0-7
OPERATIONAL TIPS
1.
Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery terminal before the inspection or servicing of electrical parts.
2.
Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to
prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate
in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3.
Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble
requires disassembly or replacement for remedying.
4.
Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without
permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids, etc.
and treat them properly by requesting disposal by specialized companies.
5.
Jack up points
Jack up points are provided in the front and rear portions of the
vehicle. Always apply jacks at the jack up points.
Front side:
A circular groove to accept a screw jack is provided under the
front side of the frame.
When a garage jack is used, jack up at the bottom surface of
the frame.
Rear side:
Pn models
A circular groove to accept a screw or garage jack is provided
at the bottom surface of the counterweight.
Cu models
(except Cu1 ton series)
Jack up at the under the counterweight or the bottom surface
of the frame.
For screw
jack
For garage jack
(Pn2·3 ton series)
For screw jack
(Pn models)
General
Section 0
0-7a
Summary of Contents for 8FDU15
Page 3: ...0 2a EXTERIOR VIEWS General Section 0 ...
Page 4: ...0 2 0 2 EXTERIOR VIEWS General Section 0 0 2b ...
Page 21: ...0 17 8FG D U15 32 8FGCU20 32 COMPONENTS WEIGHT 8FGCU15 18 SU20 General Section 0 ...
Page 33: ...1 2 1 2 ENGINE EXTERIOR VIEW 4Y Engine Engine Section 1 ...
Page 34: ...1 3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E 1DZ II Engine Engine Section 1 ...
Page 55: ...1 18 1 18 RADIATOR COMPONENTS 4Y 1DZ II 1603 1603 Engine Section 1 8FG D U15 32 8FGCU20 32 ...
Page 57: ...RADIATOR COMPONENTS 1603 Engine Section 1 8FGCU15 18 SU20 1 19b ...
Page 64: ...1 23 BATTERY COMPONENTS 4Y 1DZ II 1901 1901 Engine Section 1 ...
Page 68: ...1 27 ACCELERATOR PEDAL COMPONENTS 4Y 1DZ II 2601 2601 Engine Section 1 ...
Page 71: ...1 30 1 30 EZ PEDAL OPT COMPONENTS 2601 Engine Section 1 ...
Page 83: ......
Page 86: ...ENGINE EXTERIOR VIEW 4Y M 4Y E Repair Section 1 1 0 ...
Page 87: ...4Y E OPT 4Y E Repair Section 1 1 0 ...
Page 88: ...ENGINE SECTIONAL VIEW 4Y E Repair Section 1 1 0 ...
Page 89: ...4Y E Repair Section 1 1 0 ...
Page 103: ......
Page 126: ...CYLINDER HEAD COMPONENTS 40 3 WAY CATALYTIC 4Y E Repair Section 1 1 2 ...
Page 127: ...4Y E Repair Section 1 1 2 ...
Page 128: ...Refer to 2601 HJ 4Y E Repair Section 1 1 2 ...
Page 138: ...TIMING GEAR COMPONENTS 4Y E Repair Section 1 1 2 ...
Page 139: ...4Y E Repair Section 1 1 2 ...
Page 140: ...4Y E Repair Section 1 1 2 ...
Page 151: ...I I L l l l l l l J I I s 2 0 c L l l l 1114 4Y E Repair Section 1 1 2 ...
Page 165: ......
Page 173: ...CYLINDER HEAD COMPONENTS 4Y E Repair Section 1 1 3 ...
Page 174: ...4Y E Repair Section 1 1 3 ...
Page 175: ...4Y E Repair Section 1 1 3 ...
Page 185: ...TIMING GEAR COMPONENTS 4Y E Repair Section 1 1 3 ...
Page 186: ...4Y E Repair Section 1 1 3 ...
Page 187: ...4Y E Repair Section 1 1 3 ...
Page 198: ...I I L l l l l l l I I I L l l l I I l J T 4Y E Repair Section 1 1 3 ...
Page 214: ...FUEL PUMP COMPONENTS 4Y E Repair Section 1 1 4 ...
Page 218: ...COMPONENTS 4Y E Repair Section 1 1 4 ...
Page 231: ...AIR GOVERNOR COMPONENTS 4Y E Repair Section 1 1 4 ...
Page 237: ......
Page 240: ...THROTTLE BODY COMPONENTS 4Y E Repair Section 1 1 5 ...
Page 243: ...INJECTOR COMPONENTS 4Y E Repair Section 1 1 5 ...
Page 248: ...FUEL PUMP COMPONENTS COOLER I I FUEL CAP WIKEY I 4Y E Repair Section 1 1 5 ...
Page 253: ......
Page 255: ...VENTILATION VALVE COMPONENTS 4Y E Repair Section 1 1 6 ...
Page 257: ......
Page 259: ...WATER PUMP COMPONENTS 4Y E Repair Section 1 1 7 ...
Page 265: ...SST TO BE USED Illustration I I Part No Part name 4Y E Repair Section 1 1 8 ...
Page 268: ...OIL PUMPmSTRAINER COMPONENTS 4Y E Repair Section 1 1 8 ...
Page 273: ......
Page 275: ...CIRCUIT DIAGRAM Ignition key Switch Black with two orange stripes 4Y E Repair Section 1 1 9 ...
Page 277: ...DISTRIBUTOR COMPONENTS I I Refer to Refer to FIG 1901 FIG 1901 4Y E Repair Section 1 1 9 ...
Page 290: ...DISTRIBUTOR COMPONENTS Refer to Refer to 4Y E Repair Section 1 1 10 ...
Page 295: ......
Page 298: ...STARTER MOTOR COMPONENTS 4Y E Repair Section 1 1 11 ...
Page 309: ...ALTERNATOR ELECTRICAL CIRCUIT DIAGRAM COMPONENTS 4Y E Repair Section 1 1 12 ...
Page 327: ... This Page Intentionally Left Blank ...
Page 329: ... This Page Intentionally Left Blank ...
Page 332: ...ENGINE EXTERIOR VIEWS 1DZ II Repair Section 1 2 0 ...
Page 333: ...ENGINE SECTIONAL VIEWS 1DZ II Repair Section 1 2 0 ...
Page 334: ...1DZ II Repair Section 1 2 0 ...
Page 368: ...CYLINDER HEAD COMPONENTS 1DZ II Repair Section 1 2 2 ...
Page 369: ...1DZ II Repair Section 1 2 2 ...
Page 379: ...TIMING GEAR COMPONENTS 1DZ II Repair Section 1 2 2 ...
Page 380: ...1DZ II Repair Section 1 2 2 ...
Page 381: ...2 22 DISASSEMBLY INSPECTION AND REASSEMBLY 1DZ II Repair Section 1 2 2 ...
Page 392: ...CYLINDER BLOCK COMPONENTS 1DZ II Repair Section 1 2 2 ...
Page 393: ...1DZ II Repair Section 1 2 2 ...
Page 414: ...1DZ II Repair Section 1 2 3 ...
Page 419: ...3 8 INJECTION NOZZLE COMPONENTS 1DZ II Repair Section 1 2 3 ...
Page 425: ...1DZ II Repair Section 1 2 3 ...
Page 463: ...1DZ II Repair Section 1 2 3 ...
Page 465: ...WATER PUMP COMPONENTS Refer to 5701 30 1DZ II Repair Section 1 2 4 ...
Page 469: ...1DZ II Repair Section 1 2 4 ...
Page 474: ...OIL PUMP COMPONENTS 1DZ II Repair Section 1 2 5 ...
Page 480: ...PREHEATING SYSTEM ELECTRIC CIRCUIT DIAGRAM COMPONENTS 1DZ II Repair Section 1 2 6 ...
Page 483: ...STARTER MOTOR COMPONENTS 1DZ II Repair Section 1 2 6 ...
Page 493: ...1DZ II Repair Section 1 2 6 ...
Page 497: ...ALTERNATOR ELECTRIC CIRCUIT DIAGRAM COMPONENTS 1DZ II Repair Section 1 2 7 ...
Page 523: ... This Page Intentionally Left Blank ...
Page 537: ... This Page Intentionally Left Blank ...
Page 549: ... This Page Intentionally Left Blank ...
Page 569: ... This Page Intentionally Left Blank ...
Page 618: ...4 5 WIRING DIAGRAM ...