Toyota 1HD-T Repair Manual Download

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STARTING SYSTEM - Starter ST-19

Brush Holder

INSPECT BRUSH HOLDER INSULATION

Using an ohmmeter, check that there is no continuity
between the positive ( + ) and negative (-) brush holders.

If there is continuity, repair or replace the brush holder.

Clutch and Gears

1. INSPECT GEAR TEETH

Check the gear teeth on the pinion gear, idler gear and the
clutch assembly for wear or damage.

If damaged, replace the gear or clutch assembly.

If damaged, also check the flywheel ring gear for wear or

damage.

2. INSPECT CLUTCH PINION GEAR

Rotate the pinion gear clockwise and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
check that it locks.

If necessary, replace the clutch assembly.

3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY

A. Disassembly starter housing and clutch assembly

(a) Push down the pinion gear and starter housing.

(b) Using a plastic-faced hammer, tap in the stop collar.

Summary of Contents for 1HD-T

Page 1: ......

Page 2: ...ies HDJ80 series HZB30 series HDB30 series Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine All information in this manual is based on the latest product information at the time of publication However specifications and procedures are subject to change without notice TOYOTA MOTOR CORPORATION Manual Name Land Cr...

Page 3: ...air and service When performing the operations following the procedures using this manual be sure to use tools spe cified and recommended If using non specified or recommended tools and service method be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer s vehicle before starting the operation If part replacement is necessary must rep...

Page 4: ...NG SYSTEM CHARGING SYSTEM SERVICE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS SSTANDSSM 2001 TOYOTA MOTOR CORPORATION All rights reserved This book may not be repro duced or copied in whole or in part without the written permission of Toyota Motor Corporation First Printing Feb 8 1990 01 900208 00 34th Printing Aug 28 2001 34 010828 06 2 ...

Page 5: ...IN 1 INTRODUCTION Page HOW TO USE THIS MANUAL IN 2 IDENTIFICATION INFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 4 ABBREVIATIONS USED IN THIS MANUAL IN 7 ...

Page 6: ...section PRECAUTIONS are given that pertain to all repair operations contained in that section Read these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution REPAIR PROCEDURES Most repair operations ...

Page 7: ...rnings always stand out in bold type REFERENCES References have been kept to a minimum However when they are required you are given the page to refer to SPECIFICATIONS Specifications are presented in bold type throughout the text where needed You never have to leave the procedure to look up your specifications They are also found in Appendix A for quick reference CAUTIONS NOTICES HINTS CAUTIONS ar...

Page 8: ...minal nut and raise the cable straight up with out twisting or prying it d Clean the battery terminal posts and cable terminals with a shop rag Do not scrape them with a file or other abrasive object e Install the cable terminal to the battery post with the nut loose and tighten the nut after installation Do not use a hammer to tap the terminal onto the post f Be sure the cover for the positive te...

Page 9: ...ing fuses be sure the new fuse is the correct amperage DO NOT exceed the rating or use one of a lower rating 11 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the proper locations a If the vehicle is to be jacked up only at the front or rear end be sure to block the wheels in order to ensure safety b After the vehicle is jacked up be sure t...

Page 10: ...t the tester probe carefully to prevent terminals from bending g When using a vacuum gauge never force the hose onto a connector that is too large Use a step down adapter instead Once the hose has been stretched it may leak 13 After removing and reinstalling the injection pump and fuel hoses clean off the fuel on engine components In partic ular be sure to check the radiator hose and by pass hose ...

Page 11: ... Bottom Dead Center Ex Except FL Fusible Link FIPG Formed in Place Gasket HAC High Altitude Compensator LH Left Hand LHD Left Hand Drive LST Load Sensing Timer MP Multipurpose M T Manual Transmission OHC Over Head Cam O S Oversized PCS Power Control System PCV Positive Crankcase Ventilation RH Right Hand RHD Right Hand Drive SSM Special Service Materials SST Special Service Tools STD Standard SW S...

Page 12: ...RIPTION EM 2 TROUBLESHOOTING EM 4 Diesel Engine Diagnosis EM 4 Diesel Electrical System Diagnosis EM 14 ENGINETUNE UP EM 17 COMPRESSION CHECK EM 30 TIMING BELT EM 32 TIMINGGEARS EM 42 CYLINDER HEAD EM 54 CYLINDER BLOCK EM 84 Page ...

Page 13: ...CAL Description DESCRIPTION The 1 PZ engine is an in line 5 cylinder 3 5 liter OHC engine The 1 HZ and 1 HD T engines are an in line 6 cylinder 4 2 liter OHC engine 1PZ 1HZ 1HD T EM8795 EM8792 EM8965 EM8793 EM8966 EM8794 ...

Page 14: ...HD T of the camshaft journal Adjustment of the valve clearance is done by means of an outer shim type system in which valve adjusting shims are located above the valve lifters This permits replacement of the shims without removal of the camshaft Pistons are made of highly temperature resistant aluminum alloy As the 1 HD T engine is the direct injection type a deep combustion chamber has been provi...

Page 15: ...fore performing fuel system checks ensure that the engine is in good running condition If necessary first check the compression timing and major components or systems 2 Check the air filter and clean or replace it if necessary 3 Check that there is sufficient fuel in the tank 4 Check if the fuel is contaminated with gasoline or other foreign elements Only good quality diesel fuel should be used 5 ...

Page 16: ...nator output and drive belt If necessary repair See page CH 5 3 INOPERATIVE STARTER Check for battery voltage at starter terminals 30 and 50 If Okay see STARTING SYSTEM for repair proce dure see page ST 15 ENGINE CRANKS SLOWLY WILL NOT START HINT Minimum cranking speed Cold HZJ80 A T and HDJ80 A T 110 rpm Others 100 rpm Hot 150 rpm Possible Cause Check Procedure and Correction Method 1 LOOSE OR CO...

Page 17: ...ge to sole noid when starter switch is ON If battery voltage is confirmed fuel cut solenoid is faulty and should be replaced If no voltage refer to ELECTRICAL DIAGNOSIS and make necessary re pairs Disconnect inlet hoses from fuel filter and feed clean fuel from separate container directly into fuel pump HINT When feeding fuel tank directly into pump keep container at same level as vehicle fuel tan...

Page 18: ...0 0531 in If not as above injection pump is improperly adjusted Check timer piston stroke and fast idle lever opening angle with an injection pump tester when cold start advance is operated Check injection pressure with a nozzle tester See page FU 10 or 20 Opening pressure 1PZand1HZ 135 155 kg cm2 1 920 2 205 psi 13 239 15 200 kPa 1HD T No 1 opening pressure 180 190 kg cm2 2 560 2 702 psi 17 652 1...

Page 19: ...ew or make other required repairs 2 IDLE SPEED TOO LOW Check idle speed See page EM 27 Idle speed 1PZ 600 700 rpm 1HZM T 600 700 rpm 1HZA T 660 760 rpm 1HD T M T 600 700 rpm 1HD T A T 750 850 rpm HINT If less than standard idling would normally be rough If not as above adjust with idle speed adjusting screw Check for leaks at injection pump connections pump distributive head bolts injection nozzle...

Page 20: ...le with a nozzle tester See page FU 10 or 20 Opening pressure IPZandiHZ 135 155 kg cm2 1 920 2 205 psi 13 239 15 200 kPa 1HD T No 1 opening pressure 180 190 kg cm2 2 560 2 702 psi 17 652 18 633 kPa No 2 opening pressure Inspection pressure 132 138 kg cm2 1 877 1 963 psi 12 945 13 533 kPa If not as above nozzle adjustment is improper and pressure should be readjusted If pressure cannot be adjusted ...

Page 21: ...d repair accordingly Refer to ENGINE CRANKS NORMALLY BUT WILL NOT START above and check accordingly HINT No operation noise from fuel cut solenoid may be due to loose electrical connections so check connectors before proceeding with further repairs Refer to step 3 of ENGINE CRANKS NORMALLY BUT WILL NOT START above Possible Cause Check Procedure and Correction Method 1 IMPROPER ADJUSTMENT OF ACCELE...

Page 22: ...MING 2 CLOGGED FUEL FILTER 3 FAULTY INJECTION NOZZLES HINT Overflow screw is marked OUT and has an inner jet Although both fittings are same size they must not be interchanged Refer to step 3 of ROUGH IDLE WITH WARM EN GINE Disconnect inlet hose to fuel filter and feed clean fuel directly into pump HINT When feeding fuel directly into pump keep container at same level as vehicle fuel tank If engin...

Page 23: ...r to step 3 of ROUGH IDLE WITH WARM ENGINE After sufficiently warming up engine check idle speed See page EM 27 Idle speed 1PZ 600 700 rpm 1HZM T 600 700 rpm 1HZA T 660 760 rpm 1HD T M T 600 700 rpm 1HD T A T 750 850 rpm If not as above adjust with idle speed adjusting screw Check maximum speed See page EM 27 Maximum speed 1PZ and 1 HZ 4 500 4 700 rpm 1HD T 4 300 4 500 rpm If not as above adjust w...

Page 24: ... Possible Cause Check Procedure and Correction Method BINDING ACCELERATOR CABLE Operate adjusting lever on top of injection pump and check if engine returns to idle See page EM 27 If so accelerator cable is binding or improperly ad justed and should be repaired accordingly If engine does not return to idle injection pump is faulty and should be replaced ENGINE WILL NOT SHUT OFF WITH KEY Possible C...

Page 25: ...r if necessary Check indicator light bulb Bulb No Good Replace bulb Bulb OK Starter switch OFF Check for battery voltage to terminal 3 of pre heating timer connector on wire harness side If okay pre heating timer is faulty and should be replaced Check for battery voltage to terminal 1 of pre heating timer with starter switch ON No Voltage Check that there is 1 V or less to terminal 9 If okay timer...

Page 26: ...age Starter switch OFF Place starter switch at ON and check for voltage to glow plug a few seconds later Thereafter volt age should drop about 1 2 No Voltage at ALL Check for battery voltage at negative side of glow plug resistor If no voltage No 1 glow plug relay is faulty and should be replaced OK Check for battery voltage to positive side of glow plug resistor If okay replace the resistor If no...

Page 27: ... noise clicking sound while repeatedly connecting and disconnecting fuel cut solenoid valve Noise Fuel cut solenoid valve okay No Noise Check fuse Fuse OK Fuse Blown Check for short circuit and repair as necessary Check wire harness from fuse to fuel cut solenoid Noise Apply battery voltage directly to solenoid and check for noise No Voltage Replace fuel cut solenoid valve ...

Page 28: ...1L 1 25 1 27 when fully charged at 20 C 68 F INSPECTION OF AIR FILTER Paper Filter Type 1 INSPECT AIR FILTER Visually check that the filter element is not excessively dirty damaged or oily 2 CLEAN AIR FILTER Clean the filter element with compressed air First blow from the inside thoroughly Then blow off the outside of the filter element Washable Type 1 INSPECT AIR FILTER Visually check that the fi...

Page 29: ... water by shaking the filter element or blowing with compressed air NOTICE Do not beat or drop filter element e Wipe off dust on the air cleaner case interior INSPECTION OF ALTERNATOR DRIVE BELT See step 3 on page CH 5 Drive belt deflection New belt 6 7 mm 0 24 0 28 in Used belt 8 11 mm 0 31 0 43 in Drive belt tension Reference New belt 45 55 kg Used belt 20 35 kg INSPECTION OF GLOW PLUGS See page...

Page 30: ...cylinder are loose and valve lifters on the No 6 cylinder are tight If not turn the crankshaft one revolution 360 and align the mark as above 4 ADJUST VALVE CLEARANCE a Check only those valves indicated in the illustration Using a thickness gauge measure the clearance between the valve lifter and camshaft Record the valve clearance measurements which are out of specification They will be used late...

Page 31: ...kness of the removed shim Calculate the thickness of the new shim so the valve clearance comes within specified value T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 40 mm 0 016 in Select a new shim with a thickness as close as possible to the calculated values HINT Shims are available in twenty sizes in increments of 0 05 m...

Page 32: ...ting Shim Selection Using Chart Intake Intake valve clearance Cold 0 15 0 25 mm 0 006 0 010 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and the measured clearance is 0 300 mm 0 0118 in Replace the 2 800 mm 0 1102 in shim with a No 21 shim ...

Page 33: ...sting Shim Selection Using Chart Exhaust Exhaust valve clearance 0 35 0 45 mm 0 014 0 018 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and the measured clearance is 0 300 mm 0 0118 in Replace the 2 800 mm 0 1102 in shim with a No 11 shim ...

Page 34: ...1 HZ and 1HD T SET NO 1 OR NO 6 CYLINDER TO TDC COMPRESSION Turn the crankshaft pulley clockwise and align its groove with the timing gear cover groove 4 1HD T w BACS REMOVE AIR CONTROL VALVE ACV 5 INSTALL SST AND DIAL INDICATOR a 1HD T Loosen the union nut of the No 5 cylinder injection pipe b Remove the plug bolt from the distributive head plug of the injection pump c Install SST plunger stroke ...

Page 35: ...erform the operation carefully ex 1PZ b Turn the crankshaft to the left and right and check that the dial indicator shows the minimum value NOTICE Make sure that the minimum value is set at 0 mm 0 in c Slowly rotate the crankshaft pulley clockwise until pulley groove is aligned with the timing gear cover groove d Measure the plunger stroke Plunger stroke 1 PZ 0 82 0 88 mm 0 0323 0 0346 in 1HZ 1 03...

Page 36: ...f the stroke is less than specification tilt the pump toward the engine If the stroke is greater than specification tilt the pump away from the engine h Tighten the following nuts and bolt 1 Two nuts holding injection pump to timing gear case Torque 185 kg cm 13 ft lb 18 N m 2 Bolt holding injection pump to injection pump stay Torque 700 kg cm 51 ft lb 69 N m Recheck the plunger stroke 8 w ACSD RE...

Page 37: ... bolt of the distrib utive head plug Torque IPZ and 1HZ 170 kg cm 12 ft lb 17 Nm 1HD T 260kg cm 19 ft lb 25 Nm 10 TORQUE UNION NUTS OF INJECTION PIPES Torque 1PZ and 1HZ 150kg cm 11 ft lb 15 Nm 1HD T 250kg cm 18 ft lb 25 N m 11 1HD T w BACS INSTALL AIR CONTROL VALVE ACV 12 INSTALL TIMING BELT COVER See step 9 on page EM 41 13 START ENGINE AND CHECK FOR LEAKS ...

Page 38: ...e engine c Check the idle speed Idle speed 1PZ 600 700 rpm 1HZ M T 600 700 rpm 1HZ A T 660 760 rpm 1HD T M T 600 700 rpm 1HD T A T 750 850 rpm d Adjust the idle speed Disconnect the accelerator linkage Loosen the lock nut of the idle speed adjusting screw Adjust the idle speed by turning the IDLE SPEED ADJUSTING SCREW Idle speed 1PZ 650 rpm 1HZ M T 650 rpm 1HZ A T 710 rpm 1HD T M T 650 rpm 1HD T A...

Page 39: ...d adjusting screw SST 09275 54020 w o HAC Loosen the lock nut of the maximum speed adjust ing screw Adjust the maximum speed by turning the MAXI MUM SPEED ADJUSTING SCREW Maximum speed 1 PZ and 1 HZ 4 600 rpm 1HD T 4 400 rpm HINT Adjust at idle speed Then raise engine speed and recheck the maximum speed w HAC and 1HD T Using SST securely tighten the lock nut SST 09275 54020 w o HAC Securely tighte...

Page 40: ...JUST AIR CONDITIONER IDLE UP SETTING SPEED a Start the engine b A C switches ON c Disconnect the vacuum hose from the idle up actua tor d Apply vacuum to the idle up actuator e Race the engine to 2 500 rpm for a few seconds release the throttle and check the idle up setting speed A C idle up setting speed 950 rpm f Adjust the idle up setting speed by turning the IDLE UP SETTING SPEED ADJUSTING SCR...

Page 41: ...UP AND STOP ENGINE Allow the engine to reach normal operating temperature 2 DISCONNECT INJECTION PUMP FUEL CUT SOLENOID CONNECTOR 3 REMOVE GLOW PLUGS See step 9 on page EM 57 4 CHECK CYLINDER COMPRESSION PRESSURE a Install SST attachment to the glow plug hole SST 09992 00024 09992 00160 b Connect SST compression gauge to SST attach ment SST 09992 00024 09992 001 60 09992 00211 ...

Page 42: ... 27 0 kg cm2 384 psi 2 648 kPa or more 1HD T 25 0 kg cm2 356 psi 2 452 kpa or more Difference between each cylinder 5 0 kg cm2 71 psi 490 kPa or less f If the cylinder compression in one or more cylinders is low pour a small amount of engine oil into the cylinder through the glow plug hole and repeat steps a through d for the cylinder with low compression If adding oil helps the compression chance...

Page 43: ...Timing Belt TIMING BELT HINT If replacing the timing belt before the timing belt warning light comes on light comes on after 100 000 km of driving be sure to reset the timing belt counter of the speedometer to zero COMPONENTS ...

Page 44: ...se set the No 1 and No 2 camshaft pulley grooves at each position BDC mark HINT By positioning the No 1 cylinder at BDC interfer ence between the valve and piston is avoided even if the camshaft rotates 3 REMOVE TIMING BELT HINT If re using the timing belt draw a direction arrow on the timing belt in direction of engine revolution and place matchmarks on the pulleys and timing belt a Using SST rem...

Page 45: ...g pulley No 2 flange and No 2 camshaft timing pulley b Remove the four bolts camshaft timing pulley No 2 flange No 2 camshaft timing pulley and camshaft timing pulley No 1 flange 6 REMOVE INTAKE PIPE IPZancMHZ a Disconnect the PCV hose b Remove the four bolts intake pipe and gasket c 1HZ Eourope Remove the intake pipe insulator 1HD T a Disconnect the turbo vacuum hose b Loosen the air hose clamp b...

Page 46: ... bolts 1HZ and 1HD T two nuts cylinder head cover and gasket 8 REMOVE NO 1 CAMSHAFT TIMING PULLEY a Hold the hexagonal wrench head portion of the cam shaft with a wrench and remove the No 1 camshaft timing pulley bolt b Using SST remove the No 1 camshaft timing pulley SST 09950 20017 c Remove the set key ...

Page 47: ...ing pulley If there are any defects as shown in the illustration check the following points a Premature parting Check for proper installation Check the timing belt cover gasket for damage and check for proper installation b If the belt teeth are cracked or damaged check to see if the camshaft is locked c If there are cracks or noticeable wear on the belt face check to see if there are nicks on one...

Page 48: ...ecessary replace the idler pulley b Check that the idler pulley and the pulley bolt slide smoothly If necessary replace the idler pulley 3 INSPECT TENSION SPRING a Measure the free length of the tension spring Free length 72 7 mm 2 862 in If the free length is not as specified replace the tension spring b Measure the tension of the tension spring at the specified installed length Installed tension...

Page 49: ... lb 98 Nm 2 INSTALL CYLINDER HEAD COVER a Remove any old packing FIPG material b Apply seal packing to the cylinder head as shown in the illustration Seal packing Part No 08826 00080 or equivalent c Install the gasket to the cylinder head cover d Install the cylinder head cover with the twelve bolts 1PZ or fourteen bolts 1 HZ and 1HD T and two nuts 3 INSTALL INTAKE PIPE 1PZand1HZ a 1HZ Eourope Pla...

Page 50: ...que 315 kg cm 23 ft lb 31 N m 5 INSTALL TIMING BELT IDLER PULLEY Using SST install the plate and timing belt idler pulley with the bolt SST 09923 00020 Torque 270 kg cm 20 ft lb 26 N m 6 SET NO 1 CYLINDER TO BDC Set the timing pulleys at each position NOTICE When turning the crankshaft the valve heads will hit against the piston top So do not turn it more than necessary 7 INSTALL TIMING BELT NOTIC...

Page 51: ...ulley 3 Timing belt idler pulley c Using SST install the tension spring SST 09718 20010 d Install and torque the spring bolt of the timing belt idler Torque 270 kg cm 20 ft lb 26 Nm 8 CHECK VALVE TIMING Turn the crankshaft pulley clockwise and check that each pulley align with the timing marks TDC mark as shown in the illustration If the marks do not align remove the timing belt and reinstall it ...

Page 52: ...material b Apply seal packing to the camshaft oil seal retainer and timing gear cover as shown in the illustration Seal packing Part No 08826 00080 or equivalent c Install the gasket to the timing belt cover d Install the timing belt cover with the three seal wash ers three bolts and four clips ...

Page 53: ...EM 42 ENGINE MECHANICAL Timing Gears TIMING GEARS COMPONENTS ...

Page 54: ... SEAL RETAINER See step 14 on page EM 59 4 REMOVE OIL PIPE a Remove the two union bolts and four gaskets b Remove the bolt and oil pipe 5 REMOVE VACUUM PUMP a Remove the two nuts and vacuum pump b Remove the O ring 6 IHZandiHD T REMOVE NO 2 CRANKSHAFT PULLEY Remove the six bolts and No 2 crankshaft pulley 7 REMOVE NO 1 CRANKSHAFT PULLEY a Using SST remove the pulley bolt and plate SST 0921 3 58011...

Page 55: ... Pry out the timing gear cover 9 CHECK THRUST CLEARANCE OF IDLER GEAR Using a thickness gauge measure the thrust clearance Standard thrust clearance 0 05 0 15 mm 0 0020 0 059 in Maximum thrust clearance 0 30 mm 0 0118 in If the thrust clearance is greater than maximum replace the thrust plate If necessary replace the idler gear and or idler gear shaft 10 REMOVE PUMP DRIVE SHAFT GEAR Using SST remo...

Page 56: ...jection pump drive gear set nut SST 09330 00021 b Remove the O ring c Using SST remove the injection pump drive gear SST 09213 60017 09213 00020 09213 00030 09213 00060 and 09950 20017 NOTICE Tighten the two bolts of SST more than 8 mm 0 31 in Set the SST so that it is balanced 13 REMOVE CRANKSHAFT TIMING GEAR Using SST remove the crankshaft timing gear SST 09213 36020 and 09950 20017 ...

Page 57: ...eter 44 950 44 975 mm 1 7697 1 7707 in c Subtract the idler gear shaft diameter measurement from the idler gear inside diameter measurement Standard oil clearance 0 025 0 075 mm 0 0010 0 0030 in Maximum oil clearance 0 20 mm 0 0079 in If the clearance is greater than maximum replace the gear and shaft 2 INSPECT INJECTION PUMP DRIVE GEAR BEARING Check that bearing is not rough or worn 3 IF NECESSAR...

Page 58: ...ress in a new bearing SST 09214 76011 4 CHECK BACKLASH OF TIMING GEARS Using a dial indicator measure the backlash Standard gear backlash 0 05 0 15 mm 0 0020 0 0060 in Maximum gear backlash 0 30 mm 0 0118 in If the gear backlash is greater than maximum replace the gears as a set ...

Page 59: ...mer tap out the oil seal b Using SST and a hammer tap in a new oil seal until its surface is flush with the timing gear cover edge SST 09223 78010 c Apply MP grease to the oil seal lip B If timing gear cover is installed to the cylinder block a Using SST remove the oil seal SST 09308 10010 and 09950 20017 b Apply MP grease to a new oil seal lip c Using SST and a hammer tap in the oil seal until it...

Page 60: ... b Using SST and a hammer tap in a new oil seal until its surface is flush with the timing gear cover edge SST 09214 76011 c Apply MP grease to the oil seal lip B If timing gear cover is installed to the cylinder block a Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the injection pump drive gear Tape the screwdriver tip b Apply MP grease to the oil seal lip c Using SST a...

Page 61: ...IVE GEAR a Install the set key to the groove of the injection pump drive shaft b Align the set key with the key groove of the injection pump drive gear and install the drive gear c Install a new O ring to the drive gear d Install the injection pump drive gear set nut e Using SST torque the nut SST 09330 00021 Torque 1 000 kg cm 72 ft lb 98 N m 3 INSTALL IDLER GEAR a Install the idler gear shaft b ...

Page 62: ...n the contact surfaces of the timing gear cover and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the timing gear cover as shown in the illustration Seal packing ...

Page 63: ...ing in the No 1 crankshaft pulley groove b Align the pulley set key with the key groove of the pulley c Using SST and a hammer tap in the pulley SST 09214 60010 d Using SST install and torque the plate and bolt Torque 5 000 kg cm 362 ft lb 490 N m 7 1HZand1HD T INSTALL NO 2 CRANKSHAFT PULLEY Install the No 2 crankshaft pulley with the six bolts Torque 250 kg cm 18 ft lb 25 N m ...

Page 64: ...29 ft lb 39 Nm 9 INSTALL OIL PIPE Install the oil pipe with the bolt two union bolts and four new gaskets Torque Bolt 200 kg cm 14 ft lb 20 Nm Union bolt 185 kg cm 13 ft lb 18 Nm 10 INSTALL CAMSHAFT OIL SEAL RETAINER See step 6 on page EM 79 11 INSTALL PULLEYS AND TIMING BELT See page EM 38 12 INSTALL WATER PUMP PULLEY FAN AND DRIVE BELT See step 5 on page CO 9 ...

Page 65: ...EM 54 ENGINE MECHANICAL Cylinder Head CYLINDER HEAD COMPONENTS ...

Page 66: ...il dipstick guide 5 REMOVE INTAKE MANIFOLD a Disconnect the fuel hose from the nozzle leakage pipe b 1PZ Remove the ten bolts seal washers intake manifold and five gaskets c 1 HZ and 1HD T Remove the twelve bolts seal washers intake mani fold and six gaskets 6 REMOVE WATER OUTLET a 1HD T Disconnect the water by pass hose b Remove the two nuts water outlet and gasket 7 REMOVE NOZZLE LEAKAGE PIPE 1P...

Page 67: ...move the five injection nozzles seats and gaskets SST 09268 64010 b 1HZ Using SST remove the six injection nozzles seats and gaskets SST 09268 64010 HINT Arrange the injection nozzles in correct order 1HD T a Remove the bolt washer nozzle holder injection nozzle and seat b Remove the O ring from the injection nozzle HINT Arrange the injection nozzles in correct order ...

Page 68: ...w grommets 1 HZ and 1 HD T b Remove the five nuts 1PZ or six nuts 1 HZ and 1HD T and glow plug connector c Using a 12 mm deep socket wrench remove the five glow plugs 1 PZ or six glow plugs 1 HZ and 1 HD T 10 IPZancMHZ REMOVE EXHAUST MANIFOLD a Remove the four bolts 1 PZ or five bolts 1 HZ and heat insulator ...

Page 69: ... 1HD T REMOVE TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY See steps 3 to 8 on pages TC 9 10 12 1HZ and 1HD T SEPARATE EXHAUST MANIFOLDS a Separate the front and rear exhaust manifolds b Using snap ring pliers remove the two manifold rings 13 REMOVE TIMING BELT AND PULLEYS See steps 1 to 3 and 5 to 7 on pages EM 33 to 35 ...

Page 70: ...the twelve bearing cap bolts in several passes in the sequence shown b 1 HZ and 1HD T Uniformly loosen and remove the fourteen bearing cap bolts in several passes in the sequence shown c Remove the six bearing caps 1 PZ or seven bearing caps 1 HZ and 1 HD T and camshaft d Remove the two bearings from the No 1 bearing cap and No 1 journal of the cylinder head e Remove the camshaft thrust plate HINT...

Page 71: ...wn SST 09011 381 21 NOTICE Head warpage or cracking could result from removing bolts in incorrect order b Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench HINT If the cylinder head is difficult to lift off pry with a screwdriver between the cylinder head and block NOTICE Be careful not to damage the cylinder head and cylinder block surface...

Page 72: ...lve lifters and shims in correct order 2 REMOVE VALVES a Using SST compress the valve spring and remove the two keepers SST 09202 43013 b Remove the spring retainer valve spring valve and spring seat HINT Arrange the valves valve springs spring seats and spring retainers in correct order c Using needle nose pliers remove the oil seal ...

Page 73: ...HZ REMOVE COMBUSTION CHAMBERS Using SST remove the five 1 PZ and six 1 HZ combus tion chambers and shims SST 09208 48010 HINT Arrange the combustion chambers and shims in correct order 4 REMOVE HALF CIRCULAR PLUG 5 REMOVE FRONT AND REAR ENGINE HANGERS ...

Page 74: ...carbon and oil from the bolt holes CAUTION Protect your eyes when using high pres sure air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the manifold and cylinder head surface NOTICE Be careful not to scratch the surfaces 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the com bustion chambers NOTICE Be careful not to scratch the head...

Page 75: ...ead 7 INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant check the combustion chamber intake and exhaust ports head surface and the top of the head for cracks If cracked replace the cylinder head 8 CLEAN VALVES a Using a gasket scraper chip any carbon from the valve head b Using a wire brush thoroughly clean the valve 9 INSPECT VALVE STEMS AND GUIDE BUSHINGS a Using a caliper gauge measure the...

Page 76: ...mm 0 0039 in If the clearance is greater than maximum replace the valve and guide bushing 10 IF NECESSARY REPLACE VALVE GUIDE BUSHINGS a Using SST and a hammer tap out the guide bushing SST 09201 60011 b Using a caliper gauge measure the bushing bore diameter of the cylinder head c Select a new guide bushing STD size or 0 S 0 05 If the bushing bore diameter of the cylinder head is greater than 13 ...

Page 77: ...n b Check that the valve is ground to the correct valve face angle Valve face angle 44 5 c Check the valve head margin thickness Standard margin thickness Intake 1 6 mm 0 063 in Exhaust 1 7 mm 0 067 in Minimum margin thickness Intake 1 1 mm 0 043 in Exhaust 1 2 mm 0 047 in If the margin thickness is less than minimum replace the valve d Check the valve overall length Standard overall length Intake...

Page 78: ...ian blue or white lead to the valve face Lightly press the valve against the seat Do not rotate the valve c Check the valve face and seat for the following If blue appears 360 around the face the valve is concentric If not replace the valve If blue appears 360 around the valve seat the guide and face are concentric If not resurface the seat Check that the seat contact is on the middle of the valve...

Page 79: ...e the squareness of the valve spring Maximum squareness 2 0 mm 0 075 in If squareness is greater than maximum replace the valve spring b Using vernier calipers measure the free length of the valve spring Free length Yellow painted mark 46 20 mm 1 8189 in Blue painted mark 49 14 mm 1 9346 in If the free length is not as specified replace the valve spring c Using a spring tester measure the tension ...

Page 80: ... 1689 2 1697 in 1HD T 54 440 54 460 mm 2 1433 2 1441 in Exhaust 55 940 55 960 mm 2 2024 2 2031 in Minimum cam lobe height Intake IPZ and 1HZ 54 59 mm 2 1492 in 1H D 53 94 mm 2 1236 in Exhaust 55 44 mm 2 1827 in If the cam lobe height is less than minimum replace the camshaft C Inspect camshaft journals Using a micrometer measure the journal diameter Journal diameter No 1 journal 34 969 34 985 mm 1...

Page 81: ...in Others 0 030 0 066 mm 0 0012 0 0026 in Maximum oil clearance 0 10 mm 0 0039 in If the oil clearance is greater than maximum replace the bearings or camshaft If necessary replace the bearing caps and cylinder head h Completely remove the Plastigage F Inspect camshaft thrust clearance a Install the camshaft See step 4 on page EM 78 b Using a dial indicator measure the thrust clearance while movin...

Page 82: ... If necessary replace the cylinder head 16 INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and thickness gauge measure the surface contacting the cylinder head for warp age Maximum warpage 0 40 mm 0 0157 in If warpage is greater than maximum replace the manifold 17 INSPECT CYLINDER HEAD BOLTS Using vernier calipers measure the minimum outer diame ter of the compressed thread a...

Page 83: ... SST and a hammer tap in a new oil seal until its surface is flush with the oil seal retainer edge SST 09223 46011 c Apply MP grease to the oil seal lip B If camshaft oil seal retainer is installed to the cylinder head a Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the camshaft Tape the screwdriver tip b Apply MP grease to a new oil seal lip c Using SST and a hammer tap...

Page 84: ...e half circular plug to the cylinder head 3 SELECT COMBUSTION CHAMBER SHIM A If using new combustion chamber Using a micrometer measure the thickness of each used combustion chamber at the position shown in the illustra tion then select the number of shims to be used Shim thickness 0 03 mm 0 0012 in NOTICE If combustion chamber shims were already being used do not perform the above step use the sa...

Page 85: ... 0012 in If the protrusion is greater than specification replace the chamber and recheck the protrusion 5 INSTALL VALVES a Install the following parts 1 Oil seal 2 Valve 3 Spring seat 4 Valve spring 5 Spring retainer b Using SST compress the valve spring and place the two keepers around the valve stem SST 09202 43013 c Using a plastic faced hammer lightly tap the valve stem tip to assure proper fi...

Page 86: ...r block gasket surface and piston head when taking the measurments d Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclock wise e Measure each cylinder at two places as shown in the illustration making a tatal of ten measurements 1PZ or twelve measurements 1 HZ and 1HD T f For the piston protrusion value of each cylinder use the average of the two me...

Page 87: ...t piston protrusion value from the measure ments made then select the appropriate cylinder head gasket according to the table below 1HZ and 1HD T HINT There are five types of cylinder head gasket cutout number 1 to 5 installed at factory but only three types for supply parts cutout number 1 3 and 5 so when replacing the gasket select from one of three types above New cylinder head gasket thickness...

Page 88: ... cylinder head gasket B Install cylinder head bolts HINT The cylinder head bolts are tightened in three progressive steps If any of bolts break or deform replace them a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b First using SST install and uniformly tighten the twenty two cylinder head bolts 1 PZ or twenty six cylinder head bolts 1 HZ and 1HD T...

Page 89: ...thrust plate to the cylinder head b Install the camshaft bearings to the No 1 bearing cap and No 1 journal of the cylinder head c Place the camshaft on the cylinder head facing the key groove upward d Install the six 1PZ or seven 1 HZ and 1HD T bear ing caps in their proper locations e 1PZ Install and uniformly tighten the twelve bearing cap bolts in several passes in the sequence shown Torque No ...

Page 90: ... material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the camshaft oil seal retainer as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled wi...

Page 91: ...e ends e Install the manifold collar f Assembly the front and rear manifolds 9 IPZandiHZ INSTALL EXHAUST MANIFOLD a Install new gaskets in direction as shown in the illustration b Install the exhaust manifold with the ten nuts 1PZ or twelve nuts 1HZ Torque 400 kg cm 29 ft lb 39 N m HINT Apply 330 kg cm 24 ft lb 32 N m of torque when performing additional tightening of loosed nuts ...

Page 92: ...OLD See steps 4 to 10 on pages TC 13 to 15 11 INSTALL GLOW PLUG a Using a 12 mm deep socket wrench install the five glow plugs 1PZ or six glow plugs 1HZ and 1HD T Torque 130 kg cm 9 ft lb 13 N m b Install the glow plug connector with the five nuts 1 PZ or six nuts 1 HZ and 1 HD T c Install the five screw grommets 1 PZ and six screw grommets 1 HZ and 1 HD T ...

Page 93: ...all a new O ring to the injection nozzle b Place new nozzle seats into the injection nozzle holes of the cylinder head c Install the injection nozzles with the washer and bolt Torque 400 kg cm 29 ft lb 39 N m 13 INSTALL NOZZLE LEAKAGE PIPE 1PZand1HZ a 1PZ Install five new gaskets and the leakage pipe with the five nuts Torque 300 kg cm 22 ft lb 29 N m b 1HZ Install six new gaskets and the leakage ...

Page 94: ...he twelve bolts and seal washers Torque 200 kg cm 14 ft lb 20 Nm 16 INSTALL OIL DIPSTICK GUIDE AND OIL DIPSTICK a Install a new O ring to the dipstick guide b Install the oil dipstick guide assembly with the two bolts Torque Intake manifold side 200 kg cm 14 ft lb 20 Nm Oil cooler cover side 200 kg cm 14 ft lb 20 Nm 17 INSTALL INJECTION PIPES See step 3 on page FU 15 Torque IPZandiHZ 150 kg cm 11 ...

Page 95: ...EM 84 ENGINE MECHANICAL Cylinder Block CYLINDER BLOCK COMPONENTS ...

Page 96: ... bolt end plate and dust cover 5 INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 6 REMOVE TIMING BELT AND PULLEYS See page EM 33 7 REMOVE CYLINDER HEAD See page EM 55 8 REMOVE WATER PUMP See page CO 6 9 REMOVE ALTERNATOR 10 REMOVE TIMING GEARS See page EM 43 11 REMOVE INJECTION PUMP See page FU 27 12 REMOVE OIL PAN AND TIMING GEAR CASE OIL PUMP See page LU 8 13 REMOVE OIL COOLER See page LU 14 14 R...

Page 97: ...m thrust clearance 0 30 mm 0 0118 in If the thrust clearance is greater than maximum replace the connecting rod assembly If necessary replace the crank shaft 3 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Using paint place the matchmarks on the connecting rod and cap to ensure correct reassembly b Using SST remove the connecting rod cap bolts SST 09011 381 21 c Using the removed connecting...

Page 98: ... the connecting rod cap See step 8 on page EM 111 Torque 1st 375 kg cm 27 ft lb 37 Nm 2nd turn 90 HINT Do not turn the crankshaft h Remove the connecting rod cap See procedure b and c above i Measure the Plastigage at widest point Standard oil clearance STD 0 036 0 054 mm 0 0014 0 0021 in U S 0 25 and U S 0 50 0 037 0 077 mm 0 0015 0 0030 in Maximum oil clearance 0 10 mm 0 0039 in If the oil clear...

Page 99: ...4 62 020 mm 2 4415 2 4417 in Mark 2 62 020 62 026 mm 2 4417 2 4420 in Mark 3 62 026 62 032 mm 2 4420 2 4422 in Crankshaft pin diameter Mark 1 58 994 59 000 mm 2 3226 2 3228 in Mark 2 58 988 58 994 mm 2 3224 2 3226 in Mark 3 58 982 58 988 mm 2 3221 2 3224 in Standard sized bearing center wall thickness Mark 2 1 486 1 489 mm 0 0585 0 0586 in Mark 3 1 489 1 492 mm 0 0586 0 0587 in Mark 4 1 492 1 495 ...

Page 100: ...k and forth with a screwdriver Standard thrust clearance 0 04 0 24 mm 0 0016 0 0094 in Maximum thrust clearance 0 30 mm 0 0118 in If the thrust clearance is greater than maximum replace the thrust washers as a set Thrust washer thickness 2 930 2 980 mm 0 1154 0 1173 in 6 REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE a Remove the thirteen bolts 1 PZ or fifteen bolts 1 HZ and 1HD T b Uniformly loo...

Page 101: ...hers together with the cylinder block e Clean each main journal and bearing f Check each main journal and bearing for pitting and scratches If the journal or bearing are damaged replace the bearings If necessary grind or replace the crankshaft g Place the crankshaft on the cylinder block h Lay a strip of Plastigage across each journal i Install the main bearing cap with the bearings See step 6 on ...

Page 102: ... of the bearing cannot be determined select the correct bearing by adding together the numbers inprinted on the main bearing cap and crankshaft then selecting the bearing with the same number as the total There are five sizes of standard bearings marked 2 3 4 5 and 6 accordingly EXAMPLE Main bearing cap 2 Crankshaft 1 Total number Use bearing 3 Reference Cylinder block main journal bore diameter M...

Page 103: ...784 in Mark 6 1 991 1 994 mm 0 0784 0 0785 in I Completely remove the Plastigage 7 REMOVE CRANKSHAFT a Lift out the crankshaft b Remove the upper main bearings and thrust washers from the cylinder block HINT Arrange the main bearings and thrust washers in correct order 8 REMOVE CHECK VALVES AND OIL NOZZLES Remove the five 1 PZ or six 1 HZ and 1HD T check valves and oil nozzles 9 REMOVE CYLINDER BL...

Page 104: ... the surfaces contacting the cylinder head gasket for warpage Maximum warpage 0 20 mm 0 0079 in If warpage is greater than maximum replace the cylinder block 4 INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches If deep scratches are present rebore all five 1PZ or six 1HZ and 1HD T cylinders If necessary replace the cylinder block 5 INSPECT CYLINDER BORE DIAM...

Page 105: ...295 in If the diameter is greater than maximum rebore all five 1 PZ or six 1 HZ and 1 HD T cylinders If necessary replace the cylinder block 6 REMOVE CYLINDER RIDGE If the wear is less than 0 2 mm 0 008 in use a ridge reamer to machine the piston ring ridge at the top of the cylinder 7 INSPECT MAIN BEARING CAP BOLTS Using vernier calipers measure the minimum diameter of the compressed thread at th...

Page 106: ...ND PISTON PIN Try to move the piston back and forth on the piston pin If any movement is felt replace the piston and pin as a set 2 REMOVE PISTON RINGS a Using a piston ring expander remove the two com pression rings and oil ring b Remove the coil by hand HINT Arrange the rings in correct order only 3 DISCONNECT CONNECTING ROD FROM PISTON a Using a small screwdriver remove the snap rings ...

Page 107: ... the piston to approx 80 C 176 F c Using a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod HINT The piston and pin are a matched set Arrange the pistons pins rings connecting rods and bearings in correct order ...

Page 108: ...ISTON DIAMETER AND OIL CLEARANCE HINT There are three sizes of the standard piston diam eter marked 1 2 and 3 accordingly The mark is stamped on the top of the piston a Using a micrometer measure the piston diameter at right angles to the piston pin center line at the indicated distance from the piston head Distance 1PZ and 1 HZ 58 6 mm 2 3071 in 1HD T 65 7 mm 2 5866 in Piston diameter STD Mark 1 ...

Page 109: ...andard bore diameter mark on the cylinder block 3 INSPECT CLEARANCE BETWEEN WALL OF RING GROOVE AND NEW PISTON RING No 1 Ring Install new No 1 piston ring to the piston Using a thickness gauge measure the clearance between the piston ring and wall of the piston ring groove Ring groove clearance No 1 0 050 0 095 mm 0 0020 0 0037 in No 2 and Oil Rings Using a thickness gauge measure the clearance be...

Page 110: ... piston ring rebore all five 1 PZ or six 1 HZ and 1 HD T cylinders or replace the cylinder block 5 INSPECT PISTON PIN FIT At 80 C 176 F you should be able to push the piston pin into the piston pin hole with your thumb 6 INSPECT CONNECTING ROD A Inspect connecting rod alignment Using a rod aligner check the connecting rod alignment Check for bending Maximum bending 0 03 mm 0 0012 in per 100 mm 3 9...

Page 111: ...shing inside diameter IPZ and 1HZ 29 008 29 020 mm 1 1420 1 1425 in 1HD T 33 008 33 020 mm 1 2995 1 3000 in b Using a micrometer measure the piston pin diameter Piston pin diameter 1PZ and 1HZ 29 000 29 012 mm 1 1417 1 1422 in 1HD T 33 000 33 012 mm 1 2992 1 2997 in c Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oil clearance 0 004 0 012 mm 0 0...

Page 112: ...shings a Using a round file lightly file off any roughness from the small end of the connecting rod b 1HD T Attach the bushing to SST with the ball of SST inside the oil hole of the bushing SST 09222 17010 09222 05030 c Align the oil holes of the bushing and connecting rod ...

Page 113: ...5030 09222 05040 C Hone connecting rod bushing and check piston pin fit a Using a pin hole grinder hone the bushing to obtain the standard specified clearance see page EM 100 between the bushing and piston pin b Check the piston pin fit at normal room temperature Coat the piston pin with engine oil and push it into the connecting rod with your thumb ...

Page 114: ... Using a micrometer measure the piston diameter at right angles to the piston pin center line at the indicated distance from the piston head Distance 1 PZ and 1 HZ 58 6 mm 2 3071 in 1HD T 65 7 mm 2 5866 in b Calculate the amount each cylinder is to be rebored as follows Size to be rebored P C H P Piston diameter C Piston oil clearance 0 04 0 06 mm 0 0016 0 0024 in H Allowance for honing 0 02 mm 0 ...

Page 115: ... 2 6278 2 6281 in U S 0 50 66 495 66 505 mm 2 6179 2 6183 in Crank pin diameter STD 58 982 59 000 mm 2 3221 2 3228 in U S 0 25 58 745 58 755 mm 2 3128 2 3132 in U S 0 50 58 495 58 505 mm 2 3029 2 3033 in If the diameter is not as specified check the oil clearance See pages EM 86 to 92 b Check each main journal and crank pin for taper and out of round as shown Maximum taper and out of round 0 02 mm...

Page 116: ...ap in a new oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 56010 c Apply MP grease to the oil seal lip B If rear oil seal retainer is installed to cylinder block a Using a knife cut off the oil seal lip b Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screwdriver tip c Apply MP grease to a new oil seal lip d Usin...

Page 117: ...hen push the snap ring into the piston groove starting from end A b Gradually heat the piston to about 80 C 176 F c Apply a light coat of engine oil to the piston pin d Align the front marks of the piston and connecting rod and push in the piston pin with your thumb e Install a new snap ring on the other side of the piston pin hole using the same method as in a above 2 INSTALL PISTON RINGS a Insta...

Page 118: ... the two compres sion rings with the code mark facing upward Code mark No 1 1T No 2 2T d Position the piston rings so that the ring ends are as shown NOTICE Do not align the ring ends 3 INSTALL BEARINGS a Align the bearing claw with the claw groove of the connecting rod or connecting cap b Install the bearings in the connecting rod and con necting rod cap ...

Page 119: ...ICE 3 INSTALL OIL NOZZLES AND CHECK VALVES a Align the pin of the oil nozzle with the pin hole of the cylinder block b Install the oil nozzle with the check valve Install the five 1PZ or six 1 HZ and 1HD T oil nozzles and check valves Torque 275 kg cm 20 ft lb 27 Nm 4 INSTALL MAIN BEARINGS a Align the bearing claw with the claw groove of the main bearing cap or cylinder block b Install the bearing...

Page 120: ...block Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the cylinder block as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 5 mm 0 20 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be remove...

Page 121: ...e of the main bearing cap bolts does not meet the torque specification replace the main bearing cap bolt c Mark the front of the main bearing cap bolt head with paint d 2nd retighten the main bearing cap bolts 90 in the numerical order shown above e Check that the painted mark is now at a 90 angle to the front f Check that the crankshaft turns smoothly g Check the crankshaft thrust clearance See s...

Page 122: ...Install the connecting rod cap with the front mark facing forward B Install connecting rod cap bolts HINT The connecting rod cap bolts are tightened in two progressive steps If any of the connecting rod bolts break or deform replace them a Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts b 1 st using SST install and alternately tighten the bolts o...

Page 123: ... and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the rear oil seal retainer as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install ...

Page 124: ...e page CO 8 9 INSTALL CYLINDER HEAD See page EM 75 10 INSTALL PULLEYS AND TIMING BELT See page EM 38 11 REMOVE ENGINE STAND 12 INSTALL REAR END PLATE Install the end plate with the bolt Torque 185 kg cm 13 ft lb 18 Nm 13 M T INSTALL FLYWHEEL a Install the flywheel on the crankshaft b Install and uniformly tighten the eight mount bolts in several passes in the sequence shown Torque 1 300 kg cm 94 f...

Page 125: ...TC 1 TURBOCHARGER Page DESCRIPTION TC 2 PRECAUTIONS TC 4 TROUBLESHOOTING TC 5 TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS HZJ80 TC 7 TURBOCHARGER TC 8 ...

Page 126: ...t type using the engine crankshaft etc to mechan n o t h e r w o r d s b installing a special turbo ically turn the pump etc For LAND CRUISER c n a r g e r a n d p r o v i d i n g a h i g n e r air than usual and COASTER 1HD T engine the turbocharger e n g m e o u t p u t c a n be i n c r e a s e d by increasing the type has been adopted average combustion pressure without increasing The turbochar...

Page 127: ...s increasa approx 20 000 11 5 000 rpm thus the turbocharged air pressure grows greater and engine output increases Waste Gate Valve If the turbocharged air pressure exceeds the prescribed air pressure the flow of exhaust gas by passes the turbine controlling turbine wheel revolutions and turbocharged air pressure This by pass valve which controls the quantity of ex haust gas flowing to the turbine...

Page 128: ... grasp it by easily deformed parts such as the actuator or rod when moving it 5 Before removing the turbocharger plug the intake and exhaust ports and oil inlet to prevent entry of dirt or other foreign material 6 If replacing the turbocharger check for accumulation of sludge particles in the oil pipes and if necessary replace the oil pipes 7 Completely remove the gasket adhered to the lubrica tio...

Page 129: ...ticles entering will damage the wheels which run at extremely high speed TROUBLESHOOTING HINT Before troubleshooting the turbocharger first check the engine itself Valve clearance engine compres sion injection timing etc INSUFFICIENT ACCELERATION LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION Check Procedure and Correction Method Possible Cause ...

Page 130: ...XCESSIVE OIL CONSUMPTION OR WHITE EXHAUST TC 6 TURBOCHARGER SYSTEM Troubleshooting ABNORMAL NOISE Possible Cause Check Procedure and Correction Method Possible Cause Check Procedure and Correction Method ...

Page 131: ...TURBOCHARGER SYSTEM Turbocharger Electrical System Diagnosis HZJ80 TC 7 TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS HZJ80 TROUBLESHOOTING OF TURBOCHARGER INDICATOR LIGHT AND WARNING LIGHT OPERATION ...

Page 132: ... replace 3 CHECK TURBOCHARGING PRESSURE a Warm up engine b Connect a 3 way union to the intake pipe pressure hose and install SST turbocharger pressure gauge to it SST 09992 00241 b Press in the clutch pedal then press the accelerator pedal down as far as it will go Measure the turbo charging pressure at maximum speed 4 400 rpm Standard pressure 0 50 0 65 kg cm2 7 1 9 2 psi 49 64 kPa If the pressu...

Page 133: ...TURBOCHARGER SYSTEM Turbocharger TC 9 COMPONENTS ...

Page 134: ...se for the boost compen sator b Disconnect the air hose clamp bolt c Remove the three bolts and intake pipe 3 REMOVE EXHAUST MANIFOLD HEAT INSULATOR Remove the five bolts and heat insulator 4 DISCONNECT WATER BY PASS HOSES 5 REMOVE TURBO HEAT INSULATOR Remove the two bolt and heat insulator 6 REMOVE TURBOCHARGER STAY Remove the three bolts and turbocharger stay ...

Page 135: ...il pipe and gasket 8 REMOVE TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY Remove the twelve nuts the turbocharger and exhaust manifold assembly and gaskets 9 SEPARATE TURBOCHARGER AND EXHAUST MANIFOLD Remove the four nuts turbocharger and gasket 10 REMOVE NO 2 TURBO HEAT INSULATOR Remove the two bolts and No 2 turbo heat insulator 11 REMOVE NO 1 TURBO WATER PIPE Remove the two nuts No 1 turbo water p...

Page 136: ...ELLER WHEEL Insert a dial indicator into the exhaust side hold the tur bine wheel edge by hand and check the axial play Axial play 0 13 mm 0 0051 in or less If the axial play is not as specified replace the turbocharger assembly 3 INSPECT RADIAL PLAY OF TURBINE SHAFT a From the oil outlet hole insert the dial indicator through the hole in the spacer bearing and set it in the center of the turbine ...

Page 137: ...tor INSTALLATION OF TURBOCHARGER See page TC 9 NOTICE After replacing the turbocharger assembly pour approx 20 cc 1 2 cu in of new oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing 1 INSTALL TURBINE OUTLET ELBOW Install a new gasket and the turbine outlet elbow with the four nuts Torque 530 kg cm 38 ft lb 52 Nm 2 INSTALL NO 1 TURBO WATER PIPE Install a new gas...

Page 138: ...t manifold assem bly with the twelve nuts Torque 400 kg cm 29 ft lb 39 N m HINT Apply 330 kg cm 24 ft lb 32 N m of torque when performing additional tightening of loosed nuts 6 INSTALL TURBO OIL PIPE a Install a new gasket and the turbo oil pipe w th the two nuts Torque 185 kg cm 13 ft lb 18 N m b Connect the turbo oil hose c Install two new gaskets and the union bolt of the turbo oil pipe Torque ...

Page 139: ...EXHAUST MANIFOLD HEAT INSULATOR Install the heat insulator with the five bolts Torque 185 kg cm 13 ft lb 18 Nm 11 INSTALL INTAKE PIPE a Connect the air hose and install a new gasket and the intake pipe with the three bolts Torque 200 kg cm 14 ft lb 20 Nm b Connect boost compensator vacuum hose 12 FILL ENGINE WITH COOLANT See page CO 5 13 START ENGINE AND CHECK FOR LEAKS 14 CHECK ENGINE OIL LEVEL ...

Page 140: ...es refer to TROUBLE SHOOTING EM Section Page DESCRIPTION FU 2 REPLACEMENT OF FUEL FILTER FU 4 FUEL HEATER SYSTEM FU 6 INJECTION NOZZLES 1PZ and 1 HZ FU 9 INJECTION NOZZLES 1HD T FU 16 INJECTION PUMP FU 27 POWER CONTROL SYSTEM PCS HDB30 w M T only FU 95 ...

Page 141: ...housing is distributed to the injection nozzles according to the injection order and injected at high pressure into the combustion chamber Excess fuel in the pump housing flows through the overflow valve and along the overflow pipe and returns to the fuel tank The fuel cycle provides both cooling and lubrication for the pump The cycling of fuel through the pump chamber warms the fuel so that it is...

Page 142: ...ower part of the injection pump is operated by the fuel pressure of the pump housing and movement of the roller ring by the timer advances the injection angle and controls the injection timing The fuel cut solenoid valve is connected to the starter switch IG circuit and when the starter switch is turned to OFF the current is cut off the solenoid is de energized fuel is cut off and the engine stops...

Page 143: ...g and drain the fuel 3 REPLACE FUEL FILTER A Remove fuel filter Using SST remove the fuel filter SST 09228 64010 B Remove fuel filter warning switch from fuel filter Using pliers remove the warning switch and O ring NOTICE Be careful not to damage the warning switch C Install fuel filter warning switch to new fuel filter a Install a new O ring to the warning switch b Apply fuel to the O ring of th...

Page 144: ... gasket of a new fuel filter c Lightly screw the fuel filter into place and tighten it until the gasket comes into contact with the seat d Tighten it additional 3 4 turn by hand 4 FILL FUEL FILTER WITH FUEL Operate the hand pump until you feel more resistance 5 CONNECT FUEL FILTER WARNING SWITCH CONNECTOR 6 START ENGINE AND CHECK FOR FUEL LEAKS ...

Page 145: ...FU 6 FUEL SYSTEM Fuel Heater System FUEL HEATER SYSTEM SYSTEM CIRCUIT ...

Page 146: ... the vacuum switch port b Using an ohmmeter check that there is continuity between terminal 1 and the switch body If operation is not as specified replace the fuel heater and vacuum switch assembly INSPECTION OF COMPONENTS Fuel Heater INSPECT FUEL HEATER a Apply a vacuum of 350 50 mmHg 13 78 1 97 in Hg 46 7 6 7 kPa or more to the vacuum switch port b Using an ohmmeter measure the resistance betwee...

Page 147: ...eck that there is continuity between terminals 1 and 3 c Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION b Apply battery voltage across terminals 1 and 3 c Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as specified replace the relay ...

Page 148: ...VAL OF INJECTION NOZZLES 1 REMOVE INTAKE PIPE See step 6 on page EM 34 2 REMOVE INJECTION PIPES a Loosen the union nuts of the injection pipes from the injection nozzles b Loosen the union nuts of the injection pipes from the injection pump c Remove the three clamps and injection pipes ...

Page 149: ...CTION PRESSURE TEST a Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut CAUTION Do not place your finger over the nozzle injection hole b Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole c Pump the tester handle slowly and observe the pres sure gauge d Read the pressure gauge just as the injection...

Page 150: ... in changes the injection pressure by about 3 5 kg cm2 50 psi 343 kPa 1HZ Only one adjusting shim should be used f There should be no dripping after injection 2 LEAKAGE TEST While maintaining pressure at about 10 20 kg cm2 142 284 psi 981 1 961 kPa below opening pressure adjust by tester handle check that there is no dripping for 10 seconds from the injection hole or around the retaining nut If th...

Page 151: ...8 64010 NOTICE When disassembling the nozzle be careful not to drop the inner parts b Remove the pressure spring shim pressure pin dis tance piece and the nozzle assembly CLEANING AND INSPECTION OF INJECTION NOZZLES 1 NOZZLE CLEANING a To wash the nozzles Use a wooden stick and brass brush Wash them in clean diesel fuel HINT Do not touch the nozzle mating surfaces with your fingers ...

Page 152: ...damage or corrosion If any of these conditions are present replace the nozzle assembly 2 INSPECT NOZZLE ASSEMBLY a Wash the nozzle in clean diesel fuel HINT Do not touch the nozzle mating surfaces with your fingers b Tilt the nozzle body about 60 degrees and pull the needle out about one third of its length c When released the needle should sink down into the body vent smoothly by its own weight d...

Page 153: ...efects 2 PERFORM PRESSURE AND SPRAY PATTERN TEST See pages FU 10 11 INSTALLATION OF INJECTION NOZZLES See page FU 9 1 INSTALL INJECTION NOZZLES a Place new gaskets and the nozzle seats into the injection nozzle holes of the cylinder head b Using SST install the injection nozzles SST 09268 64010 Torque 650 kg cm 47 ft lb 64 Nm NOTICE Over torquing could cause nozzle deformation and needle adhesion ...

Page 154: ...ke manifold b Connect the injection pipes to injection nozzle Torque 150 kg cm 11 ft lb 15 Nm c Connect the injection pipes to injection pump Torque 150 kg cm 11 ft lb 15 Nm d Secure the injection pipes with clamps and bolts 4 INSTALL INTAKE PIPE See step 3 on page EM 38 5 START ENGINE AND CHECK FOR FUEL LEAKS ...

Page 155: ...REMOVE INTAKE PIPE See step 6 on page EM 34 2 DISCONNECT INJECTION PIPES Loosen the union nuts of the six injection pipes from the six injection nozzles 3 REMOVE NOZZLE LEAKAGE PIPE a Disconnect the fuel hose from the nozzle leakage pipe b Remove the six hollow bolts leakage pipe and twelve gaskets ...

Page 156: ... 981 1 961 kPa below No 1 opening pressure adjust by tester handle check that there is no dripping for 10 seconds from the injection hole or around the retaining nut If the nozzle drips within 10 seconds replace or clean and overhaul the nozzle assembly 2 SPRAY PATTERN TEST a The injection nozzle should shudder at a certain pumping speed between 15 60 times old nozzle or 30 60 times new nozzle per...

Page 157: ...ul not to drop the inner parts b Remove the nozzle sub assembly and distance piece straight pins No 1 pressure pin No 1 pressure spring adjusting shim capsule sub assembly and adjusting shim CLEANING AND INSPECTION OF INJECTION NOZZLES 1 NOZZLE CLEANING a To wash the nozzles Use a wooden stick and brass brush Wash them in clean diesel fuel HINT Do not touch the nozzle mating surfaces with your fin...

Page 158: ...ge or corrosion If any of these conditions are present replace the nozzle assembly 2 INSPECT NOZZLE ASSEMBLY a Wash the nozzle in clean diesel fuel HINT Do not touch the nozzle mating surfaces with your fingers b Tilt the nozzle body about 60 degrees and pull the needle out about one third of its length c When released the needle should sink down into the body vent smoothly by its own weight d Rep...

Page 159: ... Install the SST to the dial indicator so that the protrusion shown in the illustration is 2 0 mm 0 079 in or less SST 09268 17010 b Set the dial indicator scale to 0 mm 0 in on top of SST or surface plate SST 09268 17010 c Place the nozzle sub assembly distance piece straight pins and No 1 pressure pin on the SST as shown in the illustration SST 09268 17010 d Install SST holes to the straight pin...

Page 160: ... 276 in or less SST 09268 17010 f Set the dial indicator scale to 0 mm 0 in on top of SST or surface plate SST 09268 17010 g Place the adjusting shim the capsule sub assembly and straight pins on the nozzle holder body h Install SST holes to the straight pins and measure dimension 1 SST 09268 17010 Dimension f1 Reference 4 79 mm 0 1886 in ...

Page 161: ...turns the plug screw of the capsule sub assembly with SST SST 09268 17010 HINT When the plug screw is loosened by one or two turns the pre lift from installation in the nozzle holder be comes 0 mm 0 in b Assemble the following parts 1 Nozzle holder body 2 Adjusting shim selected in step 1 above 3 Capsule sub assembly in the condition from step 2 a 4 No 1 pressure pin 5 Distance piece 6 Straight pi...

Page 162: ... over the nozzle injection hole e Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole f Pump the tester handle slowly and observe the pres sure gauge g Read the pressure gauge just as the injection pressure begins to drop No 2 opening pressure Inspection pressure 132 138 kg cm2 1 877 1 963 psi 12 945 13 533 kPa HINT Proper nozzle operation can be ...

Page 163: ...stance piece straight pins and the nozzle sub assembly and finger tighten the retaining nut HINT Align the holes of the nozzle body distance piece and nozzle holder body When the thickness of the originally used adjusting shim is not known use a shim 1 5 mm 0 59 in thick instead b Using a 14 mm deep socket wrench torque the retaining nut Torque 350 kg cm 25 ft lb 34 N m NOTICE Over torquing could ...

Page 164: ... 17 652 18 633 kPa HINT Proper nozzle operation can be determined by a swishing sound If the opening pressure is not as specified disassemble the nozzle and change the adjusting shim on the top of the No 1 pressure spring HINT Varying the adjusting shim thickness by 0 01 mm 0 0004 in changes the injection pressure by about 1 5 kg cm2 21 psi 147 kPa Only one adjusting shim should be used f There sh...

Page 165: ... injection nozzles with the washer nozzle holder clamp and bolt Torque 400 kg cm 29 ft lb 39 N m 2 INSTALL NOZZLE LEAKAGE PIPE a Install new gaskets and the leakage pipe with the hollow bolts Torque 125 kg cm 9 ft lb 12 N m b Connect the fuel hose to the return pipe 3 CONNECT INJECTION PIPES Connect the injection pipes to injection nozzle Torque 250 kg cm 18 ft lb 25 N m 4 INSTALL INTAKE PIPE See ...

Page 166: ...FUEL SYSTEM Injection Pump FU 27 INJECTION PUMP REMOVAL OF INJECTION PUMP ...

Page 167: ...A C IDLE UP VACUUM HOSE 7 w ACSD DISCONNECT WATER BY PASS HOSES FROM THERMO WAX 8 DISCONNECT INJECTION PUMP CONNECTOR 9 DISCONNECT FUEL HOSES FROM INJECTION PUMP 10 1HD T DISCONNECT BOOST COMPENSATOR HOSE 11 w PCS DISCONNECT PCS VACUUM HOSE 12 w BACS DISCONNECT BACS VACUUM HOSE 13 REMOVE INJECTION PIPES See step 2 on page FU 9 14 REMOVE INJECTION PUMP a Using SST remove the injection pump drive ge...

Page 168: ... the injection pump SST 09213 60017 09213 00020 09213 00030 09213 00060 and 09950 20017 NOTICE Tighten the two bolts more than 8 mm 0 31 in Set SST so that it is balanced Do not hold or carry the injection pump by the adjusting lever Do not put the injection pump with HAC or for the 1 HD T at an angle more than 45 from the horizon tal f Remove the cylinder block insulator 1 PZ and 1 HZ M T for Eur...

Page 169: ...FU 30 FUEL SYSTEM Injection Pump COMPONENTS ...

Page 170: ...FUEL SYSTEM Injection Pump FU 31 COMPONENTS Cont d ...

Page 171: ...FU 32 FUEL SYSTEM Injection Pump COMPONENTS Cont d ...

Page 172: ...IPES Place the matchmarks on the fuel inlet pipe and governor cover 5 w ACSD REMOVE IDLE UP LEVER Using a 5 mm hexagon wrench remove the three bolts and idle up lever 6 w ACSD REMOVE THERMO WAX a Using a screwdriver turn the cold starting lever coun terclockwise approx 20 b Put a metal plate thickness of 3 5 7 5 mm 0 138 0 295 in between the cold starting lever and thermo wax plunger c Using a 5 m...

Page 173: ...ove the two bolts and PCS actuator assembly 8 w PCS REMOVE NO 1 PCS LEVER Remove the nut and No 1 PCS lever 9 w Dash Pot REMOVE DASH POT Remove the dash pot and gasket 10 REMOVE FUEL CUT SOLENOID a Disconnect the lead wire connector from the bracket b Disconnect the dust cover from the fuel cut solenoid c Remove the nut lead wire and dust cover ...

Page 174: ...E PICKUP SENSOR Remove the pickup sensor and O ring 12 REMOVE ADJUSTING LEVER a Place the matchmarks on adjusting lever and shaft b Remove the nut return spring guide adjusting lever and return spring 13 REMOVE GOVERNOR COVER a w HACand 1HD T Remove the idle speed adjusting screw b Using a 5 mm hexagon wrench remove the four bolts ...

Page 175: ...nd gasket 14 REMOVE GOVERNOR ADJUSTING LEVER SHAFT FROM GOVERNOR COVER Remove the following parts from the governor cover 1 Adjusting lever shaft O ring and washer assembly 2 O ring 3 Washer 15 1PZ w HAC and1HZ w HAC DISASSEMBLE HIGH ALTITUDE COMPENSATOR A Remove lever control spring Remove the bolt gasket and lever control spring B Remove pneumatic bellows a Using a 5 mm hexagon wrench remove the...

Page 176: ...llows 5 Two rubber caps 6 Push rod 7 Pneumatic bellows spring C Remove control lever a Using a 4 mm hexagon wrench remove the two bolts and gaskets b Using a small screwdriver push out the support pin and remove the control lever c Using needle nose pliers remove the connecting pin NOTICE Be careful not to damage the connecting Tape the tip of the pliers ...

Page 177: ...asket and lever control spring B Remove boost compensator diaphragm a Using a 5 mm hexagon wrench remove the four bolts b Remove the following parts 1 Diaphragm cover 2 Diaphragm 3 Spring 4 Boost compensator shim C Remove guide bushing D Remove control lever a Using a 4 mm hexagon wrench remove the two bolts and gaskets ...

Page 178: ...l not to damage the connecting pin Tape the tip of the pliers E Remove ISIo 2 PCS lever Remove the following pars from the the governor cover 1 No 2 lever O ring and washer assembly 2 O ring 3 Washer F Remove No 2 overflow screw Remove the cover and No 2 overflow screw 17 CHECK FLYWEIGHT HOLDER THRUST CLEARANCE See step 20 on page FU 58 Thrust clearance 0 15 0 35 mm 0 0059 0 0138 in ...

Page 179: ... following part 1 Flyweight holder assembly 2 No 1 flyweight washer 3 Governor gear adjusting washer HINT Be careful not to drop the two washers into the pump housing c Remove the following parts from the flyweight holder 1 Governor sleeve 2 No 2 flyweight washer 3 Four flyweights 19 REMOVE INJECTION PUMP STAY Using a 5 mm hexagon wrench remove the three bolts and stay 20 REMOVE DISTRIBUTIVE HEAD ...

Page 180: ... and spring seats SST 09260 5401 2 09269 54020 b Remove the delivery valves and gaskets NOTICE Do not touch the sliding surfaces of the delivery valve with your hand HINT Arrange the delivery valves springs spring seats and holders in order 22 REMOVE DISTRIBUTIVE HEAD a Using a 5 mm hexagon wrench remove the four bolts ...

Page 181: ...he pump plunger and plunger adjust ing shim together with the following parts 1 Spill ring 2 Lower spring seat 3 Upper plunger plate 4 Lower plunger plate SST 09260 54012 09269 54030 NOTICE Do not touch the sliding surfaces of the pump plunger with your hand 24 REMOVE GOVERNOR LINK Using SST remove the two support bolts gaskets and governor link SST 09260 54012 09269 54040 25 REMOVE FACE CAMPLATE ...

Page 182: ... b Push the slide pin toward inside c 1PZ Push the drive shaft and remove the roller ring three rollers and shims assembly 1 HZ and 1HD T Push the drive shaft and remove the roller ring four rollers and shims assembly NOTICE Be careful not to drop the rollers Do not alter the position or assembly of the rollers ...

Page 183: ...the drive shaft 27 REMOVE TIMER a Using a 5 mm hexagon wrench remove the four bolts b Remove the following parts 1 LH timer cover timer adjusting screw and nut assembly 2 Spring 3 O ring 4 RH timer cover 5 O ring 6 Piston 7 Sub piston c Remove the nut from the LH timer cover d Using a 5 mm hexagon wrench remove the timer adjusting screw e Remove the O ring from the timer adjusting ring ...

Page 184: ...cover c Remove the feed pump rotor four blades and liner NOTICE Be careful not to interchange the blade positions Be careful not to damage the pump body 29 REMOVE REGULATOR VALVE Using SST remove the regulator valve and two O rings SST 09260 54012 09262 54020 30 REMOVE FUEL INLET HOLLOW SCREW Remove the hollow screw and gasket ...

Page 185: ... down with your finger When your finger is released the valve should rise back to its original position c Remove your thumb from the valve seat hole The valve should close completely by its own weight If operation is not as specified replace the valve as a set HINT Before using a new valve set wash off the rust prevention compound with light oil or gasoline Then re wash with diesel fuel and perfor...

Page 186: ...UARENESS Using a steel square check the squareness of the plunger springs Maximum squareness 2 0 mm 0 079 in If squareness is greater than maximum replace the springs 4 INSPECT SPRING LENGTH Using vernier calipers measure the free length of each spring Spring free length Delivery valve spring 1 PZ and 1 HZ 24 4 mm 0 961 in 1HD T 19 1 mm 0 752 in Plunger spring 1PZand1HZ 30 0 mm 1 181 in 1HD T 31 2...

Page 187: ... click from the solenoid valve when the battery power is connected and disconnected If the solenoid valve is not operating properly replace it 7 INSPECT PICKUP SENSOR Using an ohmmeter measure the resistance between the terminals Resistance 600 800 Q If resistance is not as specified replace the sensor 8 IF NECESSARY REPLACE OIL SEAL a Using a wrench pry out the oil seal NOTICE Be careful not to d...

Page 188: ...the two O rings to the regulator valve b Using SST install the regulator valve SST 09260 54012 09262 54020 Torque 90 kg cm 78 in Ib 8 8 Nm 4 INSTALL FUEL FEED PUMP a Install the liner rotor and four blades b Check that the liner and blades are facing in the correct direction as shown c Check that the blades move smoothly d Align the fuel outlet holes of the cover and liner e Install the pump cover...

Page 189: ...haft as shown b Install two new joint rubbers into the drive gear c Position the key groove of the feed pump rotor upward d Install the set key and drive shaft washer on the drive shaft and insert the drive shaft assembly into the pump housing e Check that the drive shaft turns without catching ...

Page 190: ...pump housing 7 INSTALL ROLLER RING a 1PZ Install the slide pin three rollers and washers on the roller ring as shown in the illustration b 1 HZ and 1HD T Install the slide pin four rollers and washers on the roller ring c Check that the roller is facing the flat surface of the washer d Install the roller ring into the pump housing e Carefully install the slide pin into the sub piston ...

Page 191: ...the LH timer cover and temporarily install the nut c Install the following parts 1 New O ring 2 RH timer cover 3 Timer spring 4 New O ring 5 LH timer cover timer adjusting screw and nut assembly d Using a 5 mm hexagon wrench install the the four bolts 9 PRESET TIMER ADJUSTING SCREW a Using vernier calipers measure the protrusion of the adjusting screw from the timer cover Protrusion 7 5 8 0 mm 0 2...

Page 192: ... Upper plunger plate 6 Lower plunger plate 7 Pump plunger HINT Do not assemble the plunger spring shims at this time b Using vernier calipers measure clearance A indicated in the illustration c Determine the plunger spring shim size by using the following formula and chart IPZand 1HZ New plunger spring shim thickness 5 8 A 1HD T New plunger spring shim thickness 5 1 A A Measured plunger position P...

Page 193: ...d face camplate HINT Do not assemble the coupling spring b Clean the plunger adjusting shim and contacting surface area c Align the pin groove of the pump plunger with the face camplate pin d Using SST install the used plunger adjusting shim and pump plunger SST 09260 54012 09269 54030 e Install the distributive head with the four bolts Torque 120 kg cm 9 ft lb 12 N m NOTICE Be careful not to dama...

Page 194: ... shim selection chart EXAMPLE The 2 4 mm 0 094 in shim is installed and measured clearance is 3 7 mm 0 146 in Replace the 2 4 mm 0 094 in shim with a 2 8 mm 0 110 in shim h Install a new plunger adjusting shim and recheck dimension B Dimension B 3 2 3 4 mm 0 126 0 134 in i Remove the distributive head j Using SST remove the following parts 1 Pump plunger 2 Plunger adjusting shim 3 Face camplate SS...

Page 195: ...INSTALL GOVERNOR LINK a Using SST install the governor link with two new gaskets and the two support bolts Torque 140 kg cm 10 ft lb 14 N m SST 09260 54012 09269 54040 b Check that the governor link moves smoothly 15 INSTALL PUMP PLUNGER a 1PZ Place the previously used plunger adjusting shim on center of the camplate 1 HZ and 1HD T Place the previously used plunger adjusting shim on the center of ...

Page 196: ...spill ring e Using SST install the pump plunger and two plunger springs SST 09260 5401 2 09269 54030 16 INSTALL DISTRIBUTIVE HEAD a Apply No 50 DENSO grease to the following parts and install them to the distributive head 1 Two plunger spring guides 2 Two new selected plunger spring shims 3 Two upper spring seats 4 Two lever support springs 5 New O ring b Install the distributive head NOTICE Be ca...

Page 197: ...GHT HOLDER a Install the following parts to the flyweight holder 1 Four flyweight 2 No 2 flyweight washer 3 Governor sleeve HINT Replace the four flyweights as a set b Install a new O ring to the governor shaft c Place the flyweight holder assembly 1 in position and install the No 1 flyweight washer 2 and gover nor gear adjusting washer 3 between the flyweight holder and pump housing d Install the...

Page 198: ... SHAFT a Using vernier calipers measure the protrusion of the governor shaft Protrusion 0 5 2 0 mm 0 020 0 079 in If the protrusion is not as specified adjust by turning the governor shaft b Install and tighten the nut while holding the governor shaft with a 5 mm hexagon wrench 22 1 PZ w HAC and 1 HZ w HAC ASSEMBLE HIGH ALTITUDE COMPENSATOR Install control lever a Insert the connecting pin into go...

Page 199: ...ll No 2 overflow screw Install the No 2 overflow screw and cover B Install No 2 PCS lever Install the following parts to the governor cover 1 Plate washer 2 O ring 3 No 2 lever O ring and washer assembly C Install control lever a Insert the connecting pin into governor cover b Using a small screwdriver install the control lever with the support pin ...

Page 200: ...COVER a Install the speed control spring to the adjusting shaft b Install a new gasket to the groove of the governor cover c Install the damper spring and spring seat and connect the speed control spring to the spring seat d Using a 5 mm hexagon wrench install the governor cover with the four bolts Torque 85 kg cm 74 in lb 8 3 Nm HINT Use the bolt which is 35 mm 1 38 in in length e w HACand 1HD T ...

Page 201: ...g lever on the governor shaft c Align the lines of the adjusting lever shaft and adjust ing lever d Install the adjusting lever with the spring guide and nut 27 w TACHOMETER INSTALL PICKUP SENSOR a Install a new O ring and pickup sensor b Connect the two lead wires to the connector Torque 210 kg cm 15 ft lb 21 Nm ...

Page 202: ... 49 kPa of air is applied to SST bubbles appear on the upper surface of the plunger SST 09275 17010 e Slowly rotate the drive shaft in the pump rotation direction clockwise and read the dial indicator when the bubbles on the top of the plunger disappear Pre stroke 0 15 0 25 mm 0 0059 0 0098 in If the pre stroke is not as specified replace the plunger adjusting shim under the plunger with a differe...

Page 203: ...COMPENSATOR A Install pneumatic bellows a Insert 3 4 cc 0 18 0 24 cu in of engine oil into the bushing hole b Place the following parts on the governor cover 1 Pneumatic bellows spring 2 Push rod c Install the following parts to the pneumatic bellows cover 1 Pneumatic bellows 2 Two rubber caps 3 Pneumatic bellows and two rubber caps assem bly 4 Shims d Install a new gasket and the pneumatic bellow...

Page 204: ...Install boost compensator diaphragm a Adjust boost compensator shim 1 Place the shim on the guide bushing 2 Using vernier calipers measure the dimension B as shown in the illustration Dimension B Europe 4 8 5 0 mm 0 189 0 197 in Others 6 0 6 2 mm 0 236 0 244 in If the dimension is not within specification select and install the correct shim Adjusting shim thickness 1 1 mm 0 043 in 1 3 mm 0 051 in ...

Page 205: ...u in of engine oil into the bushing hole b Adjust the installation direction of boost compensator diaphragm 1 Install the shim and diaphragm HINT Do not assemble the spring 2 While pushing on the diaphragm measure dimen sion X with vernier calipers as shown Dimension X 6 9 7 1 mm 0 272 0 280 in HINT Measure at the center of the hole 3 Place matchmarks on the diaphragm and gover nor cover 4 Remove ...

Page 206: ...olenoid b Install the strainer valve spring a new gasket and the fuel cut solenoid Torque 225 kg cm 16 ft lb 22 Nm c Install the lead wire to the fuel cut solenoid with the nut d Install the dust cover to the fuel cut solenoid e Install the lead wire connector to bracket 33 w Dash Pot INSTALL DASH POT Install the dash pot and gasket 34 w PCS INSTALL NO 1 PCS LEVER a Align the lines of the levers ...

Page 207: ... the two bolts b Install the clip c Install the PCS adjusting screw 36 w ACSD INSTALL THERMO WAX a Using a screwdriver turn the cold starting lever coun terclockwise approx 20 b Put a metal plate thickness of 3 5 7 5 mm 0 138 0 295 in between the cold starting lever and thermo wax plunger c Install a new O ring and the thermo wax with the two bolts ...

Page 208: ...T 09241 76022 and 09245 54010 40 PERFORM AIR TIGHT TEST a Install a bolt to the overflow port b Connect an air hose to the fuel inlet pipe and place the injection pump into diesel fuel c Apply 0 5 kg cm2 7 psi 49 kPa of pressure and confirm that there are no leaks d Next check that there are no leaks with 5 0 kg cm2 71 psi 490 kPa of pressure applied 41 INSTALL SET KEY OF INJECTION PUMP DRIVE PULL...

Page 209: ... Check the accuracy of the tachometer Allowable error 40 rpm c Install the angle gauge stand d Mount the injection pump body on the pump tester HINT Place a mark on the key groove portion of the coupling e Install an injection pipe with the following specifica tions Outer diameter 6 0 mm 0 236 in Inner diameter 2 0 mm 0 079 in Length 840 mm 33 07 in Minimum bending radius 25 mm 0 98 in or more f R...

Page 210: ... pump to be adjusted i Using a 5 mm hexagon wrench remove the two bolts and RH timer cover j Install the inner pressure gauge with the timer mea suring device Part No 95095 10220 and 95095 10231 NIPPONDENSO HINT Bleed the air by the air bleed screw k 1HD T Connect SST turbocharger pressure gauge to the boost compensator SST 09992 00241 ...

Page 211: ...attery as far away from the solenoid as possible so that a spark does not occur When connecting the battery cable connect the solenoid side first n The pressure for feeding fuel to the injection pump should be 0 2 kg cm2 2 8 psi 20 kPa The fuel temperature for pump testing should be 40 45 C 104 113 F o Install an angle gauge to the stand and set it to the adjusting lever p Secure the adjusting lev...

Page 212: ... the distributive head Using SST remove the delivery valve holder SST 09260 54012 09269 54020 Check that fuel is flowing out when the mark is in the position shown in the illustration If not it is improperly assembled Disassemble and change the camplate position 180 in the opposite direction HINT At this time disconnect the fuel cut solenoid wire harness Using SST install the delivery valve holder...

Page 213: ...tion pump for 5 minutes at 2 000 rpm NOTICE Check that there is no fuel leakage or ab normal noise HINT Measure the volume of each injection cylinder with a measuring cylinder Before measuring the injection volume first hold the cylinder tilted for at least 30 seconds to discard all the fuel ...

Page 214: ...g cm2 18 3 psi 127 kPa of pressure to the boost compensator e 1HD T w PCS Apply vacuum to the PCS actuator f Measure the injection volume g Remove the collar seal as follows Hold the full load set screw and release the collar seal from the spot weld by turning the lock nut counterclockwise by 90 or more Using a screwdriver remove the collar seal h w Wire Seal Type Cut off the wire seal i Adjust by...

Page 215: ...ly 760 1 5 mmHg 29 92 0 06 in Hg 101 3 0 2 kPa absolute pressure c 1HD T w o BACS Apply 0 81 kg cm2 11 5 psi 79 kPa of pressure to the boost compensator d 1HD T w BACS Apply 1 29 kg cm2 18 3 psi 1 27 kPa of pressure to the boost compensator e 1HD T w PCS Apply vacuum to the PCS actuator f Measure the injection volume 5 ADJUST PUMP INNER PRESSURE a Measure the pump inner pressure at the below liste...

Page 216: ...w volume at the below listed rpm HINT Always use the overflow screw installed on the pump to be adjusted 7 w ACSD RELEASE COLD STARTING SYSTEM FOR NEXT INSPECTIONS a Using a screwdriver turn the cold starting lever coun terclockwise approx 20 b Put a metal plate thickness of 3 5 7 5 mm 0 138 0 295 in between the cold starting lever and thermo wax plunger HINT Keep the cold starting system released...

Page 217: ...crease with turn to clockwise and increase with turn to counterclockwise 9 1HD T CHECK AIR TIGHTNESS OF BOOST COMPENSATOR a Apply 1 00 kg cm2 14 2 psi 98 kPa of pressure to the boost compensator b Measure the time it takes for the pressure to drop to 0 97 kg cm2 13 8 psi 95 kPa Pressure drop 10 seconds or more 10 ADJUST FULL LOAD INJECTION VOLUME a The adjusting lever angle for the adjustment belo...

Page 218: ...tor d 1HD T w BACS Apply 1 29 kg cm2 18 3 psi 1 27 kPa of pressure to the boost compensator e 1HD T w PCS Apply vacuum to the PCS actuator f Measure the full load injection volume g Adjust by turning the full load set screw HINT The injection volume will increase about 3 cc 0 18 cu in with each 1 2 turn of the screw h 1HD T w PCS Release the vacuum to the PCS actuator i 1HD T w PCS Measure the inj...

Page 219: ... check that the clearance between No 1 PCS lever and adjusting screw at least 3 mm 0 12 in 11 ADJUST MAXIMUM SPEED a 1PZ w HAC and 1HZ w HAC Apply 760 1 5 mmHg 29 92 0 06 in Hg 101 3 0 2 kPa absolute pressure b 1HD T w o BACS Apply 0 81 kg cm2 11 5 psi 79 kPa of pressure to the boost compensator c 1HD T w BACS Apply 1 29 kg cm2 18 3 psi 127 kPa of pressure to the boost compensator d 1HD T w PCS Ap...

Page 220: ... f Adjust by turning the maximum speed adjusting screw 12 CHECK INJECTION VOLUME a 1 PZ w HAC and 1 HZ w HAC Apply 760 1 5 mmHg 29 92 0 06 in Hg 101 3 0 2 kPa absolute pressure b 1PZand1HZ Measure the injection volume at each pump rpm ...

Page 221: ... and boost pressure If the injection volume at 100 rpm is not as specified replace the governor sleeve plug as follows Using SST and a press press out the sleeve plug assembly from the governor sleeve SST 09236 00101 09237 00070 Remove the E ring and following parts from the sleeve plug 1 Stop ring 2 Bearing and two bearing retainers ...

Page 222: ...a new sleeve plug HINT Lengthening the plug 0 1 mm 0 004 in will decrease injection volume by 0 6 cc 0 04 cu in Install the following parts to the new sleeve plug with a new E ring 1 Bearing and two retainers 2 Stop ring Using a press press in the sleeve plug assembly to the governor sleeve ...

Page 223: ...JECTION VOLUME a Measure the injection volume 14 1HD T ADJUST BOOST COMPENSATOR CHARACTERISTIC a Apply pressure to the boost compensator b Measure the injection volume bushing c Using a screwdriver adjust the guide bushing HINT When the guide bushing is turned clockwise as seen from above the injection volume will increase ...

Page 224: ...ompensa tor pressure is lowered from 0 81 kg cm2 11 5 psi 79 kPa to 0 kg cm2 0 psi 0 kPa and conversely when it is raised from zero w BACS Compare the injection volume when the boost compensa tor pressure is lowered from 1 25 kg cm2 18 3 psi 127 kPa to 0 kg cm2 0 psi 0 kPa and conversely when it is raised from zero HINT Make measurements after moving the adjusting lever between idle and maximum th...

Page 225: ... whether or not there is any oil 17 w o HIGH ALTITUDE ADJUST LOAD SENSING TIMER a Using a 5 mm hexagon wrench adjust the starting and end points of the load sensing timer by turning the governor shaft b 1 PZ w HAC and 1 HZ w HAC Apply 760 1 5 mmHg 29 92 0 06 in Hg 101 3 0 2 kPa absolute pressure c 1HD T w o BACS Apply 0 81 kg cm2 11 5 psi 79 kPa of pressure to the boost compensator d 1HD T w BACS ...

Page 226: ...t the point where the pump inner pressure stops dropping k 1HD T Europe Check the timer piston stroke when the the pump rpm is 1 440 rpm and injection volume is 8 4 9 2 cc 0 51 0 56 cu in Timer piston stroke 2 0 mm 0 079 in or less I 1HD T Others Check the injection volume when the pump rpm is 1 440 rpm and timer piston stroke is 3 7 4 3 mm 0 146 0 169 in Injection volume 6 cc 0 37 cu in HINT The ...

Page 227: ...protrusion of the governor shaft Protrusion 0 5 2 0 mm 0 020 0 079 in 18 ADJUST IDLE SPEED a w Dash Pot Using pliers remove the dash pot cover b w Dash Pot Fully loosen the dash pot adjusting screw c Measure the injection volume for each pump rpm ...

Page 228: ... adjusting screw e w Dash Pot Set the adjusting lever to the angle for the injection volume shown below f w Dash Pot Adjust the injection volume with the dash pot adjust ing screw HINT The stroke will decrease with turn to clockwise and increase with turn to counterclockwise ...

Page 229: ...pump drive shaft in a vertical or horizontal position c Set the scale of the timer measuring device to zero d Check the adjusting lever opening angle and consider this angle as zero e Remove the metal plate between the cold starting lever and thermo wax plunger f Torque the cold starting lever clockwise to approx 50 kg cm 43 in lb 4 9 N m and keep the lever tightened for about 10 seconds Then rele...

Page 230: ...stroke decrease 20 w ACSD ADJUST FAST IDLE a Measure the clearance between the adjusting lever and idle speed adjusting screw b Adjust by turning the fast idle adjusting screw 21 POST ADJUSTMENT CHECK a Check that injection stops when the fuel cut solenoid harness is removed Pump revolution 100 rpm ...

Page 231: ... movement Adjusting lever angle 38 48 22 SEAL PARTS Seal the maximum speed adjusting screw and full load set screws with new lead seals 23 INSTALL TWO FUEL PIPES Torque Inlet 250 kg cm 18 ft lb 25 Nm Outlet 225 kg cm 16 ft lb 22 Nm 24 INSTALL INJECTION PUMP STAY ...

Page 232: ...ng d Align the set key on the drive shaft and groove of the injection pump drive gear e Align the period lines or matchmarks of the injection pump and timing belt case f Install the two nuts holding the injection pump to the timing gear case Torque 185 kg cm 13 ft lb 18 N m g Install the pump stay mount bolt Torque 700 kg cm 51 ft lb 69 N m NOTICE Before tightening to the standard torque check whe...

Page 233: ...Z 150 kg cm 11 ft lb 15 Nm 1HD T 250 kg cm 18 ft lb 25 Nm 4 w BACS CONNECT BACS VACUUM HOSE 5 w PCS CONNECT PCS VACUUM HOSE 6 1HD T CONNECT BOOST COMPENSATOR HOSE 7 CONNECT FUEL HOSES TO INJECTION PUMP 8 CONNECT INJECTION PUMP CONNECTOR 9 w ACSD CONNECT WATER BY PASS HOSES TO THERMO WAX 10 w A C CONNECT A C IDLE UP VACUUM HOSE 11 A T CONNECT THROTTLE CABLE 12 CONNECT ACCELERATOR CONNECTING ROD 13 ...

Page 234: ...eck the operation of the actuator at each shift position Standard Shifting to 1st or Reverse Actuator not operating Sifting to other positions Actuator operates INSPECTION OF POWER CONTROL SYSTEM PCS COMPONENTS 1 INSPECT PCS VSV A Inspect VSV for open circuit Using an ohmmeter check that there is continuity between the terminals Resistance Cold 33 39 Q If there is no continuity replace the VSV B I...

Page 235: ...s c Check that air flows from pipe E to F If operation is not as specified replace the VSV 2 INSPECT SHIFT POSITION SWITCH a Check that there is no continuity between terminals when the switch is pushed shift position 1st or reverse b Check that there is continuity between terminals when switch is free shift position others If continuity is not as specified replace the switch ...

Page 236: ...CO 1 COOLING SYSTEM DESCRIPTION CO 2 TROUBLESHOOTING CO 4 CHECK AND REPLACEMENT OF ENGINE COOLANT CO 4 WATER PUMP CO 6 THERMOSTAT CO 10 RADIATOR CO 12 Page ...

Page 237: ...tilizes a pressurized water forced circulation cooling system which includes a thermostat equipped with a by pass valve mounted on the inlet side IPZand1HZ From Heater To Heater Thermostat Radiator 1HD T From Heater To Heater Thermostat Radiator C01049 C01050 ...

Page 238: ...212 F A relief valve pressurization valve and a vacuum valve negative pressure valve are built into the radiator cap When the pressure generated inside the cooling system exceeds the limit coolant temperature 110 120 C 230 248 F pressure 0 3 1 0 kg cm2 4 3 14 2 psi 29 4 98 1 kPa the relief valve is opened by the pressure and lets steam escape through the overflow pipe The vac uum valve opens to al...

Page 239: ...Replace fluid coupling Replace hose Replace water pump Check radiator Repair as necessary CH 5 CO 12 CO 10 EM 24 CO 7 CO 7 CO 12 CHECK AND REPLACEMENT OF ENGINE COOLANT 1 CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The coolant level should be between the LOW and FULL lines If low check for leaks and add coolant up to the FULL line 2 CHECK ENGINE COOLANT QUALITY There should not be any excessive d...

Page 240: ... 0 US qts 9 2 Imp qts A T 10 2 liters 10 8 US qts 9 0 Imp qts HZB30 and HDB30 10 2 liters 10 8 US qts 9 0 Imp qts Capacity w Heater PZJ70 73 75 10 3 liters 10 9 US qts 9 1 Imp qts HZJ70 73 75 M T 10 6 liters 11 2 US qts 9 3 Imp qts A T 10 4 liters 11 0 US qts 9 2 Imp qts HZJ80and HDJ80 M T 11 1 liters 11 6 US qts 9 8 Imp qts A T 10 9 liters 11 5 US qts 9 6 Imp qts HZB30 and HDB30 14 6 liters 15 4 ...

Page 241: ...o Water Pipe Alternator Adjusing Bar 200 14 20 200 14 20 400 29 39 Drive Belt Gasket Water Pump 200 14 20 Water Pump Pulley w o Fluid Coupling Fan Spacer w Fluid Coupling 200 14 20 Fluid Coupling Fan 200 14 20 200 14 20 Fan 200 14 20 Specified torque Non reusable part CO0956 kg cm ft lb N m ...

Page 242: ...he four nuts fan and fluid coupling fan spacer assembly and pulley 3 REMOVE TIMING BELT AND IDLER PULLEY See steps 1 to 4 on pages EM 33 to 34 4 REMOVE NO 1 CAMSHAFT TIMING PULLEY See steps 6 to 8 on pages EM 34 to 35 5 REMOVE CAMSHAFT OIL SEAL RETAINER See step 14 on page EM 55 6 REMOVE WATER PUMP a 1HD T Disconnect the turbo water by pass hoses b Remove the three bolts and alternator adjusting b...

Page 243: ...1 INSTALL WATER PUMP a Install a new gasket the water pump and No 2 turbo water pipe 1 HD T with the five bolts and two nuts Torque 200 kg cm 14 ft lb 20 N m b Install the alternator adjusting bar with the two bolts A Torque 400 kg cm 29 ft lb 39 N m c Temporarily install the lock bolt B d 1HD T Connect the water by pass hoses 2 INSTALL CAMSHAFT OIL SEAL RETAINER See step 6 on page EM 79 3 INSTALL...

Page 244: ...fluid fan and coupling fan spacer assembly with the four nuts b Place the drive belt on each pulley c Stretch the belt tight and torque the four nuts Torque 200 kg cm 14 ft lb 20 N m d Adjust the drive belt deflection See step 3 on page CH 5 6 FILL WITH ENGINE COOLANT See page CO 5 7 START ENGINE AND CHECK FOR LEAKS ...

Page 245: ...temperature a Immerse the thermostat in water and gradually heat the water b Check the valve opening temperature Valve opening temperature 74 78X 165 172 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 10 mm 0 39 in or more at 90 C 194 F If the valve lift is not as specified replace the thermostat d Check that the valve spring is tigh...

Page 246: ... gasket to the thermostat b Install the thermostat with the jiggle valve upward 2 INSTALL WATER INLET TO CYLINDER BLOCK Install the water inlet with the three bolts Torque 200 kg cm 14 ft lb 20 N m NOTICE Torque the two upper bolts first 3 FILL WITH ENGINE COOLANT See page CO 5 4 START ENGINE AND CHECK FOR LEAKS ...

Page 247: ...adiator cap tester pump the tester and measure the relief valve opening pressure Standard opening pressure 0 75 1 05 kg cm2 10 7 14 9 psi 74 103 kPa Minimum opening pressure 0 6 kg cm2 8 5 psi 59 kPa If the opening pressure is less than minimum replace the radiator cap 2 INSPECT COOLING SYSTEM FOR LEAKS a Fill the radiator with coolant and attach a radiator cap tester b Warm up the engine c Pump i...

Page 248: ...ON SYSTEM Page DESCRIPTION LU 2 TROUBLESHOOTING LU 4 OIL PRESSURE CHECK LU 5 REPLACEMENT OF ENGINE OIL AND OIL FILTER LU 6 OILPUMP LU 8 OIL COOLER RELIEF VALVE AND CHECK VALVE LU 15 OIL NOZZLES AND CHECK VALVES LU 20 ...

Page 249: ...LU 2 LUBRICATION SYSTEM Description DESCRIPTION A fully pressurized fully filtered lubrication system has been adopted for this engine ...

Page 250: ...ween the two rotors changes Oil is drawn in when the space widens and is discharged when the space becomes narrow OIL PRESSURE REGULATOR RELIEF VALVE At high engine speeds the oil pump supplies more oil to each part that is necessary For this reason an oil pressure regulator which works to prevent oversupply of oil is installed on the oil pump During normal oil supply a coil spring and valve keep ...

Page 251: ...LU 4 LUBRICATION SYSTEM Troubleshooting TROUBLESHOOTING ...

Page 252: ...INE OIL LEVEL The oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to F mark NOTICE Do not fill with engine oil above the F mark 3 REMOVE OIL PRESSURE SENDER GAUGE 4 INSTALL OIL PRESSURE GAUGE 5 WARM UP ENGINE Allow the engine to reach normal operating temperature 6 CHECK OIL PRESSURE Oil pressure At idling 0 3 kg cm2 4 3 psi 29 kPa or more At 3...

Page 253: ...ne oil to minimize the frequency and length of time your skin is exposed to used engine oil Protec tive clothing and gloves that cannot be penetrated by oil should be worn The skin should be tho rougthly washed with soap and water or use wa terless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents In order to preserve the environment used oil and used oil filters ...

Page 254: ...ilter change 7 7 liters 8 1 US qts 6 8 Imp qts Dry fill 9 3 liters 9 8 US qts 8 2 Imp qts Capacity HZJ70 73 75 Drain and refill w Oil filter change 9 5 liters 10 0 US qts 8 4 Imp qts w o Oil filter change 8 2 liters 8 7 US qts 7 2 Imp qts Dry fill 9 8 liters 10 4 US qts 8 6 Imp qts Capacity HZJ80 and HDJ80 Drain and refill w Oil filter change 9 3 liters 9 8 US qts 8 1 Imp qts w o Oil filter change...

Page 255: ...LU 8 LUBRICATION SYSTEM Oil Pump OIL PUMP COMPONENT ...

Page 256: ...nd three nuts b Insert the blade of SST between the cylinder block and oil pan cut off applied sealer and remove the oil pan SST 09032 001 00 NOTICE Do not use SST for the timing gear case side and rear oil seal retainer Be careful not to damage the oil pan flange 5 REMOVE OIL STRAINER Remove the two bolts two nuts oil strainer and gasket 6 REMOVE OIL PUMP TIMING GEAR CASE a Before removing the tw...

Page 257: ...he seven bolts timing gear case and gasket d Using a plastic faced hammer lightly tap out the timing gear case e Remove the gasket DISASSEMBLY OF OIL PUMP 1 REMOVE DRIVEN ROTOR 2 REMOVE RELIEF VALVE Remove the plug gasket spring and relief valve ...

Page 258: ... mm 0 0079 in If the body clearance is greater than maximum replace the oil pump assembly B Inspect rotor side clearance Using a thickness gauge and precision straight edge measure the clearance between the rotors and precision straight edge Standard side clearance 0 03 0 09 mm 0 0012 0 0035 in Maximum side clearance 0 15 mm 0 0059 in If the side clearance is greater than maximum replace the oil p...

Page 259: ...sing a razor blade and gasket scraper remove all the old packing FIPG material from the gasket surfaces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the timing gear case as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut ...

Page 260: ...ump period lines or match marks are aligned If not correct align the period lines or matchmarks by tilting the injection pump 2 POUR ENGINE OIL INTO OIL PUMP a Using a 5 mm hexagon wrench remove the taper screw plug b Pour in approx 10 cc 0 061 cu in of engine oil into the oil pump c Apply adheshive to two or three threads of the taper screw Adhesive Part No 08833 00070 THREE BOND 1324 or equivale...

Page 261: ...h sealing surfaces NOTICE Do not use a solvent which will affect the painted surfaces b Apply seal packing to the oil pan as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 5 mm 0 20 in opening Parts must be assembled within 5 minutes of appli cation Otherwise the material must be removed and reapplied Immediately remove nozzle from ...

Page 262: ...LUBRICATION SYSTEM Oil Cooler Relief Valve and Check Valve LU 15 OIL COOLER RELIEF VALVE AND CHECK VALVE COMPONENTS ...

Page 263: ...ND GUIDE a Remove the two bolts oil dipstick and guide b Remove the oil ring from the oil dipstick guide 5 REMOVE OIL COOLER AND OIL COOLER COVER ASSEMBLY Remove the thirteen bolts two nuts oil cooler and oil cooler assembly and gasket 6 SEPARATE OIL COOLER AND OIL COOLER COVER Remove the four nuts oil cooler and two gaskets from the oil cooler cover 7 REMOVE RELIEF VALVE Remove the relief valve a...

Page 264: ...CK VALVE 1 INSPECT RELIEF VALVE Push the valve with a wooden stick to check if it is stuck If stuck replace the relief valve 2 INSPECT CHECK VALVE Push the valve with a wooden stick to check if it is stuck If stuck replace the check valve 3 INSPECT OIL COOLER Check the oil cooler for damage or clogging If necessary replace the oil cooler ...

Page 265: ... BOND 1324 or equivalent b Install and torque the drain cock as shown Torque 200 kg cm 14 ft lb 20 Nm 2 INSTALL CHECK VALVE Install the check valve with a new gasket Torque 275 kg cm 20 ft lb 27 N m 3 INSTALL RELIEF VALVE Install the relief valve with a new gasket Torque 400 kg cm 29 ft lb 39 Nm 4 ASSEMBLE OIL COOLER AND OIL COOLER COVER Install two new gaskets and the oil cooler to the oil cooler...

Page 266: ... OIL DIPSTICK GUIDE AND DIPSTICK a Install a new O ring to the oil dipstick guide b Apply engine oil to the new O ring c Install the oil dipstick and guide with the two bolts Torque Intake manifold side 200 kg cm 14 ft lb 20 N m Oil cooler cover side 200 kg cm 14 ft lb 20 N m 7 INSTALL INJECTION PUMP See page FU 93 8 INSTALL OIL FILTER See page LU 6 9 FILL WITH ENGINE COOLANT See page CO 5 10 STAR...

Page 267: ... NOZZLES AND CHECK VALVES COMPONENTS REMOVAL OF OIL NOZZLES AND CHECK VALVES 1 DRAIN ENGINE OIL See page LU 6 2 REMOVE OIL PAN See step 4 on page LU 9 3 REMOVE CHECK VALVE AND OIL NOZZLES Remove the five 1 PZ or six 1 HZ and 1HD T check valves and oil nozzles ...

Page 268: ...ing If necessary replace the oil nozzle INSTALLATION OF OIL NOZZLES AND CHECK VALVES See page LU 20 1 INSTALL OIL NOZZLES AND CHECK VALVES a Align the pin of the oil nozzle with the pin hole of the cylinder block b Install the oil nozzle with the check valve Install the five 1PZ or six 1HZ and 1HD T oil nozzles and check valves Torque 275 kg cm 20 ft lb 27 Nm 2 INSTALL OIL PAN See step 4 on page L...

Page 269: ...e PZJ HZJ75 HZB and HDB ex Europe and Australia ST 11 TROUBLESHOOTING ST 13 STARTING SYSTEM CIRCUIT ST 13 STARTER ST 15 STARTER RELAY PZJ HZJ and HDJ ST 26 STARTER RELAY HZB and HDB ST 27 VOLTAGE CONVERTER TIMER HZJ80 and HDJ80 w 24 V Starter ST 28 VOLTAGE CONVERTER RELAY HZJ80 and HDJ80 w 24 V Starter ST 29 24 V HOLD WARNING RELAY HZJ80 and H DJ80 w 24 V Starter ST 30 ...

Page 270: ...ST 2 STARTING SYSTEM Pre Heating System Super Glow Type PRE HEATING SYSTEM Super Glow Type Europe and Australia SYSTEM CIRCUIT ...

Page 271: ...TEM Pre Heating System Super Glow Type ST 3 SYSTEM CIRCUIT Cont d INSPECTION OF PRE HEATING SYSTEM HINT Refer to Diesel Electrical System Diagnosis inspection procedures See page EM 14 TIMER CHARACTERISTIC DIAGRAM ...

Page 272: ...ST 4 STARTING SYSTEM Pre Heating System Super Glow Type TIMER CHARACTERISTIC DIAGRAM Cont d ...

Page 273: ...MER CIRCUIT Disconnect the connector from the pre heating timer and check the connector on the wire harness side as shown in the following chart No 1 Glow Plug Relay LOCATION In the engine compartment on the left side 1 INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is continuity between terminals E and g b Check that there is no continuity between terminals B and G If continuity is...

Page 274: ...partment on the left side 1 INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is continuity between terminals E and g b Check that there is no continuity between terminals B and G If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals E and g b Using an ohmmeter check that there is continuity between terminals B and G If o...

Page 275: ...an ohmmeter check that there is continuity between the glow plug terminal and ground If there is no continuity replace the glow plug HINT Be careful not to damage the glow plug pipes as it could cause an open circuit or shorten life of the plugs Avoid getting oil and gasoline on the glow plug when cleaning During inspection be sure to wipe any oil off the glow plug terminal and bakelite washer wit...

Page 276: ...ing System Super Glow Type Water Temperature Sensor INSPECT TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the sensor terminals Resistance Refer to chart If the resistance is not as specified replace the sensor ...

Page 277: ...ION OF PREHEATING SYSTEM 1 INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the starter switch ON measure the lighting time Light lighting time Approx 5 seconds 2 INSPECT PREHEATING TIME Turn the starter switch ON and measure the time battery voltage is applied to terminal 1 of the pre heating timer Pre heating time Approx 18 seconds ...

Page 278: ...LOCATION Under the instrument panel on the passenger side Disconnect the connector from the pre heating timer and check the connector on the wire harness side as shown in the following chart Glow Plug Relay See No 2 Glow Plug Relay PZJ HZJ and HDJ on page ST 6 LOCATION In the engine compartment on the left side Glow Plug See page ST 7 ...

Page 279: ...STARTING SYSTEM Pre Heating System Fixed Delay Type ST 11 Fixed Delay Type PZJ HZJ75 HZB and HDB ex Europe and Australia SYSTEM CIRCUIT ...

Page 280: ...IRCUIT LOCATION PZJ HZJ75 Under the instrument panel on the passenger side HZB HDB Under the instrument panel center Disconnect the connector from the pre heating timer and check the connector on the wire harness side as shown in the following chart Glow Plug Relay PZJ and HZJ75 See No 2 Glow Plug Relay PZJ HZJ and HDJ on page ST 6 LOCATION In the engine compartment on the left side Glow Plug Rela...

Page 281: ...STARTING SYSTEM Troubleshooting Starting System Circuit ST 13 TROUBLESHOOTING STARTING SYSTEM CIRCUIT ...

Page 282: ...ST 14 STARTING SYSTEM Starting System Circuit STARTING SYSTEM CIRCUIT Cont d ...

Page 283: ... and spring washer and disconnect the lead wire from the magnetic switch terminal b Remove the two through bolts spring washers plate washers and O rings c Pull out the field frame together with the armature d Remove the felt washer and lock plate 2 REMOVE STARTER HOUSING CLUTCH ASSEMBLY AND GEARS a Remove the three screws ...

Page 284: ... 5 Bearing 3 REMOVE STEEL BALL Using a magnetic finger remove the steel ball from the clutch shaft hole 4 REMOVE BRUSH HOLDER a Remove the two screws and end cover from the field frame b Using a screwdriver hold the spring back and discon nect the brush from the brush holder Disconnect the four brushes and remove the brush holder 5 REMOVE ARMATURE FROM FIELD FRAME ...

Page 285: ...nuity replace the armature Commutator 1 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE If the surface is dirty or burnt correct with sandpaper No 400 or on a lathe 2 INSPECT COMMUTATOR FOR RUNOUT a Place the commutator on V blocks b Using a dial indicator measure the circle runout Maximum circle runout 0 05 mm 0 0020 in If the circle runout is greater than maximum correct it on a lathe 3 INSPECT C...

Page 286: ... no continuity replace the field frame 2 INSPECT FIELD COIL FOR GROUND Using an ohmmeter check that there is no continuity between the field coil end and field frame If there is continuity replace the field frame Brushes INSPECT BRUSH LENGTH Using calipers measure the brush length Standard length 20 5 21 0 mm 0 807 0 827 in Minimum length 13 0 mm 0 512 in If the length is less than minimum replace...

Page 287: ... damage If damaged replace the gear or clutch assembly If damaged also check the flywheel ring gear for wear or damage 2 INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise and check that it turns freely Try to rotate the pinion gear counterclockwise and check that it locks If necessary replace the clutch assembly 3 IF NECESSARY REPLACE CLUTCH ASSEMBLY A Disassembly starter housing and clu...

Page 288: ...tch assembly a 1st assemble the following parts 1 Clutch shaft 2 Compression spring 3 Starter clutch b 2nd assemble the following parts 1 Clutch shaft and starter shaft assembly 2 Starter housing 3 Compression spring 4 Retainer 5 Pinion gear 6 Stop collar c Push down the pinion gear and starter housing d Using snap ring pliers install the snap ring e Using pliers compress the snap ring f Check tha...

Page 289: ...EARINGS Turn each bearing by hand while applying inward force If resistance is felt or if the bearing sticks replace the bearing 2 IF NECESSARY REPLACE BEARINGS A Remove bearings Using SST remove the bearing SST 09286 46011 B Install bearings Front Using a press press in a new bearing Rear Using SST and a press press in a new bearing SST 09285 76010 ...

Page 290: ... body If there is no continuity replace the magnetic switch ASSEMBLY OF STARTER See pageST 15 HINT Use high temperature grease to lubricate the bear ings and gears when assembling the starter 1 PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings and insert the armature into the field frame 2 INSTALL BRUSH HOLDER a Place the brush holder on the armature b Using a screwdriver hold ...

Page 291: ...ll into the clutch shaft hole 4 INSTALL GEAR CLUTCH ASSEMBLY AND STARTER HOUSING a Apply grease to the return spring b Insert the return spring into the magnetic switch hole c Install the plate washer to the magnetic switch d Install the following parts to the starter housing 1 Idler gear 2 Bearing e Assemble the starter housing and magnetic switch with the three screws ...

Page 292: ...the lock plate to the cutout portion of the magnetic switch c Align the lock plate with the cutout portion of the field frame d Install the field frame and armature assembly with two new O rings the two plate washers spring washers and two through bolts e Connect the lead wire to terminal C and install the spring washer and nut ...

Page 293: ...sconnect the negative lead from terminal C Check that the pinion gear remains out If the clutch pinion gear returns inward replace the mag netic switch assembly 3 INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative lead from the switch body Check that the clutch pinion gear returns inward If the clutch pinion gear does not return replace the magnetic switch assembly 4 PERFORM NO LOAD PERFORM...

Page 294: ...uity between terminals E and ST b Check that there is no continuity between terminals B and MG If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals E and ST NOTICE If the vehicle has a voltage coverter per form the check using a 12 V battery b Using an ohmmeter check that there is continuity between terminals B and MG If operation i...

Page 295: ...ohmmeter check that there is continuity between terminals E and ST b Check that there is no continuity between terminals B and MG If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals E and ST b Using an ohmmeter check that there is continuity between terminals B and MG If operation is not as specified replace the relay ...

Page 296: ...and HDJ80 w 24 V Starter LOCATION In the cowl on the passenger s side INSPECTION OF VOLTAGE CONVERTER TIMER INSPECT VOLTAGE CONVERTER TIMER Disconnect the connector from the voltage converter timer and check the connector on the wire harness side as shown in the following chart ...

Page 297: ...y between terminals 1 and E c Check that there is continuity between terminals 1 and 2 d Check that there is no continuity between terminals 1 and 2 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals e and g b Using an ohmmeter check that there is continuity between terminals 1 and 2 c Check that there is no continuity between ter...

Page 298: ...an ohmmeter check that there is continuity between terminals 1 and 3 b Check that there is no continuity is not as specified replace the terminals 2 and 4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as specified replace ...

Page 299: ...CH 1 CHARGING SYSTEM Page PRECAUTIONS CH 2 TROUBLESHOOTING CH 2 CHARGING SYSTEM CIRCUIT CH 3 ON VEHICLE INSPECTION CH 5 ALTERNATOR CH 8 ...

Page 300: ...e warning light does not light with starter switch at ON and engine not running Fuse blown Light burned out Wiring connection loose IC regulator faulty Check fuses Replace light Tighten loose connection Replace IC regulator CH 8 CH 5 Adjust or replace drive belt Repair or replce cables Check fuse Replace fusible link Check charging system Repair wiring CH 5 Drive belt loose or worn Battery cables ...

Page 301: ...HZJ70 73 75 Starter Switch AM Fuse ENGINE 15A IG FL AM1 1 25B w Tachometer Battery w o Tachometer Stator Coil Battery 24 V Type Rotor Coil Alternator Fuse CHG 7 5A HZJ80andHDJ80 Starter Switch Fuse IGN 7 5A FL AM1 50A FL AM1 1 25B FL MAIN 2 0L Battery Alternator Rotor Coil Stator Coil Fuse CHG 7 5A ...

Page 302: ...harging System Circuit CHARGING SYSTEM CIRCUIT Cont d HZB 30 and HDB 30 Starter Switch AM IG Fuse ENGINE 10A FL MAIN 2 0L FL AM1 1 0Y Fuse GAUGE 7 5A Fuse CHG 7 5A Battery Battery 24 V Type Alternator Rotor Coil Stator Coil ...

Page 303: ...E BELTS a Visually check each belt for cracks oiliness or wear Check that the belt does not touch the bottom of the pulley groove If one belt has any of the above defects replace both belts b Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 10 kg 22 0 Ib 98 N of pressure Drive belt deflection New belt 6 7 mm 0 24 0 28 in Used belt 8 11 mm 0 3...

Page 304: ...ng light is lit d Start the engine Check that the light goes out If the light does not operate as specified troubleshoot the discharge light circuit 6 INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT If a battery alternator tester is available connect the tester to the charging circuit as per manufacturer s instructions a If a tester is not available connect a voltmeter and ammeter to the charging circu...

Page 305: ...ne and check the voltmeter reading of terminalB If the voltmeter reading is greater than standard voltage replace the IC regulator If the voltmeter reading is less than standard volt age check the alternator 7 INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the heater blower switch at HI b Check the reading on the ammeter Standar...

Page 306: ...tor Seal Plate Rectifier End Frame Rear End Cover Brush Holder Cover Brush Holder IC Regulator Rectifier Holder Rubber Insulator Type B Drive End Frame Stator Bearing Cover Rear Bearing Rear End Cover Brush Holder Rotor Retainer Front Bearing Terminal Insulator Rectifier End Frame Brush Holder Cover Spring Brush IC Regulator Rectifier Holder Rubber Insulator CH0857 CH0858 Pulley ...

Page 307: ... b HZB and HDB Remove the nut and terminal insulator c Remove the three nuts and end cover 2 REMOVE BRUSH HOLDER AND IC REGULATOR a Type A Remove the brush holder cover from the brush holder b Remove the five screws brush holder holder cover and IC regulator 3 REMOVE RECTIFIER HOLDER a Remove the four screws and rectifier holder Type A CH0845 CH0846 CH0869 CH0876 CH0892 ...

Page 308: ...n mount SST C in a vise and install the alternator to SST C d To loosen the pulley nut turn SST A in the direction shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more that one half of a turn e Remove the alternator from SST C f Turn SST B and remove SST A and B g Remove the pulley nut and pulley 5 REMOVE RECTIFIER END FRAME a PZJ HZJ and HDJ Remo...

Page 309: ...CH 11 CHARGING SYSTEM Alternator c Using SST remove the rectifier end frame SST 09286 46011 d Type A Remove the alternator washer 6 REMOVE ROTOR FROM DRIVE END FRAME SST Type A CH0870 CH0879 CH0851 ...

Page 310: ...ough or scored replace the rotor b Using vernier calipers measure the slip ring diameters Standard diameter 14 2 14 4 mm 0 559 0 567 in Minimum diameter 12 8 mm 0 504 in If the diameter is less than minimum replace the rotor Stator Drive End Frame 1 INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the coil leads If there is no continuity replace the drive en...

Page 311: ... Run the wire of the brush through the hole in the brush holder and insert the spring and brush into the brush holder c Solder the brush wire to the brush holder at the exposed length Exposed length 10 5 mm 0 413 in d Check that the brush moves smoothly in the brush holder e Cut off the excess wire f Apply insulation paint to the soldered point Rectifiers Rectifier Holder 1 INSPECT POSITIVE SIDE R...

Page 312: ...o each rectifier terminal and the other to each rectifier negative terminal b Reverse the polarity of the tester probes c Check that one shows continuity and the other shows no continuity If continuity is not as specified replace the rectifier holder Bearings 1 INSPECT FRONT BEARING Check that the bearing is not rough or worn 2 IF NECESSARY REPLACE FRONT BEARING a Remove the four screws and bearin...

Page 313: ...SST 09608 20012 09608 00030 d Install the bearing retainer with the four screws 3 INSPECT REAR BEARING Check that the bearing is not rough or worn 4 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing cover and bearing SST 09820 00021 NOTICE Be careful not to damage the fan Socket Wrench CH0856 SST CH0880 CH0868 CH0199 SST CH0200 ...

Page 314: ...D FRAME a Place the rectifier end frame on the pulley b Install the rotor to the rectifier end frame 2 INSTALL RECTIFIER END FRAME a Type A Place the alternator washer on the rotor b Using a plastic faced hammer lightly tap in the end frame c PZJ HZJ and HDJ Install the codenser and four nuts d HZBandHDB Install the four nuts SST CH0201 Pulley CH0850 Type A CH0879 CH0871 CH0855 ...

Page 315: ...shown in the illustration mount SST C in a vise and install the alternator to SST C e To torque the pulley nut turn SST A in the direction shown in the illustration Torque 1 125 kg cm 81 ft lb 110 N m f Remove the alternator from SST C g Turn SST B and remove SST A and B 4 INSTALL RECTIFIER HOLDER a Type A Place the seal plate on the rectifier end frame b Install the four rubber insulators on the ...

Page 316: ...er and connector c Place the brush holder cover on the brush holder Type B a Install the brush holder cover to the brush holder NOTICE Be careful about the holder installation di rection b Place the IC regulator together with the brush holder horizontally on the rectifier end frame c Install the five screws until there is a clearance of approx 1 1 mm 0 043 in between the brush holder and connector...

Page 317: ...ND COVER a Install the rear end cover with the three nuts b PZJ HZJ and HDJ Install the terminal insulator condenser lead wire with nut c HZB and HDB Install the terminal insulator with the nut 7 CHECK THAT ROTOR ROTATES SMOOTHLY CH0845 CH0846 CH0836 ...

Page 318: ...SERVICE SPECIFICATIONS Page ENGINE MECHANICAL A 2 TURBOCHARGER SYSTEM A 8 FUEL SYSTEM A 9 COOLING SYSTEM A 21 LUBRICATION SYSTEM A 21 STARTING SYSTEM A 22 CHARGING SYSTEM A 22 A 1 ...

Page 319: ... 95D31R and 95D31 L 9 6 liters 1O 1USqts 8 4 Imp qts 9 9 liters 10 5 US qts 8 7 Imp qts 9 7 liters 10 3 US qts 8 5 Imp qts 10 4 liters 11 0 US qts 9 2 Imp qts 10 2 liters 10 8 US qts 9 0 Imp qts 10 2 liters 10 8 US qts 9 0 Imp qts 10 3 liters 10 9 US qts 9 1 Imp qts 10 6 liters 11 2 US qts 9 3 Imp qts 10 4 liters 11 0 US qts 9 2 Imp qts 11 1 liters 11 6 US qts 9 8 Imp qts 10 9 liters 11 5 US qts 9...

Page 320: ...8 mm 0 0323 0 0346 in 1 03 1 09 mm 0 0406 0 0429 in 1 29 1 35 mm 0 0508 0 0531 in 650 rpm 650 rpm 710 rpm 650 rpm 800 rpm 4 600 rpm 4 400 rpm 950 rpm 1 2 4 5 3 1 _ 4 _ 2 6 3 5 Compression pressure Engine revolution at 250 rpm 1PZand1HZ STD Limit 1HD T STD Limit Difference of pressure between each cylinder 37 0 kg cm2 526 psi 3 628 kPa or more 27 0 kg cm2 384 psi 2 648 kPa 35 0 kg cm2 498 psi 3 432...

Page 321: ... 0 51 54 0 5148 in Valve Valve overall length STD Intake Exhaust Limit Intake Exhaust Valve face angle Stem diameter Intake Exhaust Stem oil clearance STD Intake Exhaust Limit Intake Exhaust Margin thickness STD Intake Exhaust Limit Intake Exhaust 103 29 103 69 mm 4 0655 4 0823 in 103 14 103 54 mm 4 0606 4 0764 in 102 79 mm 4 0468 in 102 64 mm 4 0409 in 44 5 7 975 7 990 mm 0 3140 0 3146 in 7 960 7...

Page 322: ... in 0 03 mm 0 0012 in Cylinder block Cylinder head surface warpage Limit Cylinder bore diameter STD Mark 1 Mark 2 Mark 3 Limit STD 0 S 0 50 Main journal bore diameter Reference STD Mark 1 Mark 2 Mark 3 0 20 mm 0 0079 in 94 000 94 010 mm 3 7008 3 701 2 in 94 010 94 020 mm 3 701 2 3 7016 in 94 020 94 030 mm 3 7016 3 7020 in 94 23 mm 3 7098 in 94 73 mm 3 7295 in 71 000 71 006 mm 2 7953 2 7955 in 71 0...

Page 323: ... 441 5 2 4417 in 62 020 62 026 mm 2 4417 2 4420 in 62 026 62 032 mm 2 4420 2 4422 in Main bearing Thrust clearance STD Limit Thrust washer thickness STD Main journal oil clearance STD STD U S 0 25 U S 0 50 Limit Main journal diameter STD Mark T Mark 2 Mark 3 U S 0 25 U S 0 50 Main bearing center wall thickness Reference STD Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Crank pin diameter STD Mark 1 Mark 2 Ma...

Page 324: ...For additional tighteninig torque Glow plug x Cylinder head Injection nozzle x Cylinder head 1 PZ and 1 HZ 1HD T Nozzle leakage pipe x Injection nozzle 1 PZ and 1 HZ 1HD T Water outlet x Cylinder head Intake manifold x Cylinder head Oil dipstick guide x Intake manifold Oil dipstick guide x Oil cooler cover Main bearing cap x Cylinder head Connecting rod cap x Connecting rod 1st 2nd Main bearing ca...

Page 325: ...pipe x Turbocharger No 2 turbo heat insulator x Turbocharger Turbocharger Exhaust manifold Exhaust manifold x Cylinder head For additional tighteninig torque Turbo oil pipe x Cylinder block Union bolt Turbo oil pipe x Turbocharger Turbocharger stay x Cylinder block Turbocharger stay x Turbocharger Turbocharger heat insulator x Turbocharger Exhaust manifold heat insulator x Exhaust manifold Intake ...

Page 326: ...mm 0 0423 in 1 100 mm 0 0433 in 1 125 mm 0 0443 in 1 150 mm 0 0453 in 1 175 mm 0 0463 in 1 200 mm 0 0472 in 1 225 mm 0 0482 in 1 250 mm 0 0492 in 1 275 mm 0 0502 in 1 300 mm 0 0512 in 1 325 mm 0 0522 in 1 350 mm 0 0531 in 1 375 mm 0 0541 in 1 400 mm 0 0551 in 1 425 mm 0 0561 in 1 450 mm 0 0571 in 1 475 mm 0 0581 in 1 500 mm 0 0591 in 1 525 mm 0 0600 in 1 550 mm 0 0610 in 1 575 mm 0 0620 in 1 600 m...

Page 327: ...0423 in 1 100 mm 0 0433 in 1 125 mm 0 0443 in 1 150 mm 0 0453 in 1 175 mm 0 0463 in 1 200 mm 0 0472 in 1 225 mm 0 0482 in 1 250 mm 0 0492 in 1 280 mm 0 0504 in 1 290 mm 0 0508 in 1 300 mm 0 0512 in 1 310 mm 0 0516 in 1 320 mm 0 0520 in 1 330 mm 0 0524 in 1 340 mm 0 0528 in 1 350 mm 0 0531 in 1 360 mm 0 0535 in 1 370 mm 0 0539 in 1 380 mm 0 0543 in 1 390 mm 0 0547 in 1 400 mm 0 0551 in 1 410 mm 0 0...

Page 328: ...ows spring IPZand 1HZ w HAC Boost compensator spring 1HD T Europe 1HD T Others w o BACS 1HD T Others w BACS Pickup sensor resistance Timer adjusting screw protrusion pre setting Plunger spring shim thickness Plunger adjusting shim thickness 1PZ Clockwise as seen from drive side 1 2 4 5 3 D E A B C 1 4 2 6 3 5 D E F A B C 0 02 mm 0 0008 in 2 0 mm 0 079 in 24 4 mm 0 961 in 19 1 mm 0 752 in 30 0 mm 1...

Page 329: ...5 mm 0 0925 in 2 40 mm 0 0945 in 2 45 mm 0 0965 in 2 50 mm 0 0984 in 2 55 mm 0 1004 in 2 60 mm 0 1024 in 2 65 mm 0 1043 in 2 70 mm 0 1063 in 2 75 mm 0 1083 in 2 80 mm 0 1102 in 2 85 mm 0 1122 in 2 90 mm 0 1142 in 2 94 mm 0 1157 in 2 99 mm 0 1177 in 3 04 mm 0 1197 in 3 09 mm 0 1216 in 3 14 mm 0 1236 in 3 19 mm 0 1256 in 0 1 5 0 35 mm 0 0059 0 0138 in 0 5 2 0 mm 0 020 0 079 in 1 05 mm 0 0413 in 1 25...

Page 330: ...HZ 1HD T w o BACS 1HD T w BACS Maximum speed side Maximum speed side Maximum speed side 1 200 200 1 800 200 1 800 200 Maximum speed pre setting Item Adjusting lever position Pump rpm No of measuring strokes 11 80 12 20 0 72 0 74 13 58 14 18 0 83 0 87 13 14 13 74 0 80 0 84 Injection volume cc cu in 4 0 6 0 0 24 0 37 3 0 5 0 0 18 0 31 3 0 5 0 0 18 0 31 200 200 200 2 300 2 300 2 200 Maximum speed sid...

Page 331: ...22 3 48 8 583 1 083 35 6 66 1 Piston stroke mm in 0 58 1 58 0 0228 0 0622 3 02 4 02 0 1189 0 1583 4 65 5 65 0 1830 0 2224 6 28 7 28 0 2472 0 2866 6 88 7 88 0 2709 0 3102 LST non operational 0 43 1 43 0 0169 0 0563 3 23 4 23 0 1272 0 1665 5 09 6 09 0 2004 0 2398 6 88 7 88 0 2709 0 3102 6 88 7 88 0 2709 0 3102 LST non operational 1 4 2 4 0 055 0 094 3 0 4 0 0 118 0 157 5 9 6 9 0 232 0 272 7 7 8 7 0 ...

Page 332: ... Plus 21 31 1 200 100 500 200 200 200 11 78 12 18 0 72 0 74 0 4 0 02 9 60 14 40 0 59 0 88 1 2 0 07 10 56 11 76 0 64 0 72 0 6 0 04 0 6 0 04 0 4 0 02 1 2 0 07 11 62 12 82 0 71 0 78 11 80 12 20 0 72 0 74 9 60 14 40 0 59 0 88 200 200 200 2 000 1 200 100 0 6 0 04 0 6 0 04 0 6 0 04 9 74 10 94 0 59 0 67 10 96 12 16 0 67 0 74 13 52 14 72 0 83 0 90 200 200 200 500 2 000 1 100 Plus 21 31 1HZ 1HD T Europe Pl...

Page 333: ...22 in 3 2 mm 0 126 in 3 3 mm 0 130 in 3 4 mm 0 134 in 3 5 mm 0 138 in 3 6 mm 0 142 in 3 7 mm 0 146 in 3 8 mm 0 150 in 3 9 mm 0 154 in 4 0 mm 0 158 in 4 1 mm 0 161 in 4 2 mm 0 165 in 3 0 mm 0 118 in 3 1 mm 0 122 in 3 2 mm 0 1 26 in 3 3 mm 0 130 in 3 4 mm 0 134 in 3 5 mm 0 138 in 3 6 mm 0 142 in 3 7 mm 0 146 in 3 8 mm 0 150 in 3 9 mm 0 154 in 4 0 mm 0 158 in 4 1 mm 0 161 in 4 2 mm 0 165 in 4 3 mm 0 ...

Page 334: ...0 12 44 13 44 0 76 0 82 10 86 11 86 0 66 0 72 Others w o BACS Others w BACS 500 0 50 7 1 49 200 8 20 9 20 0 50 0 56 Boost compensator characteristic tendency 1HD T only Item Pump rpm 1 100 1 100 0 48 6 8 47 0 81 11 5 79 Pressure kg cm2 psi kPa No of measuring stroke Injection volume cc cu in Hysterises cc cu in 13 52 14 72 0 82 0 90 200 200 200 200 12 44 13 44 0 76 0 82 10 50 11 70 0 64 0 71 0 3 0...

Page 335: ...nt Timer piston fluctuation mm in Idle speed 1PZ 1HZ 1HD T Europe 1HD T Others 1 600 1 600 1 440 1 440 2 19 3 1 9 0 0862 0 1 256 2 73 3 73 0 1075 0 1 469 0 70 1 70 0 0276 0 0670 1 96 2 96 0 0772 0 1165 Item 1PZ 1HZ M T 1HZ A T Adjusting lever angle Minus 12 22 Minus 12 22 Minus 12 22 Pump rpm 325 300 400 375 350 450 325 375 350 450 375 No of measuring strokes Injection volume cc cu in 200 200 200 ...

Page 336: ...8 12 58 0 62 0 77 q 2 84 3 84 0 17 0 23 More than q plus 0 5 0 03 0 4 0 02 No of measuring stroke 200 200 Injection volume cc cu in Remark q 0 5 0 9 0 03 0 05 Lever set q Plus 0 2 0 3 0 01 0 02 Adjust 200 200 q 0 1 0 3 0 01 0 02 q Plus 0 2 0 3 0 01 0 02 Lever set Adjust 1 3 mm 0 mm 1 6 mm 0 mm 0 051 in 0 in 0 063 in 0 in 38 48 Lever moving angle Adjusting lever Fast idle w ACSD IPZand 1HZ at fuel ...

Page 337: ...Feed pump cover x Injection pump body Distributive head x Injection pump body Governor link support bolt Delivery valve holder x Distributive head IPZand 1HZ 1HD T Distributive head plug x Distributive head IPZand 1HZ 1HD T Governor cover x Injection pump body Fuel cut solenoid x Distributive head Pickup sensor x Injection pump body Fuel inlet pipe x Injection pump Fuel outlet pipe x Injection pum...

Page 338: ...y clearance STD Limit Side clearance STD Limit Tip clearance STD Limit at idling at 3 000 rpm See page A 2 0 3 kg cm2 4 3 psi 29 kPa or more 2 5 kg cm2 36 psi 245 kPa or more 0 10 0 1 7 mm 0 0039 0 0067 in 0 20 mm 0 0079 in 0 03 0 09 mm 0 0012 0 0035 in 0 15 mm 0 0059 in 0 08 0 16 mm 0 0031 0 0063 in 0 21 mm 0 0083 in Part tightened kg cm ft lb Nm Engine oil drain plug Relief valve plug x Timing g...

Page 339: ...pring installed load 12 V 2 5 kW 24 V 4 5 kW 180 A or less at 11 0 V 90 A or less at 23 0 V 3 500 rpm or more 36 0 mm 1 417 in 35 0 mm 1 378 in 0 7 0 9 mm 0 028 0 035 in 0 2 mm 0 008 in 0 05 mm 0 0020 in 20 5 21 0 mm 0 807 0 827 in 13 0 mm 0 512 in 3 2 4 0 kg 7 1 8 8 Ib 31 39 N Drive belt deflection and tension See page A 2 Battery specific gravity when fully charge at 20 C 68 F 95D31R and 95D31 L...

Page 340: ...B 1 STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS B 2 ...

Page 341: ...5T 6T 7T 8T 9T 10T 11T Stud bolt Hexagon head bolt Hexagon flange bolt w washer hexagon bolt No mark 4T No mark 4T 4 5 Bolt 6 head No 7 8 9 10 11 Hexagon head bolt Two protruding lines 5T Hexagon flange bolt w washer hexagon bolt Two protruding lines 6T Welded bolt 4T 7T 8T Four protruding lines Three protruding lines Hexagon head bolt Hexagon head bolt ...

Page 342: ...65 in lb 7 5 175 13 17 5 360 26 36 670 48 65 1 050 76 100 80 69 in lb 8 195 14 19 400 29 39 730 53 71 1 100 80 110 1 750 127 170 90 78 in lb 9 210 15 21 440 32 44 810 59 80 1 250 90 125 6 8 10 12 14 16 8T 91 10T 11T 8 10 12 8 10 12 8 10 12 8 10 12 1 1 25 1 25 1 25 1 5 1 5 1 25 1 25 1 25 1 25 1 25 1 25 1 25 1 25 1 25 1 25 1 25 1 25 110 8 10 5 260 19 25 530 38 52 970 70 95 1 500 108 145 2 300 166 23...

Page 343: ...C 1 SSTAND SSM Page SST SPECIAL SERVICE TOOLS C 2 SSM SPECIAL SERVICE MATERIALS C 6 ...

Page 344: ...lacer 09202 43013 Valve Spring Compressor 09208 48010 Combustion Chamber Remover 09213 36020 Timing Gear Remover 09213 58011 Crankshaft Pulley Holding Tool 09213 60017 Crankshaft Pulley Gear Puller Set 09213 00020 Body with Bolt 09213 00030 Handle 09213 00060 Bolt Set 09214 60010 Crankshaft Pulley Gear Replacer 09214 76011 Crankshaft Pulley Replacer 09216 00020 Belt Tension Gauge IPZand 1HZ Inject...

Page 345: ...222 05030 Guide 09222 05040 Base 09222 66010 Connecting Rod Bushing Remover Replacer 09223 00010 Cover Seal Replacer 09223 46011 Crankshaft Front Oil Seal Replacer 09223 56010 Crankshaft Rear Oil Seal Replacer 09223 78010 Crankshaft Oil Seal Replacer 09228 10001 Oil Filter Wrench 09228 64010 Fuel Filter Wrench 09236 00101 Water Pump Overhaul Tool Set 09237 00070 Shaft C Governor sleeve plug Camsha...

Page 346: ...e Adjusting Tool 09260 54012 Injection Pump Tool Set 09262 54010 Distributor Head Plug Wrench 09262 54020 Regulator Valve Wrench j 09269 54020 Socket 14 mm 09269 54030 Tweezers 09269 54040 Governor Lever Support Bolt Wrench 09268 17010 2 Spring Nozzle Tool Set 09268 64010 Injection Nozzle Wrench Set 0927517010 Pre stroke Mearing Adapter 09751 19004 O Ring 09275 54011 Plunger Stroke Measuring Tool ...

Page 347: ...12 Front Hub Drive Pinion Bearing Tool Set 09608 00030 Replacer 0971720010 Brake Shoe Return Spring Remover 09718 20010 Brake Shoe Return Spring Replacer 09820 00021 Alternator Rear Bearing Puller 09820 63010 Alternator Pulley Set Nut Wrench Set 09923 00020 Hexago 8 mm Wrench 09950 20017 Universal Puller 09992 00024 Cylinder Compression Check Gauge Set w HAC and 1HD T 1 Starter front bearing 2 Rot...

Page 348: ...ttachment 09992 00211 Gauge Assy 09992 00241 Turbocharger Pressure Gauge Part Name Part No Sec Use etc Seal packing or equivalent 08826 00080 EM Adhesive 1324 Three bond 1324 or equivalent 08833 00070 LU LU Engine drain cock Screw plug Oil pump Oil pump Timing gear case Oil Pan Harf circular plug Camshaft oil seal retainer Cylinder head cover Main bearing cap Rear oil seal retainer Timing belt cov...

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