and pressure switch ...

Page 243: ...i ne is stopped with starting switch left in ON position Caution lamp defective Caution lamp switch defective Replace Replace Faulty wiring Glow plug damaged Check and repair Replace Faulty wiring Insufficient battery voltage Check and repair Recharge battery Insufficient battery voltage Starting motor defective Recharge battery Replace Insufficient battery voltage Recharge battery Faulty wiring I...

Page 244: ...SECTION 8 MAST Group 1 Structure 8 1 Group 2 Operational Checks and Troubleshooting 8 5 Group 3 Adjustment 8 8 Group 4 Removal and Installation 8 11 ...

Page 245: ...ION 8 MAST 1 2 STAGE MAST V MAST 20D7MS01 1 Outer mast 2 Inner mast 3 Roller 4 Shim 0 5 1 0t 5 Chain 6 Anchor bolt 7 Chain wheel bearing 8 Retaining ring 9 Tilt cylinder pin 10 Trunnion cap 11 Bushing 12 Roller 13 Shim 0 5 1 0t ...

Page 246: ...CARRIAGE LIFT CYLINDER 5 2 6 7 8 12 13 TILT CYLINDER 1 4 3 9 10 11 20D7MS01 1 Outer mast 2 Inner mast 3 Roller 4 Shim 0 5 1 0t 5 Chain 6 Anchor bolt 7 Chain wheel bearing 8 Retaining ring 9 Tilt cylinder pin 10 Trunnion cap 11 Bushing 12 Roller 13 Shim 0 5 1 0t ...

Page 247: ... FREE LIFT CYLINDER CARRIAGE 2 3 4 5 7 6 8 9 10 11 12 13 14 20D7MS02 1 Outer mast 2 Inner mast 3 Chain 4 Anchor bolt 5 Back up liner 6 Shim 0 5 1 0t 7 Roller 8 Shim 0 5 1 0t 9 Tilt cylinder pin 10 Support cap 11 Bushing 12 Sheave 13 Sheave bracket 14 U bolt ...

Page 248: ...YLINDER CARRIAGE 3 2 4 5 6 7 8 9 10 11 11 1 12 13 14 15 20D7MS21 1 Outer mast 2 Middle mast 3 Inner mast 4 Chain 5 Anchor bolt 6 Roller 7 Shim 0 5 1 0t 8 Back up liner 9 Shim 0 5 1 0t 10 Sheave bracket 11 Sheave 12 Tilt cylinder pin 13 Support cap 14 Bushing 15 Clamp ...

Page 249: ...8 4 4 CARRIAGE BACKREST AND FORK 2 1 5 3 4 6 D255MS03 1 Backrest 2 Carriage 3 Load roller 4 Side roller 5 Fork assembly 6 Extension fork ...

Page 250: ...l raise forks about 10cm from ground and check front to rear clearance and left to right clearance between inner mast and fork carriage and between outer mast and inner mast Use these figures to judge if there is any play at roller or rail Front to rear clearance Within 2 0mm 0 08in Left to right clearance Within 2 5mm 0 10in Check that there is an oil groove in bushing at mast support Set mast ve...

Page 251: ...rmed mast assembly Faulty hydraulic equipment Deformed mast assembly Deformed masts or carriage Faulty hydraulic equipment Damaged load and side rollers Unequal chain tension between LH RH sides LH RH mast inclination angles are unequal Mast assembly is twisted when tilted Disassemble repair or replace See troubleshooting hydraulic pump and cylinders in section 6 hydraulic system Disassemble mast ...

Page 252: ...picking up load unevenly Difference in fork tip height 15mm Difference in fork tip width 35mm Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done Crack on the fork heel Crack on the fork weldments If the measured value is below the wear limit replace fork If the measured value exceeds ...

Page 253: ...arance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the inner outer mast roller shim Standard clearance A B 0 0 6mm Shim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast mo...

Page 254: ...e side to the following value by inserting the inner and middle mast roller shim respectively Standard clearance A 0 0 6mm Shim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast moves smoothly in the middle mast and the middle mast moves smoothly ...

Page 255: ...arance at upper middle and lower rollers after loosen the adjust screws from the side rollers Shift the carriage to one side to bring the roller into contact with the inner mast and measure the clearance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the carriage roller shim Standard clearance C 0 0 6mm Shim thickness 0 5 1 0m...

Page 256: ...CARRIAGE With the mast vertical raise the carriage high enough to place blocks under the load forks This is done to create slack in the load chains when the carriage is lowered Lower the carriage all the way down to the floor Make sure the carriage is level this will prevent any binding when the mast is raised While supporting lift chains remove the split pin and slide out chain anchor pins from t...

Page 257: ...t with mast Back off approximately 1 10 turn on screw and tighten nut to lock screw in place Run carriage up and down for the inner mast to be sure the carriage has free movement and does not stick Also make sure chains are properly adjusted Refer to chain adjustment paragraph Make adjustment when necessary and recheck operation of carriage 2 1 2 3 4 C CARRIAGE LOAD ROLLER Remove carriage as outli...

Page 258: ...lear lift cylinder After lowering the lift cylinder rods and disconnecting lift cylinder hose tilt the lift cylinders LH and RH and them with ropes to the outer mast Using the overhead hoist lower inner mast until top and bottom rollers and back up liners are exposed Using a pryer remove load rollers from load roller bracket Remove back up liners and shims Thoroughly clean inspect and replace all ...

Page 259: ... to clear lift cylinder After lowering the lift cylinder rods and disconnecting lift cylinder hose tilt the lift cylinders LH and RH and them with ropes to the outer mast Using the overhead hoist lower inner mast until top and bottom rollers and back up liners are exposed Using a pryer remove load rollers from load roller bracket Remove back up liners and shims Thoroughly clean inspect and replace...

Page 260: ...ock of wood under the free lift cylinder bracket of the inner mast then lower mast sections this will create slack in the chains Remove retaining rings securing chain sheaves to sheave support brackets While support chains remove chain sheaves and let chains hang free The upper outer and lower middle mast rollers and back up liners are now exposed Using a pryer remove load rollers from load bracke...

Page 261: ...Disconnect free lift cylinder hose Drain hose into a suitable pan or container and cap hose While supporting free lift cylinder assembly remove bolts and washers securing cylinder to mast crossmember Place a sling around free lift cylinder and attach to an overhead hoist Slowly raise and move cylinder to one side Attach chains or sling to the inner mast section at top crossmember Using an overhead...

Page 262: ...n or damaged parts Reverse the above to assemble and install 6 1 Outer mast Chain Sheave Inner mast Carriage Anchor bolt Sheave Sheave Chain VF mast only 20D7MS16 Middle mast Chain Sheave Anchor bolt Chain Inner mast Free lift cylinder Carriage Anchor bolt 20D7MS17 Rear chain sheave TF mast Raise and securely block carriage and inner mast section Remove the split pin securing the chain anchor pins...

Page 263: ...fer to this section for Load chain lubrication and adjustment Carriage chain Place a sling around carriage front plate and attach to an overhead hoist Lift and secure carriage high enough so that split and chain anchor pins on carriage can be easily be removed Remove chain anchor pins from carriage and drape chains out over carriage Place a wooden block under the carriage and lower the carriage on...

Page 264: ...ened plate edges Oil rusty chains and replace chains with bent or peened components P Protruding or turned pins Heavily loaded chains operating with lube generate tremendous friction between pins and plates In extreme cases the frictional torque in the joint can actually turn pins in the press fit outside plates If chain is allowed to operate in this condition the pins slowly work out of the chain...

Page 265: ...ire a film of oil between mating parts to prevent rapid wear Oil must penetrate the chain joint to prevent wear Applying oil to external surfaces will prevent rust but oil must flow into the live bearing surfaces for maximum wear life Frequency of re lube will vary with operating conditions and environment the best estimate of lube period is 200 hours Trucks parked outdoors or trucks in extremely ...

Page 266: ... over stretching of chains Prevent chains from jumping off sheaves if they are too loose A Adjustment procedure With mast in its fully collapsed and vertical position lower the fork to the floor Adjust the chain length by loosening or tightening nut on the chain anchor After making adjustment on the mast be sure to tighten the nut ...

Page 267: ...MODEL L4GC SHOP MANUAL FOR INDUSTRIAL USE ...

Page 268: ...hods to extend its life and benefit Improper service methods and procedures may shorten the engine life resulting from its low performance Hyundai genuine parts are designed and built to provide the best performance in your engine If your claim is caused by using non Hyundai genuine parts or servicing at places not recommended your warranty is not available Hyundai Motor Co Inc makes efforts to en...

Page 269: ...t could cause injury or damage to the driver occupants or repairman The following list contains some general warnings that you should follow when you work on an engine Always wear safety glasses for eye protection Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Operate the engine only in a well ventilated area to avoid the danger carbon mon...

Page 270: ...CONTENTS 4 FUELSYSTEM 4 1 3 ENGINEELECTRICALSYSTEM 3 1 2 ENGINE MECHANICAL SYSTEM 2 1 1 GENERAL 1 1 ...

Page 271: ...1 GENERAL 1 1 2 RECOMMENDEDLUBRICANTSANDCAPACITIES 1 5 3 SCHEDULEDMAINTENANCE 1 6 CHAPTER 1 GENERAL ...

Page 272: ...ment order G engine 4 Engine capacity C 1975 CC engine 5 Production year 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 6 Engine production sequence number 000001 999999 L4GC200A GENERAL L 4 G C X 0 0 0 0 0 1 1 2 3 4 5 6 ENGINE IDENTIFICATION NUMBER LO CATION The engine identification number is stamped on the left side of the top edge of the exhaust manifold cylinder block ...

Page 273: ...e parts and similar parts in order when disassembling not to make a mistake while reassembling 1 Arrange the removed parts in order 2 Sort replacement parts and re use parts 3 When replacing bolts and nuts necessarily use the specified standard parts GENERAL 3 REPLACEMENT PARTS The following parts should be replaced with new parts after removing 1 Oil seal 2 Gasket except the locker cover gasket 3...

Page 274: ... It is recommended to use spare parts prepared in the set or kit 3 Spare parts can be different from actual assembled parts as the result of parts unification so start the job after checking the parts catalog GENERAL Certificate attached Certificate removed Genuine parts L4GC204A ...

Page 275: ...astened 3 If oil is applied to threads and surfaces If you reduce the torques in the table to the per centage indicated below under the following conditions it will be the standard value 1 If spring washers are used 85 2 If threads and bearing surfaces are stained with oil 85 Head mark 7 0 5 0 6 0 9 1 1 2 0 2 5 4 0 5 0 6 8 12 14 18 21 26 30 36 42 48 55 61 70 Head mark 4 Bolt nominal diameter mm 0 ...

Page 276: ...ECOMMENDED LUBRICANTS AND CAPACITIES LUBRICANTS CAPACITIES Engine oil Description Capacities Oil pan Oil filter Total Specified oil Above API SG 10W 30 or 15W 40 Coolant for engine 3 7 0 3 4 0 3 0 It varies according to the radiator capacity ...

Page 277: ... classification guide 2 Proper SAE classification number should be selected within ambient temperature ranges Do not use the lubricant with SAE classification number and API grade not identified on the container L4GC209A 7 13 18 30 10W 5W 20 5W 1 30 50 20W 40 15W C 1 5W 20 engine oil is recommended for everywhere If 5W 20 is not applicable proper engine oil will be possible according to temperatur...

Page 278: ...ew engine oil to the oil filler L4GC211A Oil capacity including filter 4 0 CAUTION Over replenishing can happen oil saturation and overpressure 6 Close the oil filler cap 7 Run the engine 8 Stop the engine and after checking the oil level add oil if necessary CHECKING ENGINE OIL LEVEL 1 Check that the oil level is between MIN and Max marks on the engine oil level gauge 2 If the oil level is below ...

Page 279: ... pump pulley and alternator pulley with 10kg f 2 Inspect the belt deflection by pressing it 3 If the belt deflection is out of the standard adjust it as follows Item Standard Drive belt deflection 4 0 4 4mm New belt Used belt 5 1 5 7mm CHECKING SPARK PLUG INSPECTION 1 Remove the spark plug from the cylinder head using a spark plug wrench CAUTION Prevent foreign material from getting in the spark p...

Page 280: ...om damage State Contact point is black Contact point is white SPARK PLUG TEST After connecting the spark plug to the high tension cable con nect the outer terminal main body to the ground and crank the engine Because the discharging clearance is narrow in the air only slight spark will arise But if the spark plug is defect spark does not arise because insulation is damaged L4GC217A Clearance SPARK...

Page 281: ... tains mixture of antifreeze 40 and water 60 Because the cylinder head and the water pump are made of aluminum alloy the mixture should contain antifreeze ethylene glycol of 30 60 to prevent those from corrosion freezing and bursting NOTE If the coolant contains less than 30 of antifreeze anticorrosion is decreased If the coolant contains more than 60 of antifreeze the engine will be fatally affec...

Page 282: ...t counterclockwise to drop the pressure through the reservoir tank tube and then slowly turn the cap to open 1 After opening the radiator cap loosen the drain plug and the engine drain plug and drain the coolant 2 Remove the reservoir tank and drain the coolant 3 After draining the coolant completely close the drain plug fill the engine and the radiator full with a radiator cleaner and clean the e...

Page 283: ...L 2 1 2 CYLINDERBLOCK 2 20 3 MAINMOVINGSYSTEM 2 29 4 COOLINGSYSTEM 2 56 5 LUBRICATIONSYSTEM 2 62 6 INTAKEANDEXHAUSTSYSTEM 2 64 7 CYLINDERHEADASSEMBLY 2 69 8 TIMINGSYSTME 2 78 CHAPTER 2 ENGINE MECHANICAL SYSTEM ...

Page 284: ...GENERAL 2 1 GENERAL OUTLINE L4GC001A ...

Page 285: ...GENERAL 2 2 L4GC002A ...

Page 286: ...lve seat hole Intake 0 3 OS 0 6 OS Exhaust 0 3 OS 0 6 OS Oversize of valve guide hole 0 05 OS 0 25 OS 0 50 OS CAMSHAFT Cam height Intake Exhaust Journal O D Bearing oil clearance End play Series DOHC 4 82 mm 93 5 mm 1 975 cc 9 4 1 3 4 2 700 100 rpm BTDC 8 5 BTDC 2 ABDC 16 BBDC 18 ATDC 2 4 0 03 mm or less 0 15 mm or less 33 3 33 325 mm 33 6 33 625 mm 28 8 28 821 mm 29 1 29 121 mm 11 05 11 069 mm 11...

Page 287: ...PISTON O D Over size PISTON RING Side clearance No 1 No 2 End gap No 1 No 2 Oil ring side rail Over size CONNECTING ROD Bend Twist Side clearance 5 965 5 980 mm 5 950 5 965 mm 1 15 mm 1 35 mm 0 02 0 05 mm 0 035 0 065 mm Intake 46 Exhaust 54 5 0 05 0 25 0 50 45 0 3 0 6 48 86 mm 18 3kg 39 mm 40 0kg 30 5 mm 39 mm 1 5 mm or less 82 00 82 03 mm Less than 0 01 mm 0 02 0 04 81 97 82 00 mm 0 25 0 50 0 75 ...

Page 288: ...r pump type Thermostat type Antifreeze viscosity THERMOSTAT Valve open temperature Fully open temperature WATER TEMPERATURE SENSOR Type Resistance at 20 C 0 024 0 044 mm 0 25 0 50 0 75 45 mm 57 mm Less than 0 03 mm Less than 0 01 mm 0 06 0 260 44 725 44 740 mm 44 475 44 490 mm 44 225 44 240 mm 56 727 56 742 mm 56 477 56 492 mm 56 227 56 242 mm 0 12 0 185 mm 0 025 0 069 mm 0 04 0 09 mm 0 04 0 085 m...

Page 289: ...bolt Flywheel manual transmission bolt Drive plate automatic transmission bolt Timing belt Crankshaft pulley bolt Camshaft sprocket bolt Timing belt tensioner bolt Timing belt idler bolt Timing belt cover bolt Front case bolt Engine mounting Oil filter Oil pan bolt Oil pan drain plug Oil screen Oil seal case 3 5 5 0 4 3 5 5 1 3 1 5 2 5 60 65 60 65 3 0 60 65 60 65 1 6 2 3 4 3 5 5 0 8 1 0 1 4 1 5 0 ...

Page 290: ... Intake manifold cover and intake manifold bolt Throttle body and Surge tank nut Exhaust manifold and cylinder head bolt Exhaust manifold cover and intake manifold bolt Oxygen sensor and intake manifold bolt Water pipe bracket bolt Chain guide Starter bolt Heater protector Description Standard Kg m 1 5 2 0 1 5 2 0 2 0 2 7 2 0 2 7 2 0 4 0 2 0 2 5 0 8 1 0 1 6 2 3 1 8 2 5 1 5 2 0 4 3 5 5 1 5 2 0 5 0 ...

Page 291: ...ance adjusting tool 09220 2D000 Camshaft oil seal installer 09221 21000 Installation of front oil seal Installation of front oil seal Removal and installation of engine mounting bushing Use with 09216 22100 Removal and installation of mechanical tappet shim Installation of camshaft oil seal Use Illustration Tool number and name L4GC007A L4GC008A L4GC009A L4GC010A L4GC006A Plier Stopper ...

Page 292: ...d adaptor 09222 28000 09222 28100 Valve stem seal remover 09222 29000 Removal and installation of valve guide Removal and tightening of cylinder head bolt Installation of valve stem oil seal Removal and installation of piston pin Use with 09234 33003 Removal of valve stem seal Use Illustration Tool number and name L4GC012A L4GC013A L4GC011A L4GC014A L4GC015A A B ...

Page 293: ...n pin setting tool insert 09234 33003 1 Installation of engine rear oil seal 2 Installation of crankshaft rear oil seal Removal and installation of intake and exhaust valve Use with 09222 29000 Removal and installation of piston pin Use with 09234 33001 L4GC017A L4GC018A L4GC016A Use Illustration Tool number and name ...

Page 294: ...belt Loose water pump Water temperature wiring defective Cooling pan defective Radiator or thermostat switch defective Inefficient coolant Replace gasket Replace ring Repair or replace piston and cylinder block Repair or replace valve and seat ring Check engine oil level Replace oil pressure switch Install new filter Replace Replace engine oil Replace or inspect Replace bearing Repair relief valve...

Page 295: ...damaged Breakaway exhaust plate in muffler Rubber hanger damaged Pipe or muffler with body Interfered Pipe or muffler damaged Catalytic converter damaged Each connecting gasket damaged Replace Repair or replace Retighten Replace Retighten Repair or replace Replace Replace Repair Repair or replace Replace Replace Oil cooling system leak Exhaust gas leak Abnormal noise Symptom Remedy Possible cause ...

Page 296: ... tempera ture reaches 80 95 C 3 Stop the engine and disconnect the spark plug cable and air cleaner element 4 Remove the spark plug 5 After opening the throttle valve completely crank the en gine to remove foreign material from the cylinder CAUTION At this time necessarily screen the spark plug hole with a rag Because hot coolant oil fuel and other foreign material being penetrated in the cylinder...

Page 297: ...inder surface are worn or damaged and if the compressed pressure is decreased it means that the valve is clogged the valve contact is faulty or the pressure leaks through gasket CAUTION If a large amount of incomplete combustion gaso line comes into the catalytic converter emergency such as a fire can occur due to overheating So this job should be done quickly with the engine not operated 8 Follow...

Page 298: ...ch to the adjuster groove and turn it counterclockwise to move the arm indi cator in the middle of the base groove CAUTION If it is turned in reverse direction be sure that the tensioner may function abnormally 6 Tighten the tensioner fixing bolt with the arm indicator fixed LCAC021A L4GC023A A B LCAC021A A B 7 Rotate the crankshaft 2 turns clockwise and make sure the auto tensioner arm indicator ...

Page 299: ... to spill the coolant When removing installing the tester as well as testing take care not to deform the filler neck 4 Replace parts if leak is detected 2 Density test 1 Measure density of the coolant using a hydrometer 2 After measuring the coolant temperature calculate den sity using the following table of temperature and density Temperature and density of coolant Temp C 16 20 25 30 36 42 50 3 T...

Page 300: ...freezing and engine cooling Use only the recommended antifreeze and do not mix with other production 4 Recommended antifreeze CHECKING AND ADJUSTING DRIVE BELT TENSION 1 Checking tension 1 Press the middle of the water pump pulley and alterna tor pulley with 10Kg f 2 Inspect the belt deflection by pressing it 3 If the belt deflection is out of the standard adjust it as follows Item Standard 4 0 4 ...

Page 301: ...heck that the belt is installed correctly When the belt is loosened slip noise is heard L4GC026A ADJUSTING 1 Loosen the alternator support bolt A nut and adjusting lock bolt B 2 Adjust the belt tension by moving the alternator brace ad justing bolt to T direction Alternator adjusting lock bolt B Alternator support bolt A 1 2 1 5kg m 2 2 5kg m L4GC027A 65 75kg 40 50kg BORROUGHS type Spindle Hook Ho...

Page 302: ...ly wear of belt and insufficient power of alternator battery and water pump become inefficient and finally en gine is overheated or damaged CHECKING BELT FOR DAMAGE Check the following items and replace the belt if defective 1 Check the belt surface for damage wear and crack 2 Check the belt surface for oil or grease contamination 3 Check the rubber part for wear or hardening 4 Check the pulley su...

Page 303: ...20 CYLINDER BLOCK COMPONENTS L4GC029A Tightening torque kg m REMOVAL 1 Remove the cylinder head timing belt front case flywheel and piston 2 Remove the oil pressure switch L4GC030A Adaptor T 1 3 1 5 Oil pressure switch ...

Page 304: ...dard and the cylinder wall is scratched or furred excessively bore and hone the cylinder block and install a new oversize piston and ring L4GC031A Flatness Parallelism 0 03mm or less 0 15mm or less Cylinder I D Cylinder I D cylindricity 82 00 82 03mm 0 01mm Clearance between piston and cylinder 0 02 0 04mm Items 0 25 OS 0 50 OS 0 75 OS 1 00 OS Size 0 25mm 0 50mm 0 75mm 1 00mm 4 If the top ridge is...

Page 305: ...CYLINDER BLOCK 2 22 INSTALLATION Install the following parts in order 1 Crankshaft 2 Flywheel 3 Piston 4 Cylinder head ...

Page 306: ...que kg m T 4 0 5 0 T 2 2 7 T 1 5 2 2 T 1 0 1 2 Front case gasket Oil pump cover Oil pump outer gear Oil pump inner gear Front case Front oil seal Relief spring Oil screen gasket Oil screen Relief plunger Oil filter Drain plug T 3 5 4 5 Drain plug gasket Oil pan Cylinder block ...

Page 307: ...inner and outer gears from the front case 8 Remove the plug and then remove the relief spring and relief valve L4GC033A INSPECTION FRONT CASE 1 Check the front case for crack and damage and replace if necessary 2 Check the front oil seal for wear and damage and replace it defective Mounting mark OIL SEAL AND OIL SCREEN 1 Check the oil pan for defect damage and crack and re place if necessary 2 Che...

Page 308: ... Outer gear Inner gear OIL PUMP GEAR 1 Check the gear tooth surface for wear and damage 2 Measure clearance between the outer gear and front case 3 Check clearance between the outer gear tooth end and inner gear tooth end L4GC035A L4GC034A Body clearance Tip clearance L4GC036A L4GC037A Body clearance Tip clearance Side clearance ...

Page 309: ...LLATION OIL PUMP 1 Install the outer and inner gears to the front case 2 After installing the oil pump cover tighten the bolt to the specified torque After tightening the bolt check that the gear rotates smoothly Oil pump cover bolt 0 6 0 9kg m Relief valve plug 4 0 5 0kg m 3 Install the relief valve and spring and after tightening the plug to the specified torque apply engine oil to the relief va...

Page 310: ...T CASE 1 Install the gasket and front case assembly and tighten the bolt to the specified torque Bolt length Specified torque L4GC039A OIL SEAL 1 Install the special tool crankshaft oil seal guide 09214 32100 to the front end of the crankshaft After applying engine oil to the outer surface of the oil seal guide insert a new oil seal through the guide until it reaches the front case by hand 2 Insta...

Page 311: ...CYLINDER BLOCK 2 28 Oil pan bolt 1 0 1 2kg m 7 Install the oil pan and tighten the bolt to the specified torque ...

Page 312: ...G CHAIN CHAIN GUIDE COMPONENTS L4GC043A Tightening torque kg m HLA T 0 8 1 0 T 0 8 1 0 Center cover Cylinder head cover Gasket Bearing cap rear Chain guide Exhaust camshaft Intake camshaft Camshaft oil seal Bearing cap front Camshaft sprocket T 10 12 T 0 25 0 35 ...

Page 313: ... coil and spark plug 4 Remove the timing belt upper cover 5 Remove the cylinder head cover L4GC046A 6 Remove the tensioner 7 Loosen the camshaft sprocket bolt and remove the cam shaft sprocket 8 Loosen the bearing cap bolt and after removing the bear ing cap remove the camshaft 9 Remove the timing chain 10 Remove the HLA ...

Page 314: ...ards shaft check the endplay L4GC047A Camshaft endplay 0 1 0 2mm Limit 42 9 42 9 Items Cam height Standard 43 43 Intake Exhaust OIL SEAL 1 Check the oil seal surface for wear and if the seal lip por tion is worn replace it 2 Check the camshaft oil seal lip contact surface for partial wear and replace it if necessary L4GC048A HLA Hydraulic Lash Adjuster 1 HLA I D 33 0 025 0 041 2 How to remove nois...

Page 315: ... In case of the vehicle with HLA when initially starting the engine it is normal if valve noise is momentarily heard CAUTION 1 Because HAL is precision parts take care not to come foreign materials such as a dust from outside 2 Do not disassemble HLA 3 When cleaning HLA use clean diesel oil 4 Take care not to make scratches and sharp edges to O D of HLA 5 With HLA filled with engine oil grasp A an...

Page 316: ...nect the accelerator cable 4 Remove the cylinder head cover and gasket 7 Place the cylinder no 1 to the dead point 1 Rotate the crankshaft pulley so as to align it with T mark on the timing belt low cover 2 Check that the camshaft timing pulley hole is aligned with timing mark on the bearing cap If it is not aligned readjust it by rotate the crankshaft to 360 ...

Page 317: ...sure the gap between the camshaft and valve lift using a gauge Intake Exhaust 0 12 0 28mm 0 20 0 36mm Valve gap Engine coolant temperature 20 L4GC054A IN 1 IN 2 EX 1 EX 3 Intake side Exhaust side Adjusting valve at no 1 compression dead point Rear side ...

Page 318: ...cover 3 Check the valve gap L4GC055A L4GC056A 7 Adjust the gap between the intake and exhaust valves 1 Rotate the crankshaft so as to place the cam lobe on the adjustable valve camshaft upward IN 1 IN 2 EX 1 EX 3 Intake side Exhaust side Adjusting valve at no 1 compression dead point Rear side Upward Cam lobe ...

Page 319: ...sting shim using a small screwdriver and a magnet 4 Using a micrometer measure thickness of the removed shim 5 Calculate thickness of new shim to be valve gap within the specified value T Thickness of removed shim A Measured valve gap N Thickness of new shim Intake N T A 0 20mm Exhaust N T A 0 28mm NOTE There are 20 shims up to 2 0mm at intervals of 0 04mm 09222 2D000 Stopper Pliers Stopper Magnet...

Page 320: ... is within the specified values Intake Exhaust 0 12 0 28mm 0 20 0 36mm Valve gap Engine coolant temperature 20 REASSEMBLY 1 After cleaning sealant remnants of the cylinder head and cylinder head cover apply new sealant LOCTITE NO 5999 CAUTION Don t apply sealant too much to prevent it from coming out ...

Page 321: ...MAIN MOVING SYSTEM 2 38 L4GC060A F G Engine oil 40 or equivalent SECTION B B B B A A D E Sealant Head cover VIEW G Sealant 3 VIEW D E F Cylinder head VIEW D E F ...

Page 322: ...d cover 3 Connect the accelerator cable 4 Connect the PCV hose and intake hose to the head cover 5 Connect the spark plug cable 6 Install the timing belt upper cover 7 Install the center cover Cylinder head cover 0 8 1 0kg m Center cover 0 25 0 35kg m ...

Page 323: ...camshaft to the cylinder head CAUTION Apply engine oil to the camshaft journal and cam There a detective pin for TDC sensor in the in take camshaft rear end and a dowel pin in the intake camshaft front end L4GC064A L4GC065A 3 Install the camshaft cap Check the intake and exhaust identification marks Check cap number and arrow and take care not to change the bearing cap position and direction I Int...

Page 324: ...ecial tool camshaft oil seal installer and guide press the camshaft oil seal Necessarily apply en gine oil to the oil seal lip Insert the oil seal through the camshaft front end and install it by tapping on the installer with a hammer until the oil seal reaches 8 5mm from the camshaft front end 8 Install the camshaft sprocket to the specified torque Camshaft sprocket bolt 10 12kg m CAUTION Align t...

Page 325: ...er head replacement When installing after head cover removing nec essarily apply sealant to the head cover rear and front portion Because the head cover is made of plastic take care not to drop tools on the head cover upper portion when removing installing the engine parts When installing after head cover removing af ter checking the head gasket for damage re use it if it is normal When applying d...

Page 326: ...NENTS L4GC072A Tightening torque kg m Thrust bearing Crankshaft center bearing Crankshaft upper bearing Crankshaft lower bearing T 2 7 3 3 60 65 T 1 1 1 2 Main bearing cap Crankshaft center bearing Crankshaft Crankshaft position sensor wheel ...

Page 327: ...the main bearing cap to refer to the original position and direction INSPECTION 1 Crankshaft 1 Check the oil hoe for clogging as well as crankshaft journal pin for damage uneven wear and crack Repair or replace parts if necessary 2 Inspect out of circularity of the crankshaft journal taper and pin 2 Main bearing and connecting rod bearing Visually inspect each bearing for scratch melting sticking ...

Page 328: ...ance 0 028 0 048mm 0 024 0 044mm Main bearing cap bolt Connecting rod cap bolt 2 7 3 3kg m 60 65 5 0 5 3kg m 4 Oil seal Check the front and rear oil seal and replace it with new parts if necessary Clearance between sensor wheel and crank position sensor 0 5 1 1mm If the clearance is out of specified values check the sensor wheel for balancing and the crank position sensor for in stallation and rep...

Page 329: ...cted to the engine crank pulley L4GC074A L4GC075A L4GC076A 6 Check that the crankshaft for free rotation and proper clear ance between the center main bearing thrust flange and connecting rod big end bearing 7 Using the special tool Crankshaft oil seal installer 09231 21000 fully insert the oil seal into the crankshaft rear oil seal case Crankshaft end play 0 06 0 260mm 8 Install the rear oil seal...

Page 330: ...ING SYSTEM 2 47 FLYWHEEL HOUSING COMPONENTS L4GC077A Tightening torque kg m REMOVAL 1 Remove the flywheel 2 Remove the flywheel housing Ring gear T 12 13 Flywheel T 4 3 5 5 T 4 3 5 5 T 4 3 5 5 T 8 10 T 0 8 1 2 ...

Page 331: ...e ring gear for damage and crack and replace it if necessary ASSEMBLY 1 Install the flywheel housing and tighten the bolt to the speci fied torque 2 Install the flywheel assembly and tighten the bolt to the specified torque Flywheel bolt 12 13kg m ...

Page 332: ... 49 PISTON AND CONNECTING ROD COMPONENTS L4GC078A Tightening torque kg m T 5 0 5 3 No 1 piston ring No 2 piston ring Piston Connecting rod Upper bearing Lower bearing Connecting rod bearing cap Connecting rod bearing Bolt ...

Page 333: ...on upward 3 Using the press remove the piston pin L4GC079A INSPECTION PISTON AND PISTON PIN 1 Check the piston for scratch wear etc and replace it if necessary 2 Check the piston ring for break damage and abnormal wear and replace it if necessary When replacing the piston the ring should be replaced also 3 Check that the piston pin is inserted in the piston hole and replace the piston and pin if n...

Page 334: ... 0 20 0 60 When just replacing the ring without correction of cylinder bore place the ring to the cylinder lower part where less worn out and measure the gap When replacing the ring use the same size of ring Piston ring over size Mark None 25 50 75 1 00 STD 0 25mm OS 0 50mm OS 0 75mm OS 1 00mm OS Item NOTE Size mark is placed on the top of the ring L4GC080A CONNECTING ROD 1 When installing the con...

Page 335: ...w 1 Apply engine oil to the outer surface of the piston pin and small end bore of the connecting rod L4GC082A 2 With the front mark faced upward fix the connecting rod and piston and insert it into the piston pin assembly 3 Using a press press fit the piston pin into the pin hole with the specified pressure on the pin end through the push rod If the pressure is required more than the specified val...

Page 336: ...ng the side rail do not use a piston ring expander to expand gap as usual because the side rail is broken After placing one end of the side rail between the piston ring groove and spacer grasp the lower side securely and press the side rail to the position by hand as shown in the illustration At this time after installing the lower side rail install the upper side rail L4GC084A L4GC085A CAUTION Af...

Page 337: ...t to damage the cylin der bore and crank pin CAUTION Be sure that the piston ring gap is same as shown in the illustration If the piston ring gap is normal gaps are not aligned with direction of piston and thrust and each gap is away from gaps as far as possible Apply enough engine oil to the piston and pis ton ring round L4GC087A L4GC088A 4 Install the connecting rod cap and tighten the cap nut t...

Page 338: ...AIN MOVING SYSTEM 2 55 L4GC090A 6 Install the oil screen 7 Install the oil pan 8 Install the cylinder head 5 Inspect clearance of the connecting rod big end Clearance of connecting rod big end 0 1 0 25mm ...

Page 339: ...COOLING SYSTEM 2 56 COOLING SYSTEM COOLANT PIPE AND HOSE COMPONENTS L4GC091A Tightening torque kg m T 1 5 2 0 Water temperature sensor T 1 5 2 0 T 1 5 2 0 ...

Page 340: ... it if necessary INSTALLATION After getting water around O ring insert it the groove in the coolant intake pipe end and press fit the pipe CAUTION Do not apply oil or grease to the O ring Take care not to dirt the coolant pipe connect ing part with sand or dust Press fit the coolant intake pipe completely ...

Page 341: ...COOLING SYSTEM 2 58 WATER PUMP COMPONENTS L4GC092A Tightening torque kg m Water pump Gasket Belt T 2 0 2 7 T 0 8 1 0 Water pump pulley ...

Page 342: ...ck 2 After getting water around new O ring install it the groove in the coolant intake pipe front end Do not apply oil or grease to the O ring 3 Install a new water pump gasket and water pump assembly Tighten it to the specified torque L4GC093A L4GC094A A B 2 0 2 7 kg m 2 0 2 4 kg m WATERPUMP AND CYLINDER BLOCK 4 Install the timing belt tensioner and timing belt Adjust the timing belt tension and ...

Page 343: ...ostat as shown in the illustration and mea sure the valve open temperature and full open temperature Open Full open 82 C 95 C Valve open temperature INSTALLATION 1 Check that the thermostat flange is correctly inserted to the thermostat housing socket 2 Install a new gasket and water inlet fitting 3 Add coolant Gasket Water inlet fitting Thermostat Thermostat housing Gasket T 1 5 2 0 ...

Page 344: ...SYSTEM 2 61 FAN DRIVE COMPONENTS L4GC097A Tightening torque kg m REMOVAL 1 Remove the fan pulley 2 Remove the fan bracket INSTALLATION Installation is the reverse order of removal T 2 0 2 5 T 4 3 5 5 T 2 0 2 5 ...

Page 345: ...oil pressure switch too tight Oil pressure switch 1 3 1 5kg m INSPECTION 1 Using an ohmmeter measure an electric current and re place the oil pressure switch if an electric current is not detected L4GC098A 2 When pressing it with a thin stick if an electric current is measured between terminal and body replace the oil pres sure switch 3 When applying a negative pressure of 0 3kg cm2 through the oi...

Page 346: ...LUBRICATION SYSTEM 2 63 4 Front case Oil pump 5 Timing belt 6 Timing belt cover ...

Page 347: ...INTAKE AND EXHAUST SYSTEM 2 64 INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS Tightening torque kg m L4GC100A T 1 5 2 0 Exhaust manifold gasket Exhaust manifold ...

Page 348: ... 1 Check the exhaust manifold for damage and crack 2 Check the welding part between the exhaust manifold and catalyst for crack and damage L4GC101A L4GC102A INSTALLATION 1 Installation is the reverse order of removal CAUTION Do not reuse the exhaust manifold gasket nut 2 Exhaust manifold gasket Check the gasket for tear or damage ...

Page 349: ...INTAKE AND EXHAUST SYSTEM 2 66 INTAKE MANIFOLD COMPONENTS CAUTION Do not tighten parts excessively observe the speci fied torque L4GC103A T 5 0 6 0 T 4 3 5 5 T 1 5 2 0 Tightening torque kg m ...

Page 350: ...cuum hoses 6 Disconnect the fuel injector connector and the wiring harness 7 Remove the delivery pipe with the fuel injector attached CAUTION When removing the delivery pipe take care not to drop the injector L4GC105A 8 Remove the intake manifold stay 9 Remove the intake manifold and gasket INSPECTION 1 Intake manifold Check each component for damage and crack 2 Air hose Check each component for d...

Page 351: ...elivery pipe and injector assembly to the intake manifold L4GC105A CAUTION Check that the injector is interfered with the injec tor hole in the intake manifold 3 Install the fuel injector connector and wiring harness 4 Connect the high pressure fuel hose 5 Connect the vacuum hoses 6 Connect the P C V valve hose 7 Install the air hose 8 Check connectors for connection ...

Page 352: ...CYLINDER HEAD ASSEMBLY COMPONENTS L4GC107A Tightening torque kg m 1 Cylinder block 2 Cylinder head gasket 3 Cylinder head 4 Cylinder head bolt 5 Gasket 6 Cylinder head cover T 0 8 1 0 4 1 6 5 M10 2 3 2 7 kg m 60 65 60 65 M12 2 8 3 2 kg m 60 65 60 65 3 2 ...

Page 353: ...tem seal 5 Spring seat 6 Valve 7 Key 8 Chain sprocket 9 Intake camshaft 10 Camshaft sprocket 11 OCV Oil control valve 12 Washer 13 Exhaust camshaft 14 OCV Oil control valve filter 15 Camshaft bearing cap 16 Timing chain 17 Auto tensioner 18 Retainer lock T 1 4 1 5 T 10 0 12 0 T 4 1 5 1 T 0 8 1 0 11 12 14 13 15 17 16 10 1 18 2 3 4 5 6 7 8 9 ...

Page 354: ...ket debris into the cylinder L4GC110A 2 Using the special tool valve spring compressor 09221 29100 remove the retainer lock And then remove the spring retainer valve spring spring seat and valve NOTE Arrange parts in order disassembling not to make a mistake while reassembling L4GC111A 3 Remove the stem seal with pliers NOTE Do not reuse the stem seal L4GC109A 09222 28100 09222 28000 09222 28100 0...

Page 355: ...latness is out of the limit replace the cylinder head or slightly cut the cylinder head gasket surface Standard Limit 0 03mm or less 0 06mm Flatness of cylinder head gasket surface VALVE 1 Clean the valve with a wire brush 2 Check each valve for wear and damage and inspect the head and stem for torsion If the stem end A is cave or worn trim it At this time trim it least Also trim the valve surface...

Page 356: ...m 3 Standard Limit Valve spring 3 Measure the clearance between the valve stem and guide and if the measured value exceeds the limit replace the valve guide with the following over size parts VALVE SEAT CORRECTION Check the valve seat for overheat and inspect contact with valve surface Correct or replace it if necessary When correcting check the valve guide for wear if it is worn replace the guide...

Page 357: ...8 800 28 821 29 100 29 121 7 5 7 7 7 8 8 0 7 9 8 1 8 2 8 4 0 3 OS 0 6 OS 0 3 OS 0 6 OS 30 60 30 60 Intake valve seat ring L4GC118A 2 After removing the seat ring Cut the seat insert bore as same size as the following table using a reamer or cutter 3 Heat the cylinder head to 250 C and press fit the oversize seat At this time the oversize seat ring maintains a normal room temperature After installi...

Page 358: ... valve guide installer Use a valve guide installer to press fit the valve guide to the specified height 4 When installing start from top of valve guide cylinder head Be sure that the intake valve guide is not same size with the exhaust valve guide Intake valve guide 46 0mm ex haust valve guide 54 5mm 5 After installing the valve guide insert a new valve and check for perturbation 6 When replacing ...

Page 359: ...the valve guide Install the stem seal by tapping on it with the special tool valve stem oil seal installer 09222 22001 Wrong installation of the seal can affect oil leak from the valve guide so use the special tool to install it to exact position and take care not to twist it Do not reuse it 2 After applying engine oil to each valve insert the valve into the valve guide 3 Install the spring and sp...

Page 360: ...linder head gasket Take care not to make a mistake of gasket 7 Put the cylinder head on the cylinder block 8 Apply a slight coat of engine oil to the spiral portion of bolt 9 Insert the washer to the bolt and insert it to the cylinder head 10 Using the special tool cylinder head bolt wrench 09221 32001 install the cylinder head bolt as shown in the illustration L4GC123A M10 M12 2 5kg m 60 65 60 65...

Page 361: ...r cover 2 Camshaft sprocket 3 Cylinder head cover 4 Cylinder head cover 5 Idler 6 Tensioner 7 Crankshaft sprocket 8 Timing belt lower cover 9 Flange 10 Crankshaft pulley Tightening torque kg m 6 7 8 9 10 T 4 3 5 5 T 16 0 17 0 T 0 8 1 0 T 10 0 12 0 T 2 3 2 9 5 6 2 3 1 4 ...

Page 362: ...the timing belt form the camshaft sprocket 8 Remove the camshaft sprocket 9 Remove the timing belt NOTE When reusing the timing belt put an arrow mark on the rotation direction or front side of engine before removal to help re install it to original in stallation direction L4GC126A L4GC127A L4GC128A 6 Remove the timing belt tensioner pulley Water pump pulley drive belt Tensioner pulley Idler pulle...

Page 363: ...2 Remove the crankshaft sprocket bolt and remove the crank shaft sprocket and flange 13 Remove the timing belt tensioner 10 Remove the idler 11 Loosen the camshaft sprocket bolt and remove the cam shaft sprocket L4GC129A ...

Page 364: ...C130A 3 If grease leak is inspected replace it TIMING BELT 1 Check the belt for oil or dust deposit and replace it if necessary In case of small amount of oil or dust clean it with a rag or paper instead of a solvent L4GC131A 2 After overhauling the engine or readjusting the belt inspect the belt in detail and replace it with a new one if the follow ing defects are detected CAUTION Do not bend or ...

Page 365: ... with the tip of a finger there is no sign of it NOTE In case of normal belt it is cut precisely as if cut with a sharp cutter L4GC132A L4GC133A L4GC134A L4GC135A L4GC137A L4GC138A L4GC139A L4GC140A L4GC136A L4GC141A L4GC142A Tooth loaded from canvas is worn elastic canvas fiber rubber is worn color is faded in white canvas structure is deformed Tooth loaded from canvas is worn and rubber is worn ...

Page 366: ...nsioner and bolt 2 Install the spring bottom end to the front case as shown in the illustration 3 Install the flange and crankshaft sprocket taking care of installation direction and then tighten the washer and bolt temporarily 4 When aligning the timing marks after turning the cam shaft sprocket to place the red timing mark on the cam cap in the middle of the knock pin 4 5 bore align this timing ...

Page 367: ...lockwise to place the arm indi cator in the middle of base groove CAUTION Do not rotate the wrench clockwise or the auto tensioner is not normally functioned L4GC144A 10 With the arm indicator fixed not to move tighten the tensioner fixing bolt L4GC023A A B C D Tightening torque 2 3 2 9kgf m 11 Rotate the crankshaft to 2 turns clockwise and then be sure that the auto tensioner arm indicator is pla...

Page 368: ...ling align the crankshaft key with the pul ley groove A B L4GC146A 15 Install the timing belt upper cover Tightening torque 0 8 1 0kgf m Tightening torque 16 0 17 0kgf m 16 Install the water pump pulley 17 Install the alternator driving belt 18 Tighten the water pump pulley fixing bolt Crankshaft pulley bolt ...

Page 369: ...1 GENERAL 3 1 2 IGNITIONSYSTEM 3 3 3 CHARGINGSYSTEM 3 9 4 STARTINGSYSTEM 3 25 CHAPTER 3 ENGINE ELECTRICAL SYSTEM ...

Page 370: ... type Controlled by ECU 1 3 4 2 CRANKSHAFT POSITION SENSOR Item Type Advance system Ignition order Specification Non contacting type Controlled by ECU 1 3 4 2 IGNITION COIL Item 1st coil resistance 2nd coil resistance Specification 0 58 10 8 8 15 SPARK PLUG PFR6N RC8PYPB 0 7 0 8mm Item Specification Type Spark plug gap NGK CHAMPION No load characteristic Terminal voltage Maximum current Minimum sp...

Page 371: ...13 5V 90A 1 000 18 000rpm 14 4 0 3V 20 C 10 3mV C Electro magnetic Built in type NOTE 1 Cold cranking ampere It means that terminal voltage is maintained 7 2V or more at a certain temperature and battery current is supplied for 30 seconds 2 Reserve capacity It represents the time can be supplied 25A from battery with minimum termi nal voltage maintained 10 5V at 26 7 C ...

Page 372: ...ition system is to supply suffi cient electronic spark at a proper timing when inspecting this system necessarily contains spark checking and ignition tim ing measurement When inspecting ignition system installed to the vehicle check for possible trouble symptoms from faulty circuit power 1st low voltage circuit high voltage circuit etc 1 ENGINE IS NOT STARTED OR HARD TO START CRANKING O K A spark...

Page 373: ...ition timing so measure it at a normal RPM 4 Inspect the standard ignition timing 2 0DOHC 700 100rpm RPM BTDC 2 6 5 If ignition timing is out of the standard inspect sensors concerned with ignition timing CAUTION Because ignition timing is fixed by set data value in ECU it is impossible to control on purpose Fist check that sensors send output properly to help determine ignition timing control NOT...

Page 374: ...ure terminals 2ST coil resistance 12 1 1 8KΩ L4GC301A CAUTION When measuring 2nd coil resistance remove the ig nition coil connector IGNITIONSYSTEM 1 2 INSPECTION OF IGNITION COIL 1 1ST coil resistance measurement Measure resistance between no 1 and no 3 terminals of ig nition coil For no 1 and no 4 cylinders And measure resistance between no 3 and no 2 terminals of ignition coil For no 2 and no 3...

Page 375: ...rbon deposit 4 Gasket damaged or broken 5 Porcelain insulator of spark plug clearance L4GC302A L4GC303A L4GC304A 4 Check the plug clearance using a plug clearance gauge and if the value is not within the specified values adjust it by bending the ground clearance When installing a new spark plug install it after checking the uniform plug clearance Spark plug clearance 0 7 0 8mm L4GC305A 5 Install t...

Page 376: ...ground and crank the engine Because the discharging clearance is narrow in the air only slight spark will arise But if the spark plug is normal spark arises at emission clearance between terminals and if the spark plug is defective spark does not arise because insula tion is damaged Density of the fuel mixture is thin Ignition timing is fast Spark plug is tight Lack of torque Insulation damaged In...

Page 377: ...NO 4 11 2kΩ 9 5kΩ 6 9kΩ 5 5kΩ L4GC307A TEST 1 With the engine at idle disconnect the spark plug cable one by one and inspect change of the engine performance each time CAUTION At this time put on the gloves 2 If engine performance is not changed inspect the spark plug cable for resistance and the spark plug itself L4GC308A IGNITIONSYSTEM ...

Page 378: ...ected in B terminal of alternator Charging voltage from alternator is controlled by battery voltage detection unit Alternator consists of rotor stator rectifier capacitor brush bearing and V ribbed pulley cover and Electronic voltage regu lator is built in brush holder L4GC309A COMPONENTS L4GC310A CHARGINGSYSTEM A B C D E E G F Tightening torque kg m Alternator assembly Bolt T 2 0 2 5 Nut flange B...

Page 379: ...emedy With ignition switch ON charging warning lamp does not illuminate Fuse cut off Bulb burnt out Loose wiring connection Bad connection of L S terminals Replace Replace Retighten Inspect and replace wiring Replace voltage regulator Possible cause With the engine started warning lamp is not turned off Battery needs often charging Loose or worn drive belt Fuse cut off Fuse link cut off Faulty vol...

Page 380: ... supply circuit cut off Alternator charging fault Does charging warning lamp illuminate with ignition switch in IG position Illuminated OK Not illuminated Replace alternator If rotation is abnormally delivered to generate power battery is discharged and belt is slipped at low speed and overload Is there a deflection of 10mm when pressing the belt with 10kg f Normal OK Loose belt Re adjust tension ...

Page 381: ...al Is B terminal tightening nut securely tightened Normal OK Terminal is moving Retighten and test Charging warning lamp does not illuminate and battery is overcharged Is there no missing of L S connector Normal OK Connector fault Retighten and test Alternator charging fault or discharged battery at low speed with overload Is battery terminal voltage OK 12 0V or more OK 12 0V or less After quick c...

Page 382: ...neration Generator female circuit is normal but generator component is faulty Is charging warning lamp turned OFF Illuminated OK Not illuminated Replace generator See INSPECTION BEFORE STARTING to inspect belt slippage and readjust tension Is there any noise heard from belt Normal OK Whistling sound heard No generation overcharging and insufficient output owing to inner defection of Generator Is b...

Page 383: ...the terminal B and lead wire to the disconnected output wire NOTE In case of using a clamp type ammeter it is possible to measure current without disconnecting the harness 5 Connect a digital voltmeter between the alternator B terminal and the battery terminal Connect lead wire to the terminal B and lead wire to the battery terminal 6 Connect the battery ground cable 7 Be sure that the hood is ope...

Page 384: ...le 4 Disconnect the alternator output wire from the alternator B terminal RESULT 1 If voltmeter reading is within the standard it is normal Test voltage Maximum 0 2V 2 If voltmeter reading is more than the standard mostly wir ing is faulty In this case inspect wirings between the alter nator and the battery terminal as well as between the alternator B terminal and the fusible link 3 Also prior to ...

Page 385: ... and then battery ground cable 8 Be sure that the hood is opened L4GC321A TEST 1 Be sure that voltmeter reading is identified with battery voltage If voltmeter reading is 0V it means short circuit of wire between B terminal and the battery terminal fusible link cut off or ground fault 2 Turn the headlight ON and start the engine 3 With the engine running at 2 500 rpm turn ON the high beam headligh...

Page 386: ...it 70 of rated current NOTE The rated output current is represented on the name plate in the alternator body Output current varies according to electrical load or temperature of the alternator so during test lack of electrical load causes impossibility of measuring the rated output current In this case turn on headlight to induce the battery discharg ing or turn on other lights to increase the ele...

Page 387: ...HARGINGSYSTEM DISASSEMBLY AND INSTALLATION L4GC322A 1 2 3 4 5 9 10 12 11 13 14 15 6 7 8 16 17 18 19 20 8 Rotor coil 9 Rear bearing 10 Bearing cover 11 Stator coil 12 Rear cover 13 Through bolt 14 Seal 15 Rectifier assembly 16 Stud bolt 17 Brush holder assembly 18 Brush holder bolt 19 Slip ring guide 20 Cover ...

Page 388: ...sen the clip B 3 Loosen the alternator tension adjusting bolt A and the al ternator fixing bolt B 4 Remove the belt by pressing inward the alternator 5 Remove the alternator brocket 6 Loosen the mounting and remove the alternator assembly 7 Installation is reverse order of removal L4GC324A CHARGINGSYSTEM A B L4GC323A A B A B L4GC325A ...

Page 389: ...ARGINGSYSTEM L4GC327A L4GC329A L4GC326A DISASSEMBLY 1 After removing the mounting nuts B remove the genera tor cover A using a screwdriver 2 Loosen 3 mounting bolts A and disconnect the brush holder assembly B 3 Remove the slip ring guide A B A B A A A ...

Page 390: ...3 21 5 Loosen 4 through bolts L4GC330A L4GC048A 6 Separate the rotor and cover CHARGINGSYSTEM ...

Page 391: ... ground and check continuity between the slip ring and the core If there is continuity replace the rotor assembly STATOR 1 Inspect the stator coil for continuity and check continuity between the coil leads If there is no continuity replace the stator assembly 2 Inspect the coil ground and check continuity between the coil and the core If there is continuity replace the stator assembly L4GC331A L4G...

Page 392: ...ator coil lead connecting terminal using an ohmmeter there must have only one direction continuity If there is both direction continuity replace the rectifier assembly owing to short cir cuit of diode BRUSH REPLACEMEMENT If the brush is worn out to the limit replace the brush as the following order INSTALLATION Installation is the reverse order of disassembly Take care of the following items 1 Bef...

Page 393: ...At this time do not insert the nut 2 After pressing forward the alternator Contact the alternator front bracket with front case A as shown in the illustration 3 Insert and install the nut by tightening it to the specified torque CHARGINGSYSTEM Alternator Nut A Support bolt Front case ...

Page 394: ...y is turned to ST position current is sending to start motor solenoid coil the solenoid plunger and clutch shift lever is actuated and the clutch pinion is engaged with the ring gear resulting in cranking When starting the engine the clutch pinion is overrun to pre vent the armature coil from damage by excessive rotation L4GC340A COMPONENTS L4GC341A Tightening torque kg m Start motor T 4 3 5 5 T 1...

Page 395: ... link Start motor fault Ignition switch fault Charge or replace Repair or replace Adjust or replace Replace Repair Replace Possible cause Slow cranking Low battery charging voltage Loose corroded or worn battery cable Start motor fault Charge or replace Repair or replace Repair Continuous rotating of start motor Start motor fault Ignition switch fault Repair Replace Start motor is rotating but eng...

Page 396: ... clutch 6 Lever 7 Plate 8 Packing B 9 Shim 10 Internal gear 11 Magnetic switch 12 Planetary gear holder 13 Planetary gear 14 Ball 15 Packing A 16 Yoke assembly 17 Armature 18 Brush holder 19 Through bolt 20 Rear bracket STARTINGSYSTEM 1 2 3 4 5 9 10 11 12 13 14 6 7 8 15 16 17 18 19 20 ...

Page 397: ...al 2 Connect a 12V battery between S terminal and M terminal CAUTION This test should be done as soon as possible not to damage the coil in 10 seconds 3 If the pinion is moving outward the coil is normal if or not replace the magnetic switch HOLD IN TEST OF SOLENOID 1 Disconnect the connector from M terminal 2 Connect a 12V battery between S terminal and M terminal CAUTION This test should be done...

Page 398: ...ting speed is insufficient or the current is excessive it is be cause of excessive friction resistance And the low current or lack of operating speed is because of faulty contact or open circuit between the brush and the rectifier or between the welding points DISASSEMBLY To remove the overrunning clutch from the armature shaft re move the stop ring Remove the stop ring by moving it to the pinion ...

Page 399: ...rcuit tester If there is no continuity replace the arma ture assembly owing to open circuit of commutator segment 4 OPEN CIRCUIT TEST OF FIELD COIL Check continuity of the field coil using a circuit tester If there is no continuity replace the field coil assembly owing to open circuit of the field coil L4GC350A L4GC351A L4GC352A 5 GROUND TEST OF FIELD COIL With the yoke field coil installed inspec...

Page 400: ...1 Remove the worn brush taking care not to damage the pigtail 2 For better welding correct the pigtail end with a sand paper 3 Weld the pigtail end L4GC357A L4GC356A 8 OVERRUNNING GLUTCH 1 Check the pinion and spline teeth for wear and damage and replace it if necessary Also inspect the flywheel for wear and damage 2 Rotate the pinion The pinion must be rotated clockwise but counterclockwise Wear ...

Page 401: ...ure 1 ASSEMBLY 1 Install the overrunning clutch to the armature shaft front end 2 Install the stop ring and snap ring to the armature shaft front end and completely press the stop ring toward the snap ring 3 When installing the lever to the front bracket take care of the direction If the installation direction is in reverse the pinion will move outward only L4GC358A L4GC360A Overrunning clutch Sto...

Page 402: ...1 GENERAL 4 1 2 INJECTOR 4 14 4 PVC VALVE 4 16 CHAPTER 4 FULE SYSTEM AND OTHER ...

Page 403: ...ector type 0 5V Magnetic type IDLE rpm 600 800Hz 3000 rpm 2700 3300Hz Electric magnetic type 4 14 5 0 35 20 C SEALANTS Water temperature assembly LOCTITE 962T Fuel filter Fuel pump Including fuel filter Map sensor Intake temperature sensor Output actuator Item Specified sealant GENERAL Water temperature sensor WTS Oxygen sensor Hole sensor 1 TDC sensor Crankshaft position sensor Injector Type Resi...

Page 404: ...sensor Oxygen sensor Fuel supply pipe mounting bolt Throttle body mounting bolt High pressure hose and pipe tightening SPECIAL TOOLS Fuel pressure gauge and hose 09353 24100 Fuel pressure gauge adaptor 09353 38000 Fuel pressure gauge connector 09353 24000 Connection of fuel pressure gauge and fuel supply pipe Use Configuration Special tool L4GC251A L4GC250A Neutral N P A CON OFF L4GC252A GENERAL ...

Page 405: ...WER 1 Battery 2 Fusible link 3 Fuse 4 Injector 2 BODY GROUND 3 FUEL SUPPLY 1 Fuel line 2 Fuel filter 3 Fuel pump 4 IGNITION SYSTEM 1 Spark plug 2 High tension cable 3 Ignition coil 4 Crankshaft position sensor 5 EMISSIONS CONTROL SYSTEM 1 PCV system 2 Vacuum leak 6 OTHER 1 Ignition timing check 2 RPM 7 In case of faulty MPI system it is caused by bad contact of harness sometimes so inspect the con...

Page 406: ...ible to damage ECU element by surge 5 When checking A CON for operation use a hi scan and when from the outside relay driving source use its har ness tool It is possible to burn out ECU 6 When welding vehicle body necessarily remove ECU first It is possible to damage ECU element by surge 7 When charging battery from outside charger remove bat tery vehicle side terminal If supply voltage exceeds ra...

Page 407: ...ltage o Fusible link o Ignition switch o Starting relay o Starting motor o Wiring o Ignition switch o Starting relay o Starting motor o Wiring Self diagnosis inspection Vacuum leak check Spark plug inspection o Disconnect injector connector o With spark plug removed 8 10mm away from cylinder block crank and inspect strong spark Fault code o Use Hi scan o L wire using engine Warning display number ...

Page 408: ...3 MPI main relay o Engine cooling temperature sensor o Intake temperature sensor o Injection signal circuit 1 Injector wiring 2 ECU o Throttle position sensor TPS o MAP sensor o Crankshaft position sensor MPI electronic circuit inspection Continued Self diagnosis inspection Fuel supply to injector check o Fuel in tank o Fuel pressure Air cleaner element inspection Fault code o Use Hi scan Warning ...

Page 409: ...rpm Compression inspection o Fuel pump o Fuel filter o Fuel pressure regulator o Regulator pressure check Injector condition Ignition timing inspection BTDC 2 5 700rpm o Wiring connection o ECU power 1 Fusible link 2 Fuse 3 MPI main relay o Engine cooling temperature sensor o MAP sensor o Injection signal circuit 1 Injector wiring 2 ECU ISA inspection Not OK Clean or replace element Air cleaner el...

Page 410: ...e Hi scan Warning display number reading Injector condition Injector condition o Fuel pump o Fuel filter o Fuel pressure regulator Self diagnosis inspection Spark plug inspection Standard 0 7 0 8mm o Inspect compression if necessary o Compression Standard 15 5 16 5kg cm 50 400 rpm Ignition timing inspection BTDC 2 5 700rpm Fuel system inspection Spark plug inspection o Disconnect injector connecto...

Page 411: ...Starter Flywheel Airflow sensor circuit Fuel pressure regulator Water temperature sensor Compression Piston ring Ignition timing Timing belt Injector ECU A C circuit Connecting rod bearing Fuel chamber Crankshaft bearing Main symptom Starting Faulty idling Engine stops Other 2 1 1 2 1 2 9 4 5 1 1 11 2 4 4 4 4 8 2 3 3 3 1 1 1 1 5 6 10 4 7 7 3 6 5 8 8 7 6 9 10 11 8 7 11 8 12 7 7 4 3 12 12 7 5 9 9 13...

Page 412: ...stops With A C ON engine stops Fuel over consumption Item Sub symptom Spark plug Fuel pump Fuel line Ignition circuit Intake temperature sensor circuit Cylinder head Oxygen sensor circuit Fuel leak Main symptom Starting Faulty idling Engine stops 3 2 3 2 2 4 5 5 5 5 9 3 6 6 6 6 10 4 4 10 13 13 11 3 3 2 2 6 2 15 3 7 Other 1 2 1 3 4 5 2 6 7 8 9 10 11 12 3 Other Engine is overheated Engine is superco...

Page 413: ...ximum value difference of oxygen sensor injection fuel quan tity can be different up to 35 Check lamp Faulty sensor manage ment SENSOR CHARACTERISTICS OXYGEN SENSOR Oxygen sensor Related circuit 1 Display oxygen sensor related circuit fault 2 Inspect bad connection of connector faulty wiring 3 Check oxygen sensor for ground Measure voltage between sensor body and engine ground If measured value is...

Page 414: ...r manage ment CRANKSHAFT POSITION SENSOR CPS Oxygen sensor Related circuit 1 Display crank angular sensor related circuit fault 2 Inspect sensor to ECU wiring or sensor to connector for fault 3 Check sensor surface for foreign material 4 Inspect sensor output At idle 600 1000Hz During cranking measure between sensor no 1 and no 2 terminals 1 8V 2 5V No illumination HI SCAN Possible to check oxygen...

Page 415: ...per gear by calculating rpm vehicle speed and gear ratio backward Control ignition timing to prevent impact when repressing throttle again after releasing No 1 cylinder TDC sensor related circuit 1 Display fault of cylinder TDC detecting sensor CMP sensor and related circuit 2 Check connector for bad connection and wiring for fault 3 Inspect sensor contact surface for cleanness 4 Inspect sensor ou...

Page 416: ...eed For fuel consumption reduction engine performance enhance ment and emission reduction ECM controls fuel injection to satisfy air fuel ratio required by system by reflecting induced airflow and air fuel ratio among emission and adjusting injector operating time To enhance these control characteristics quick response of injector is required and spray feature of injector is important for perfect ...

Page 417: ... CBG24 4 ECM CBG K 2 1 1 2 1 2 1 2 Main relay Injector 1 control Injector 2 control Injector 3 control Injector 4 control Main relay Main relay Main relay 2 1 25 28 26 27 CBG24 1 2 3 4 Injector 1 2 3 4 Terminal 1 2 Connecting area Main relay ECM CBG K 25 Function Power B Injector 1 control INJECTOR 1 CBG24 1 Terminal 1 2 Connecting area ECM CBG K 28 Main relay Function Injector 2 control Power B I...

Page 418: ...e Locker Cover Side Engine condition PCV valve Vacuum path At idle or deceleration Full operating Small Intake Manifold Side Sufficient Vacuum Intake Manifold Side Low Vacuum Engine condition PCV valve Vacuum path Proper operating Proper operating Big Locker Cover Side Locker Cover Side Engine condition PCV valve Vacuum path High speed and overload Light operating Very big L4GC260A L4GC261A L4GC26...

Page 419: ...the valve B nut 3 If the plunger is not moved it means that PCV valve is clogging so clean or replace PCV valve TROUBLESHOOTING 1 Disconnect the vacuum hose from the PCV valve Discon nect the PCV valve from the locker cover and reconnect the vacuum hose 2 With the engine at idle Check the intake manifold for vacuum when clogging the opened end of PCV valve NOTE The plunger in PCV valve will move b...

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