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TROUBLESHOOTING

This page contains troubleshooting advice for the mechanical system of the travel and load handling control device.
In the case of an error code being recieved, or trouble with the electrical system, refer to the troubleshooting section.

●

Idle switch open error

Check the injection pump

Checking the components
of the travel and load
handling control device

A defect in the mechanical system of the travel and
load handling control device

.

Check the components of the travel and load
handling control device.

Not broken

Check that the injection pump return spring is
not broken.

Broken

Replace the return spring

Remove the interference.

There is
interference

Move the link by hand, and check that there is
no interference with surrounding parts.

There is no interference

Mechanically no cause can be found, therefore

refer to the travel and load handling control device

electrical system troubleshooting.

Retighten the installation bolts.

There is
looseness or
rattling

Check that there is no looseness or rattling in the
motor bracket.

There is no looseness

or rattling

Replace defective components.

There is
bending

Check that there is no bending in the connecting
rod or bracket.

There is no bending

Clean and grease the joint section.

There is
catching

Check that there is no catching on the sliding
portion of the ball joint.

There is no catching

Outside the range of the motor operation warranty.

90°C (194°F )
or more

Check that the temperature around the motor in
use is 90°C (194°F) or less.

90°C (194°F) or less

Engine

Section 1

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Summary of Contents for 8FDU15

Page 1: ...ERENTIAL 4 FRONT AXLE 5 REAR AXLE 6 STEERING 7 BRAKE 8 BODY 9 MATERIAL HANDLING SYSTEM 10 MAST 11 CYLINDER 12 OIL PUMP 13 OIL CONTROL VALVE 14 MINI LEVER JOYSTICK 15 SAS OPS 16 SSTLIST SERVICE STANDARDS LIST 17 MULTIFUNCTION DISPLAY DX OPTIONAL 18 ELECTRICAL SYSTEM TROUBLESHOOTING except Cu1 19 ELECTRICAL SYSTEM TROUBLESHOOTING Cu1 ton series 19 1 WIRING DIAGRAM E SERVICE INFORMATION BULLETINS SIB...

Page 2: ...ETER 0 8 ATTENTIVE POINTS ON SAS 0 9 CIRCUIT TESTER 0 10 STANDARD BOLT NUT TIGHTENING TORQUE 0 12 BOLT STRENGTH CLASS IDENTIFICATION METHOD 0 12 PRECOAT BOLTS 0 15 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 0 15 WIRE ROPE SUSPENSION ANGLE LIST 0 16 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE 0 16 COMPONENTS WEIGHT 0 17 RECOMMENDED LUBRICANT QUANTITY TYPES 0 18 LUBRICATION CHART 0 19 PERIODIC M...

Page 3: ...0 2a EXTERIOR VIEWS General Section 0 ...

Page 4: ...0 2 0 2 EXTERIOR VIEWS General Section 0 0 2b ...

Page 5: ...ries Pn20 4000 lbs 8FGU20 T C 4Y Gasoline 8FDU20 T C 1DZ II Diesel Pn25 5000 lbs 8FGU25 T C 4Y Gasoline 8FDU25 T C 1DZ II Diesel Pn3 ton series Pn30 6000 lbs 8FGU30 T C 4Y Gasoline 8FDU30 T C 1DZ II Diesel Pn32 6500 lbs 8FGU32 T C 4Y Gasoline 8FDU32 T C 1DZ II Diesel Classification Load Capacity Vehicle Model Transmission Type Engine Series Model Cu2 ton series Cu20 4000 lbs 8FGCU20 T C 4Y Gasolin...

Page 6: ...pacity Vehicle Model Transmission Type Engine 1 ton series 3000 lbs 8FGCU15 T C 4Y Gasoline 3500 lbs 8FGCU18 T C 4Y Gasoline 4000 lbs 8FGCSU20 T C 4Y Gasoline Series Engine Vehicle model Punching format 1 ton series 4Y 8FGCU15 8FGCSU20 10011 8FGCSU20 10011 8FGCU18 8FGCSU20 Punching position General Section 0 0 4a 8FGCU15 18 SU20 Cu1 ton series Cu1 ton series ...

Page 7: ... 10011 8FDU18 2 ton series 4Y 8FGU20 8FGU25 10011 8FGU25 1DZ II 8FDU20 8FDU25 10011 8FDU25 3 ton series 4Y 8FGU30 8FGU32 10011 8FGU32 1DZ II 8FDU30 8FDU32 10011 8FDU32 Cushion tire 2 ton series 4Y 8FGCU20 8FGCU25 10011 8FGCU25 10011 8FGCU25 3 ton series 8FGCU30 8FGCU32 10011 8FGCU32 10011 8FGCU32 EEC spec Punching position General Section 0 0 4b 8FG D U15 32 8FGCU20 32 ...

Page 8: ...B DISASSEMBLY INSPECTION REASSEMBLY Tightening torque unit T N m kgf cm ft lbf Disassembly Procedure 1 Remove the cover Point 1 2 Remove the bushing Point 2 3 Remove the gear Point Operations Point 1 Disassembly Put a match mark when removing the pump cover Point 2 Inspection Measure the bush inside diameter Limit 19 12 mm 0 7528 in Step Nos are partially sometimes omitted in illustrations When a ...

Page 9: ...tters in operation procedure requiring special attention Standard Values showing allowable range in inspection and adjustment Limit Maximum or minimum allowable value in inspection or adjustment ABBREVIATIONS Abbreviation code Meaning Abbreviation code Meaning ASC Auto Speed Control R B Relay block ATT Attachment RH Right hand Cu Cushion tire models RR Rear FR Front SAE Society of Automotive Engin...

Page 10: ... 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...

Page 11: ...nued from previous page 8FGCU15 18 SU20 5 Jack up points Front side Jack up at the bottom surface of the frame Rear side Jack up at the under the counterweight or the bottom surface of the frame General Section 0 ...

Page 12: ...orklift by the weight hook holes HOW TO START THE HOUR METER Be sure to start the hour meter when delivering a new vehicle to a customer Remove the fuse 7 5 A in position A inside the relay block and install it to position B HOUR MET Make sure that the engine is stopped when installing the fuse 25A BLR SPARE SPARE ST GAUGE BACK LP SFT TURN IGN STA RR WIP FR WIP 1 2 30A 7 5A 7 5A 2 1 7 5A 2 1 10A 2...

Page 13: ...e label See Page 16 32 5 Care should always be exercised for safety operation whenever you operate the truck Make distinction between the SAS featured trucks and those of none because the control features are different 6 The SAS oil control valves comprise many precision valves Since dirty or contaminated hydraulic oil will adversely affect the functions of these valves always wash the parts clean...

Page 14: ... digital type and analog type The result may be different between measurements with the analog type and digital type Always use a circuit tester according to its operation manual Cautions when the polarities are different between the analog type and digital type are described below 1 Analog circuit tester Measurement result example Tester range kΩ range 2 Digital circuit tester Measurement result ...

Page 15: ... measurement with a circuit tester whose power supply voltage is 3 0 V 3 Difference in measurement result by measurement range analog type In the analog type circuit tester changing the measurement range switches over the internal circuit to vary the circuit resistance Even when the same diode is measured the measurement result varies with the measurement range Always use the range described in th...

Page 16: ...torque table 2 For tightening torque of hexagon flange bolts identify bolt class based on the below chart and then determine using the tightening torque table 3 For tightening torque of nuts check the mating bolt and use the method 1 BOLT STRENGTH CLASS IDENTIFICATION METHOD Identification by Bolt Shape Shape and class Class Hexagon head bolt Bolt head No 4 4T 5 5T 6 6T 7 7T 8 8T No mark 4T Two pr...

Page 17: ... 6 5 16 32 59 91 137 65 160 330 600 930 1400 5 12 24 43 67 101 6T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 8 19 39 72 108 172 80 190 400 730 1100 1750 6 14 29 53 80 127 7T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 11 25 52 95 147 226 110 260 530 970 1500 2300 8 19 38 70 108 166 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 12 29 61 108 172 265 120 300 620 1100 1750 2700 9 22 45 80 127 195 Len...

Page 18: ...58 88 6 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 5 19 39 71 110 170 80 190 400 720 1120 1730 6 14 29 52 81 125 8 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 12 29 61 110 175 270 120 300 620 1120 1780 2750 9 22 45 81 129 199 10 9T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 15 5 38 80 145 230 360 160 390 820 1480 2350 3670 12 28 59 107 170 266 11 9T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 ...

Page 19: ...n the contact surfaces before installation 2 When connecting a high pressure hose hold the hose to align the fitting with the nipple and tighten the fitting 3 The maximum tightening torque must not exceed twice the standard tightening torque Seal lock agent Nominal diameter of screw Standard tightening torque N m kgf cm ft lbf Hose inside diameter mm in Standard Tightening range 7 16 20UNF 25 250 ...

Page 20: ...0 0 88 1940 8 mm 0 32 in 31480 3 21 7078 4410 0 45 992 3 8830 0 9 1985 8530 0 87 1918 7650 0 78 1720 6280 0 64 1411 17650 1 8 3969 17060 1 74 3937 15300 1 56 3440 12550 1 28 2322 10 mm 0 4 in 49230 5 02 11 69 6960 0 71 1565 6 14020 1 43 3153 13440 1 37 3021 11770 1 2 2646 9810 1 0 2205 27460 2 8 6174 26480 2 7 5954 23540 2 4 5292 19610 2 0 4410 12 5 mm 0 5 in 76880 7 84 17387 10980 1 12 2469 5 215...

Page 21: ...0 17 8FG D U15 32 8FGCU20 32 COMPONENTS WEIGHT 8FGCU15 18 SU20 General Section 0 ...

Page 22: ...mast max lifting height 3300 mm 131 in Pn1 ton series 31 8 2 ISO VG32 Hydraulic oil Pn2 ton series 35 9 2 Cu2 3 ton series 33 8 7 Pn3 ton series 38 10 0 Fuel tank Pn1 ton series 45 11 9 Cu2 3 ton series 45 11 9 Pn2 3 ton series 60 15 8 Brake line All models Proper quantity Reservoir Tank 0 2 0 05 SAE J 1703 DOT 3 Brake cooling oil Cu2 3 ton series 7 4 1 95 Shell DONAX TD Pn2 3 ton series 8 0 2 11 ...

Page 23: ... models 4 8 1 27 API GL 4 Hypoid gear oil SAE85W 90 Hydraulic oil V mast max lifting height 3300 mm 131 in 1 ton series 30 7 9 ISO VG32 Hydraulic oil Fuel tank All models 27 7 1 Brake All models Proper quantity Reservoir Tank 0 2 0 05 SAE J 1703 DOT 3 Chassis parts All models Proper quantity MP grease Molybdenum disulfide grease Coolant excluding reservoir tank 4Y LLC LLC 30 50 mixture for winter ...

Page 24: ...wheel bearing 7 Steering knuckle king pin 8 Oil tank 9 Engine crank case I Inspect every 8 hours daily II Inspect every 40 hours weekly III Inspect every 250 hours 6 weeks IV Inspect every 1000 hours 6 monthly V Inspect every 2000 hours annual 10 Rear axle beam front pin 11 Rear axle beam rear pin 12 Tilt steering locking mechanism 13 Mast support bushing 14 Tilt cylinder front pin 15 Propeller sh...

Page 25: ...l bearing 7 Steering knuckle king pin 8 Oil tank 9 Engine crank case I Inspect every 8 hours daily II Inspect every 40 hours weekly III Inspect every 250 hours 6 weeks IV Inspect every 1000 hours 6 monthly V Inspect every 2000 hours annual 10 Rear axle beam front pin 11 Rear axle beam rear pin 12 Tilt steering locking mechanism 13 Mast support bushing 14 Tilt cylinder front pin 15 Propeller shaft ...

Page 26: ...ssion M Cylinder head bolt loosening T Muffler rubber mount I PCV system Clogging and damage in PCV valve and piping I Governor No load maximum rpm M Lubrication system Oil leak I Oil level I Clogging and dirt of oil filter I Fuel system Fuel leak I Operation of carburetor link mechanism I Dirt and clogging of fuel filter and element I Injection timing M Injection nozzle injection pressure and spr...

Page 27: ...tall and hydraulic pressure measurement M Propeller shaft and axle shaft Loose joint T Looseness at spline connections I Looseness of universal joint I Twisting and cracks of axle shaft I DRIVE SYSTEM Wheels Tire inflation pressure M Tire cuts damage and uneven wearing l Loose rim and hub nuts T Tire groove depth M Metal chips pebbles and other foreign matter trapped in tire grooves l Wheels Rim s...

Page 28: ...fluid level I Master cylinder and wheel cylinder Function wear damage leak and mounting looseness I Brake drum and brake shoe Clearance between drum and lining M Wear of shoe sliding portion and lining I Drum wear and damage I Shoe operating condition I Anchor pin rusting I Return spring fatigue M Automatic adjuster function I Backing plate Deformation cracks and damage I Loose mounting T Wet brak...

Page 29: ...nts Abnormality and mounting condition of each part I HYDRAULIC SYSTEM Cylinder Loosening and damage of cylinder mounting T Deformation and damage of rod rod screw and rod end I Cylinder operation I Natural drop and natural forward tilt hydraulic drift M Oil leak and damage I Wear and damage of pin and pin support I Lifting speed M Uneven movement I Oil pump Oil leak and abnormal sound I Hydraulic...

Page 30: ...crack and damage I Lighting system Function and mounting condition I Horn Function and mounting condition I Direction indicator Function and mounting condition I Instruments Functions I Backup buzzer Function and mounting condition I Rear view mirror Dirt damage I Rear reflection status I Seat Loosening and damage of mounting I Seatbelt damage and function I Seat switch function I OPS Functions I ...

Page 31: ...s Engine oil z 2 Engine oil filter z 1 z Engine coolant every 2 years for LLC z Fuel filter z Torque converter oil z Torque converter oil filter z Differential oil z Hydraulic oil z Hydraulic oil filter z 1 z Wheel bearing grease z Air cleaner element z Cups and seals for brake master and wheel cylinders z Brake fluid z Spark plugs z 3 Power steering hoses z 4 Power steering rubbers parts z 4 Hydr...

Page 32: ...G SYSTEM INSPECTION OPT 1 17 RADIATOR 1 18 COMPONENTS 1 18 SPECIFICATIONS 1 19 COOLANT CAPACITY AND ANTIFREEZE TABLE 1 19 COOLANT INSPECTION 1 19 MUFFLER EXHAUST PIPE 1 21 COMPONENTS 1 21 REMOVAL INSTALLATION 1 22 BATTERY 1 23 COMPONENTS 1 23 SPECIFICATIONS 1 24 INSPECTION 1 25 V BELT TENSION ADJUSTMENT 1 26 ACCELERATOR PEDAL 1 27 COMPONENTS 1 27 INSPECTION ADJUSTMENT 1 28 EZ PEDAL OPT 1 30 COMPON...

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 35: ... PS rpm LPG convertible Gasoline 38 51 2570 43 58 2570 LPG convertible LPG 38 51 2570 42 57 2570 LPG exclusive 38 51 2570 42 57 2570 Maximum torque Gasoline exclusive 160 16 3 2100 165 16 8 2570 N m kgf m rpm LPG convertible Gasoline 160 16 3 2100 162 16 5 2570 LPG convertible LPG 160 16 3 2100 160 16 3 2200 LPG exclusive 160 16 3 2100 160 16 3 2200 Minimum fuel consumption Gasoline exclusive 298 ...

Page 36: ... 8 Maximum output Gasoline exclusive 36 48 2250 kW PS rpm LPG convertible Gasoline 36 48 2250 LPG convertible LPG 36 48 2250 LPG exclusive 36 48 2250 Maximum torque Gasoline exclusive 160 16 3 2100 N m kgf m rpm LPG convertible Gasoline 160 16 3 2100 LPG convertible LPG 160 16 3 2100 LPG exclusive 160 16 3 2100 Minimum fuel consumption Gasoline exclusive 298 219 2000 g kW h g PS h rpm LPG converti...

Page 37: ... mounted Combustion chamber type Whirl chamber Valve mechanism OHV gear drive Bore x stroke mm in 86 0 107 0 3 386 4 213 Total displacement cm3 in3 2486 151 71 Compression ratio 21 5 Maximum output kW PS rpm 39 53 2400 42 57 2500 Maximum torque N m kgf m rpm 160 16 3 2300 160 16 3 2500 Minimum fuel conspumption g kW h g PS h rpm 247 181 1400 Service weight kg lb 162 357 No load maximum speed rpm 2...

Page 38: ...ible LPG Exclusive Convertible Gasoline Exclusive Convertible Torque Shaft torque Fuel consumption ratio Gasoline Exclusive LPG Exclusive Convertible Gasoline Convertible with LPG Gasoline Exclusive LPG Exclusive Convertible Gasoline Convertible with LPG LPG Exclusive Convertible Gasoline Exclusive Convertible Engine Section 1 1 6a ...

Page 39: ...1 4 1 4 ENGINE PERFORMANCE CURVES Gasoline Exclusive Convertible LPG Exclusive Convertible Torque Shaft torque Fuel consumption ratio Engine Section 1 1 6b 4Y 8FGCU15 18 SU20 ...

Page 40: ...1 7 1DZ II Engine 8FDU15 18 1DZ II Engine 8FDU20 32 Torque Shaft torque Fuel consumption ratio Torque Shaft torque Fuel consumption ratio Engine Section 1 ...

Page 41: ...2 57 9 Drive plate set bolt For connecting the engine crank shaft 1DZ II 2Z T 125 186 1275 1897 92 2 137 2 4Y T 78 98 795 1000 57 5 72 4 Drive plate set bolt For connecting the torque converter T 14 7 21 6 150 220 10 9 15 9 Torque converter housing set bolt T 29 4 44 1 300 450 21 7 32 6 22 25 7 27 8 28 12 18 26 Engine Section 1 8FG D U15 32 8FGCU20 32 ...

Page 42: ...ire harness clamps around the engine 18 Remove the oil pump set bolt and free it 19 Remove the cover plate Point 2 20 Remove the 6 drive plate set bolts Point 3 21 Remove the engine mount nuts 22 Slightly hoist the engine Point 4 23 Support the torque converter housing with wooden blocks 24 Separate the torque converter housing and engine Point 5 25 Remove the engine ASSY 26 Remove the drive plate...

Page 43: ...int 3 Removal Installation Rotate the drive plate using the crank shaft pulley set bolt and remove the drive plate set bolt Point 4 Removal Installation SST 09010 20111 71 1 09010 23320 71 2 Removal Temporarily hoist up until the mount bolt completely comes out of the hole in the frame Cover plate SST 1 SST 2 Engine Section 1 8FG D U15 32 8FGCU20 32 ...

Page 44: ... bleeding by moving the priming pump knob up and down 2 Once the pump operation becomes heavy air bleeding is completed ENGINE INSPECTION ADJUSTMENT Note Warm up the engine beforehand and proceed with inspection and adjustment when the vehicle is in the following state Coolant temperature 75 C 167 F or above engine oil temperature 60 C 140 F or above hydraulic oil temperature 50 C 122 F or above E...

Page 45: ...010 39 8 73 1 End plate set bolt T 49 0 78 5 500 800 36 2 57 9 Drive plate set bolt for connecting engine crankshaft T 56 9 64 7 580 660 42 0 47 7 Drive plate set bolt for connecting torque converter T 14 7 21 6 150 220 10 9 15 9 Torque converter housing set bolt T 29 4 44 1 300 450 21 7 32 6 12 14 6 13 23 7 5 Engine Section 1 1 11b 8FGCU15 18 SU20 ...

Page 46: ...onnect the wiring from the starting motor 16 Remove the cover plate for drive plate 17 Remove 6 drive plate set bolts 18 Slightly hoist the engine Point 2 19 Remove the engine mounting nuts 20 Sling the torque converter housing with wire rope and support it with the head guard or support it with wooden blocks 21 Separate the torque converter housing and engine Point 3 22 Remove the engine ASSY wit...

Page 47: ...0111 71 1 09010 23320 71 2 Removal Temporarily hoist up until the mount bolt completely comes out of the hole in the frame Point 3 Removal Use a flat head screwdriver for separation If the fitting is too tight change the SST hook position and adjust the engine angle for easier separation SST 1 SST 2 Engine Section 1 1 11d 8FGCU15 18 SU20 ...

Page 48: ...0 26600 71 Note Vehicles equipped with the multifunction display OPT have the same functions as the analyzer so the plug in analyzer is not necessary For an explanation on using the multifunction display and plug in analyzer refer to the multifunction display section 2 Set the idle speed to within standard values on the idle adjustment screen No load Maximum Speed Inpsection 1 Attach a rev counter...

Page 49: ...l the timing light 4 Use the SST to short circuit terminals TC and EI of the diagnostic connector SST 09238 13130 71 Caution If the short circuit positions are incorrect this will cause a fault Make sure to short circuit the correct terminals 5 Inspect the ignition timing If the standard is not met loosen the distributor set bolt and rotate the distributor to adjust the ignition timing to the stan...

Page 50: ...ouching the maximum adjusting screw 2 Start the engine and measure the engine speed no load maximum speed when the accelerator pedal is fully pressed down Standard 8FDU15 18 2600 50 rpm 8FDU20 32 2800 50 rpm In the case of vehicles equipped with travel and load handling control the rpm tolerance is 3 Adjust the no load maximum speed Remove the sealing of the maximum adjusting screw and adjust by t...

Page 51: ... Single STD Double OPT Type Cyclone type Size 7 inch Intake type Fresh air introduction type Filtering area cm2 in2 18600 2883 Outer 18600 2883 Inner 510 79 1 Others With evacuator valve 1703 Engine Section 1 1 15a 8FG D U15 32 8FGCU20 32 ...

Page 52: ...ENTS Single STD Double OPT Type Cyclone type Size 6 inch Intake type Fresh air introduction type Filtering area cm2 in2 14000 2170 Outer 14000 2170 Inner 570 88 4 Others With evacuator valve 1703 Engine Section 1 1 15b 8FGCU15 18 SU20 ...

Page 53: ...es Then rinse the element well with clear water Water pressure 275 kPa 2 8 kgf cm2 40 psi or less After washing naturally dry the element or dry the element with a dryer cold air Note Do not damage the paper filter during washing Never use compressed air or hot air for drying 4 Clean the evacuator valve dust discharge valve Hold the tip end of the evacuator valve and discharge dust and dirt from t...

Page 54: ...comes on when the ignition key switch is turned ON and goes out when the engine starts 2 Individual inspection 1 Use a mity vac to apply a negative pressure to the vacuum switch and inspect for continuity Standard 4Y engine vehicle 2630 3218 Pa 270 330 mmAq 19 9 24 3 mmHg continuity exists 1DZ II engine vehicles 6904 8042 Pa 704 820 mmAq 51 7 60 3 mmHg continuity exists 25 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 56: ...LC 1 Measure the temperature and specific gravity of the coolant Note The coolant concentration must be 30 STD 50 or above Type Crossflow Fin type Corrugated fin Coolant capacity in radiator See the table below Cap opening pressure kPa kgf cm2 psi 88 14 7 0 9 0 15 13 2 1 Others Built in torque converter cooler torque converter vehicle Radiator capacity Total coolant capacity 30 Antifreeze mixture ...

Page 57: ...RADIATOR COMPONENTS 1603 Engine Section 1 8FGCU15 18 SU20 1 19b ...

Page 58: ... Measure the coolant concentration LLC 1 Measure the temperature and specific gravity of the coolant Note The coolant concentration must be 30 STD 50 or above Type Crossflow Fin type Corrugated fin Coolant capacity in radiator See the table below Cap opening pressure kPa kgf cm2 psi 88 14 7 0 9 0 15 13 2 1 Others Built in torque converter cooler torque converter vehicle Radiator capacity Total coo...

Page 59: ...5 C and the specific gravity is 1 035 the coolant concentration at this time can be found as follows The intersection point of 55 C and 1 035 is between the 30 line and 40 line so this point is approximately 35 In other words the concentration is approximately 35 3 Check that there is no oil etc mixed in with the coolant Measured temperature C 50 approximately 38 C 40 approximately 26 C 30 approxi...

Page 60: ...1 21 MUFFLER EXHAUST PIPE COMPONENTS 4Y 1DZ II 1 K2 K3 Ton Series 1702 1702 Engine Section 1 8FG D U15 32 8FGCU20 32 ...

Page 61: ...ght Here method 1 is explained Removal Procedure 1 Remove the counterweight See page 11 XX 2 Separate the union between the exhaust pipe and muffler 3 Remove the exhaust pipe fixation bolts 4 Remove the muffler 5 Disconnect the tail pipe from the muffler Installation Procedure The installation procedure is the reverse of the removal procedure Note Use a new gasket 3 4 2 5 Engine Section 1 1 22a 8F...

Page 62: ...MUFFLER EXHAUST PIPE COMPONENTS STD EXPORT SPEC 1702 1702 Engine Section 1 8FGCU15 18 SU20 1 22b ...

Page 63: ... radiator W counterweight Here method 1 is explained Removal Procedure 1 Remove the counterweight See Section 11 2 Separate the union between the exhaust pipe and muffler 3 Remove the exhaust pipe fixation bolts 4 Remove the muffler Installation Procedure The installation procedure is the reverse of the removal procedure Note Use a new gasket 3 4 2 Engine Section 1 8FGCU15 18 SU20 1 22c ...

Page 64: ...1 23 BATTERY COMPONENTS 4Y 1DZ II 1901 1901 Engine Section 1 ...

Page 65: ...ed according to the equipped engine Engine Specifications 4Y 1DZ II STD GR35 JIS 55D23L GR24R JIS 80D26L Voltage V 12 5 hour rated capacity Ah 48 55 Specific gravity of battery fluid in use at 20 C 68 F 1 280 Battery weight kg lb 16 2 35 7 19 0 41 9 Engine Section 1 ...

Page 66: ... 68 F St Measured specific gravity at t C t Fluid temperature at the time of measurement 3 Inspect the battery terminals If battery terminals are contaminated to white clean then and apply a thin coat of MP grease on terminals 4 Inspect the battery terminals and the harness connecting portions for loosening Retighten the battery terminals and the harness connecting portions Battery Removal 1 Disco...

Page 67: ... tension 3 Tighten the fixing bolt and recheck the belt tension Note Be careful not to apply excessive tension to the belt 1DZ II engine vehicles 1 Loosen the fixing bolt and adjusting bolt 2 Stretch the V belt using a pry bar with the length of 300 to 400 mm 11 8 to 15 7 in and tighten the alternator adjustment bolt 3 Tighten the fixing bolt then recheck the belt tension Note Adjustment of the te...

Page 68: ...1 27 ACCELERATOR PEDAL COMPONENTS 4Y 1DZ II 2601 2601 Engine Section 1 ...

Page 69: ... adjusting the length of the rod 2 Temporarily set the pedal stopper bolt height to 52 mm 2 05 in 3 Adjust the accelerator sensor 1 Connect the plug in analyzer SST 09240 26600 71 For diesel vehicles with travel and load handling control OPT use the multifunction display Note For an explanation on using the display refer to the multifunction display section A B Stopper bolt Rod 1DZ II A When the a...

Page 70: ...he change in output per single turn of the stopper bolt is 0 06 V 4 After adjustment apply thread tightener 08833 76002 71 08833 00080 to the threaded section of the stopper bolt lock nut and reassemble it 5 Clear the learned values For the 4Y Remove the battery plug for more than 10 seconds then reconnect it For diesel vehicles with drive control Turn the key ON with the accelerator sensor connec...

Page 71: ...1 30 1 30 EZ PEDAL OPT COMPONENTS 2601 Engine Section 1 ...

Page 72: ...edure is the reverse of the disassembly procedure Note Apply grease on the inner surface of each bushing After reassembly adjust the direction switch See page 1 27 Point Operations Point 1 Disassembly Extract the pin by lightly tapping the pin edge the flange less side Reassembly Push the pin in with its notched flange portion in the illustrated direction until it goes beyond the pad side hook 2 1...

Page 73: ...nto the pad Apply locking agent 08833 76002 71 08833 00080 at the tip end of the screw before tightening the nut 2 Fix the switch harness by means of the plate Avoid overlaying of three wire harnesses in the harness tube as illustrated Also push portion A of the harness so as not to be raised to prevent interference at the time of pin insertion Point 3 Reassembly Since the holder W magnet needs he...

Page 74: ...time 2 Screw in the magnet holder at the tilted side 3 Where the pad starts moving slightly is the position that the magnet come to contact with the accelerator pedal pad plate Then thread in by a half 1 2 turn from that point 4 Tighten the lock nut Secure the magnet holder so as not to turn 5 Adjust the other side in the same manner as in 1 to 4 6 After adjustment confirm that the switches are ac...

Page 75: ...lerator switch bracket to the accelerator link bracket 3 Adjust the clearance as specified in the table below while turning the accelerator switch bracket Adjusting Pedal Height for Diesel Vehicles 1 Adjust the stopper bolt height so that the link contacts the stopper bolt on the engine side when the pedal is depressed At this time the pedal play should be adjusted to within 0 4 to 1 7 Reference 8...

Page 76: ...1 35 TRAVEL AND LOAD HANDLING CONTROL DEVICE OPT 1DZ II Engine Vehicle COMPONENTS 2607 Engine Section 1 ...

Page 77: ... Remove the sedimenter 5 Remove the battery set plate 6 Disconnect the injection pump side link 7 Remove the actuator Point 1 Installation Procedure The installation procedure is the reverse of the removal procedure Note After installation adjust the throttle opening degree Refer to 1 37 After installation operate the accelerator pedal and check that the links are working normally LBA26 006 6 7 En...

Page 78: ...en 1 and 3 Approx 2 5 3 7 Ω Between 2 and 3 Approx 2 5 3 7 Ω Between 1 and 4 Approx 5 0 7 4 Ω Between 2 and 5 Approx 5 0 7 4 Ω Inspection Measure the insulation resistance between each actuator terminal and body Tester range Ω 1 M range Standard 100 MΩ or more Point 2 Inspection Inspect the continuity of the limit switch Standard Free position Ω When pushed 2 3 mm 0 091 in or more 0 Ω Engine Secti...

Page 79: ... not turn together NMR Switch Injection Pump Lever Completely Open Adjustment 1 Fix the injection pump lever in completely open state with a thickness gauge 0 3 mm 0 051 in thickness placed between the lever and the NMR set screw 2 Tighten the adjustment bolt on the NMR switch side from the state where the switch and bolt are not in contact switch OFF and adjust the bolt to the point where the swi...

Page 80: ...rence Move the link by hand and check that there is no interference with surrounding parts There is no interference Mechanically no cause can be found therefore refer to the travel and load handling control device electrical system troubleshooting Retighten the installation bolts There is looseness or rattling Check that there is no looseness or rattling in the motor bracket There is no looseness ...

Page 81: ... of the travel and load handling control device refer to 1 38 There is no catching Move the pump lever with your hand to check that there is no catching in the sliding movement There is catching Service the injection pump apply grease etc A defect in the mechanical system of the travel and load handling control device Check the components of the travel and load handling control device refer to 1 3...

Page 82: ...ENERAL0 0 TROUBLESHOOTING ENGINE OVERHAUL 4Y M ENGINE OVERHAUL 4Y E FUEL SYSTEM 4Y M FUEL SYSTEM 4Y E PCV DEVICE COOLING S LUBRICATION SYSTEM IGNITION SYSTEM 4Y M IGNITION SYSTEM 4Y E STARTING SYSTEM CHARGING SYSTEM APPENDIX 4Y E Repair ...

Page 83: ......

Page 84: ...RATING TIPS 0 10 POINTS FOR WHICH SPECIAL CARE MUST BE TAKEN 0 10 GENERAL INSTRUCTIONS 0 10 ELECTRICAL PARTS INSPECTION 0 13 BOLT NUT TIGHTENING TORQUES 0 15 BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE 0 15 PRECOATED BOLTS BOLTS WITH SEAL LOCK AGENT COATING ON THREADS 0 18 SI UNITS 0 18 HANDLING FlPG LIQUID GASKETS 0 19 4Y E Repair Section 1 1 0 ...

Page 85: ...ach vehicle model No load maximum speed rpm Idle speed rpm t t 1Weight kg Ib Refer to repair manual for each vehicle model Refer to repair manual for each vehicle model mm in t t 7 0 9 x 5 2 5 7 3 3 27 9 x 20 7 x 28 9 Number of piston rings Valve clearance 709x 513x 733 27 9 x 20 2 x 28 9 Intake valve open close interval Exhaust valve openlclose interval Compression rings Oil ring Open Close Open ...

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 90: ...re a part for which the tightening torque is specified is not shown in the illustration the name of the part will be listed inside the illustration frame DisassemblymReassembly Procedure The reassembly procedure is the reverse of the disassembly procedure Point Operations Explanation of operation point with illustration Operations that have a following explanation Point 11 Inspection Measure the b...

Page 91: ...tially described TERMINOLOGY Warning ltems that may lead to an injury to either the operator or another person and items and operation points which if not followed may lead to an injury or accident Caution ltems that must not be performed because doing so will result in damage to the vehicle or it s components and items in the operation to which special attention should be paid Note Supplemental e...

Page 92: ...ng part can be reused These parts that have smaller dimensions than STD and are referredto as UIS Over Size UIS Under Size After Top Dead Center Before Top Dead Center ATDC BTDC After the top dead center point of the piston in the cylinder Beforethe top dead center point of the piston in the cylinder Refersto the intake system Refers to the exhaust system IN EX SST Intake Exhaust Special Service T...

Page 93: ...ngine 3 Do not put your clothing or tools near to the rotating part when the engine is turning 4 When the engine is not on always have the engine switch OFF and remove the starter key 2 Preparationfor disassembly 1 Preparegeneral tools SSTs measuring instruments lubricant and parts that cannot be reused 2 When disassemblinga complex part put imprintsand match marks in placesthat will not effect th...

Page 94: ... use electric pumps or working lights as these may give off sparks or become hot d Do not use a steel hammer as there is a possibility of a spark being generated during use e Dispose of fuel soaked waste cloths separately 7 Position and orientation when reassembling 1 Reassemble each part with the same position and orientation from before it was disassembled 2 Reassemble the correct parts in the c...

Page 95: ...rt them well and ask specialized companies for appropriate disposal Also be sure to collect or wipe up spilled waste fluids 11 Protection of functional parts Before connecting the battery terminal after vehicle inspection or maintenance thoroughly check each connector for any connection failure or imperfect connection Failure to connect or imperfect connection of connectors related to controllers ...

Page 96: ... only for reference or roughjudgement Digital type A fairly accurate reading is possible However it may be difficult to observe variation or movement 1 Difference between results of measurementwith analog and digital types The results of measurements using the analog type and the digital type may be different Use the circuit tester according to its instruction manual Differences between the polari...

Page 97: ...different power supply voltages are different This manual describes the results of measurement with an analog circuit tester with a power supply voltage of 3 0 v 3 Differences in results of measurement by measurement range 3 Variable resistor 0 G Resistor i ay Voltage 1 5 V l o 6 Red 3 Black In the analog type circuit tester changing the measurement range switches over the internal circuit to vary...

Page 98: ... table below 2 Judge the tightening torque for the hexagon flange bolt based on the threading diameter 3 The nut tightening torque can be judged from its corresponding bolt type by using procedure 1 BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE Identificationby Actual Part Hexagon head bolt standard bearing surface Welded bolt Stud bolt Shape and Strength class Number in relief o...

Page 99: ... I 91611 40625 Nomtnal length mm Nominal diameter mm Strengthclass 92132 40614 Nommal length rnm Nominal diameter mm Strength class Nominal diameter Stud bolt Tightening Torque Table Nominal diameter mm Pitch mm Strength class Standard tighteningtorque N m kgfcm ft lbf 4Y E Repair Section 1 1 0 ...

Page 100: ...Shape Hexagon flange bolt Class Hexagon flange bolt No mark P No mark P Tightening Torque Table Hexagon flange bolt Nominal diameter mm Pitch mm Standardtighteningtorque Strength class 4 8T 6 8T 8 8T 4Y E Repair Section 1 1 0 ...

Page 101: ...h was establishedto unify the various systems of units used in the past for smoother international technical communication New Units Adopted in SI I Item New unit Conventional unit Conversionrate l 1 conventional unit X SI unit 1 r Force 2 I N newton I kgf I Ikgf 9 80665 N I Torque2 Moment I Pressure 2 I Spring constanV2 I N mm I kgflmm I 1 kgflmm 9 80665 Nlmm I I I I Pa pascal Revolving speed I r...

Page 102: ...Example of Application Area Points for application method and reassembling parts Caution When removingthe gasket be careful not to let broken pieces of the gasket get inside the engine 1 2 Clean the contact surfaces of every part and corresponding part with a waste cloth so that they are free of oil moisture and foreign objects Apply FlPG to the side of the part to be attached Parts requiring FlPG...

Page 103: ......

Page 104: ...TART AT ALL 1 4 ENGINE IS ROUGH OR STOPS DURING IDLING 1 5 CANNOT ACCELERATE SMOOTHLY INCLUDING HESITATION 1 6 INSUFFICIENT POWER OUTPUT INCLUDING HUNTING 1 8 ENGINE OVERHEATS 1 9 EXCESSIVE FUEL CONSUMPTION 1 10 ABNORMAL COMBUSTION 1 11 ABNORMAL ENGINE NOISE OR NOISY ENGINE 1 13 EXCESSIVE ENGINE OIL CONSUMPTION 1 16 4Y E Repair Section 1 1 1 ...

Page 105: ...r cleaner I Air governor operating condition I Coolant Engine oil Battery and terminals Spark plugs Ignition timing Idle speed status List of Items Fan belt Looseness in any engine part Status IInsufficient power output includinghunting I See PI 8 Fault I Page Engine has trouble in starting or does not start Engine running rough Abnormal combustion Engine does not crank normally Engine does not st...

Page 106: ...d or clicking sound 12 Starter motor I 3 Engine body When all the plugs are removed the engine should rotate easily I 1 Battery Point I To test whether the fault is with the circuit to the starter motor or with the starter motor itself connect the starter motor directly to the battery with the 30 terminal and 50 terminal leads If the starter motor turns then the fault is in the circuit If it does ...

Page 107: ...rk plug and position it about 6 to 8 mm 0 24 to 0 31 in away from earth Normally during cranking a strong spark should fly out Check all the plugs in the same way Ifthere is no spark at all inspectthe distributor and the primary lead side Compression Point 21 Inspect the fuel flow to the carburetor Disconnect the fuel pipe connector on the carburetor side and run the engine with the starter motor ...

Page 108: ...e is rough during idling Point I Phenomenon 2 PCV valve Main places for inspection and adjustment 1 Carburetor 13 Resistive cord I 14 Distributor I 5 Ignitiontiming 6 Tappet clearance 7 Valve contact 18 Plug I Point I lnspect non combusting cylinders Hold the bottom of the resistive cord and pull it off from the plug Work through each cylinder disconnecting the cord end from the spark plug termina...

Page 109: ... Piston I 4 Cylinder Point I Adjust the accelerator pedal and link system The opening of the throttle valve depends on the adjustment of the accelerator pedal height and the link wire Check that the throttle valve becomes fully open when the accelerator pedal is fully depressed Point 21 Check vacuum advancer function 1 Connect a timing light with the engine running Inspect to see that the degree o...

Page 110: ...m idle there should be an advance Note If this inspection is as it should be omit the inspection in 2 2 With the engine stopped remove the distributor cap When the rotor is turned by hand about 15 in the turning direction and released it should return Point 41 Check function of the VCV inside the air governor Usinga timing light to check the degree of advance disconnectthe vacuum hose from the dis...

Page 111: ...r stall test Do not mistake this for a reduction in stall speed only torque converter vehicles 1 Slipping of the clutch 2 Slipping of the torque converter one way clutch torque converter models only Point 21 Generally if the ignition timing is retarded excessively the vehicle after fires and tends to overheat easily If the ignition timing is advanced excessively this tends to cause knocking and lo...

Page 112: ...nition timing I 1 Cylinder head gasket 2 Cylinder head 3 Cylinder block 1 Coolant 2 V belt 3 Radiator Point I 4 Thermostat Point I Check for bubble formation inside radiator When bubbles form in the radiator due to a fault in the cyclinder head gasket or cylinder block the engine oil becomes cloudy 4Y E Repair Section 1 1 1 ...

Page 113: ...on pressure etc I 5 Specification differences in attachments mast lift height attachments air conditioner Places for inspection and adjustmentwhen fuel consumption has become greater than previously Classification Ignition Main placesfor inspectionand adjustment 1 Vacuum hose 2 Vacuum advancer 3 Governor controller I Drivetrain Fuel Compression 4 Cylinder 1 Slipping of the manual clutch 2 Slipping...

Page 114: ...til the intake valve opens for the next cycle igniting the air fuel mixturewhile it is still being intaken This causes a back fire in which the air fuel mixture in the intake manifold or carburetor explode Knocking Run on Classification Ignition i I Phenomenon I Main places for inspection and adjustment I Main places for inspection and adjustment 1 Ignitiontiming 2 Vacuum advancer 3 Governor contr...

Page 115: ... of any occasional missing of the ignition Are the specified spark plugs being used lnspect for soiling wear or gap defect of the spark plugs Inspectfor soiling or poor connections in the secondary circuit of the ignition system Inspectioncontent Check the operation and adjustment of parts that might make the air fuel mixturetoo lean Float level too low Insufficientejection from the accelerator pu...

Page 116: ...r pump by hand If the turning feels rough or bumpy to the hand then the bearing is defective Apply engine oil from outside the seal or spray an anti squealing agent The sound becomes quieter or stops Put a sound scope near the timing gear cover to check When the engine is warmed up the sound can be heard clearly When the engine is warm if the engine is taken from idle to high speed the sound becom...

Page 117: ... grows smaller and the side knock grows smaller If the spark plug is disconnected the sound changes and generally grows quieter Knocking m n d 1 knocking after warm up or directly after acceleration When the engine is at the speed when the knocking sound usually occurs about 1000 rpm if the spark plug is disconnected the sound changes generally becoming quieter This can be heard loudly from the bo...

Page 118: ... arm and the valve Put a sound scope on the valve section to check The sound becomes quieter or stops if engine oil is applied or an anti squealing agent is sprayed on Check by holding a wet cloth to the spot on the exhaust system to plug where the leak is suspected to be The noise becomes louder when the engine speed is increased Disconnect the spark plug to inspect When disconnected the sound be...

Page 119: ...the valve stem and the valve guide After warming the engine race it at about 2000 rpm and inspect the exhaust gas At this time a large amount of white purple exhaust gas is exhausted and this output increases gradually if the engine speed is increased 3 In flow from the crankcase emission control system PCV device Phenomenon Main places for inspection and adjustment 1 Leaking to the exterior of th...

Page 120: ...ECTION REASSEMBLY 2 22 CYLINDER BLOCK 2 31 COMPONENTS 2 31 DlSASSEMBLY INSPECTlON REASSEMBLY 2 33 ENGINE ADJUSTMENT 2 42 V BELT 1NSPECTION ADJUSTMENT 2 42 INSPECTION ADJUSTMENTOF IGNITION TIMING 2 43 INSPECTIONmADJUSTMENT OF IDLE UP SPEED 2 43 INSPECTIONmADJUSTMENT OF IDLE SPEED 2 44 NO LOAD MAXIMUM SPEED INSPECTIONAND ADJUSTMENT 2 44 COMPRESSION INSPECTION 2 44 4Y E Repair Section 1 1 2 ...

Page 121: ...t name Oil pan seal cutter Valve guide bushing remover replacer Valve spring compressor Camshafi bearing remover replacer Belt tension gauge Piston pin remover replacer Oil filter wrench Rocker arm support tool set 4Y E Repair Section 1 1 2 ...

Page 122: ...I Illustration Part No part name Valve lifter tool Bearing remover Puller B set Replacer set Replacer B set Handle set 4Y E Repair Section 1 1 2 ...

Page 123: ... I Item Removal Inspection Installation I 2 1Alternator 1 I I I I 1 IFan Pulley V belt 5 1Accelerator wire 1 I I I 3 4 6 1Carburetor 1 I I I See P2 42 Intake pipe Spark plugs See P2 42 7 8 9 10 11 12 13 Air governor Fuel pump Intake Exhaust manifolds Oil level gauge Oil filter Water pump Distributor Point I Point 21 I Point 31 Point 51 Point41 4Y E Repair Section 1 1 2 ...

Page 124: ...manifold Limit 0 40 mm 0 0157 in Inspection Using a straight edge ruler and a thickness gauge measure the amount of distortion of the exhaust manifold Limit 0 40 mm 0 0157 in Point 31 Removal Use the SST to remove the oil filter SST 09228 76001 71 09228 06501 Point 41 Installation Install the distributor 1 Align the TDC mark of the crank pully with the notch of the timing gear cover 4Y E Repair Se...

Page 125: ...e block with the center of the groove in the flange to install After installation adjust the ignition timing See P2 43 Point 51 Installation After cleaning the attachment surface of the oil filter fit an O ring to the oil filter and tighten the oil filter to the bracket by hand first and then use the SST to further tighten by 314 turn SST 09228 76001 71 09228 06501 Caution Apply a small amount of ...

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 129: ...81 1 Point 91 1 Point 141 4 5 6 7 Remove parts in procedures 1 to 13 on page 2 4 Cylinder head cover Rocker shaft ASSY Valve stem cap Valve push rod Cylinder head bolt Cylinder head gasket 9 10 Point I Point41 Point 61 Valve stem oil seal Valve guide bushing Point 21 Point 181 Point 31 Point51 Point 71 Point 101 Point 171 Point 161 Point 151 Point Ill Point 131 Point 121 4Y E Repair Section 1 1 2 ...

Page 130: ...ween the rocker arm and the shaft If the clearance is large disassemble and inspect it Inspection lnspect the oil clearance between the rocker arm and the rocker shaft 1 Measurethe rocker arm inside diameter with a caliper gauge Standard 18 500to 18 515 mm 0 7283 to 0 7289 in Measure the rocker shaft outside diameter with a micrometer Standard 18 474 to 18 487 mm 0 7273 to 0 7278 in Calculate the ...

Page 131: ... push rod 1 lnspect the runout in the push rod Limit 0 30 mm 0 0118 in If it exceeds the limit replace the push rod 2 lnspect for blockage of the push rod oil hole If there is a blockage remove it with an air gun Point 61 Disassembly Loosenthe cylinder head bolts in two or three times following the order shown in the illustration Point 71 Inspection Use a straight edge ruler and a thickness gauge ...

Page 132: ...easurethe valve guide bushing insidediameter with a caliper gauge Standard IN 8 010 to 8 030 mm 0 3154 to 0 3161 in 2 Measure the outside diameter of the valve stem Standard IN 7 970 to 7 985 mm 0 3138 to 0 3144 in EX 7 965 to 7 980 mm 0 3136 to 0 3142 in 3 Calculate the oil clearance Standard IN 0 025 to 0 060 mm 0 0010 to 0 0024 in EX 0 030 to 0 065 mm 0 0012 to 0 0026 in Limit IN 0 10 mm 0 0039...

Page 133: ...lve onto the valve seat Do not rotate the valve while it is pressed onto the valve seat 3 lnspect the width of the contact surface to see whether it is within the standard along the entire circumference Standard Contact width 1 2 to 1 6 mm 0 047 to 0 063 in If the width is not within the standard replace the valve or correct the valve seat 4 Correct the valve seat Caution Use a carbide tip cutter ...

Page 134: ...ard side grind using a 60 cutter on the IN side and a 65 cutter on the EX side Inspection Inspect the valve spring 1 Measure the squareness at the top end of the spring Limit IN EX 2 0 mm 0 079 in 2 Measure the free length Standard IN EX 46 0 mm 1 81 in Limit INmEX 45 5 mm 1 79 in Point 101 Disassembly Remove the valve guide bushing 1 Use a bar and hammer to break off the valve guide bushing 2 Rem...

Page 135: ... mm 0 5129 in or more correct the inside of the bushing bottom hole with a reamer 13 000to 13 027 0 5118 to 0 5129 13 027 0 5129 or more Bushing bottom hole inside diameter 13 050 to 13 077 mm 0 5138 to 0 5148 in STD bushing O S 0 05 bushing If the bushing bottom hole inside diameter is 13 077 mm 0 5148 in or more replace the cylinder head Point 121 Reassembly Installthe valve guide bushing 1 Grad...

Page 136: ...1 76005 71 09201 58010 Point 141 Reassembly Use the SST to reassemble the valve spring and valve SST 09202 76002 71 09202 70020 Point IS Reassembly Check the direction of the gasket and install the gasket Point 161 Reassembly Tighten the cylinder head bolts in two or three times following the order shown in the illustration Point 171 Reassembly Use the SST to position and install the push rod SST ...

Page 137: ...in two or three times following the order shown in the illustration Reassembly Check the direction of the rocker arm shaft then use the SST to position the rocker arm and install the rocker arm ASSY SST 09270 76001 71 09270 71010 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 141: ... 9 Disassembly See P2 42 See P2 10 No 1 2 3 Point I Point 21 Crank positionsensor Timing gear cover and gasket Crankshaft bearing Pump drive sprocket and drive chain crankshaft sprocket Chain tensioner Timing chain crankshaft sprocket camshafi sprocket Item Fan pulley V belt alternator Cylinder head ASSY Crankshaft ullev Point 31 Point41 Point I91 Point 181 Point 171 4Y E Repair Section 1 1 2 ...

Page 142: ...ing gear case Front oil seal Camshaft bearing SST 09950 76014 71 1 09950 40011 09950 76018 71 2 09950 60010 Point 21 Inspection Point 51 Point 71 Point Ill Point 121 Disassembly Use the SST to remove the bearing case side Reassembly Point 161 Point 141 Point 131 SST 09320 23000 71 Disassembly Use the SST to remove the bearing gear side SST 09950 76014 71 1 09950 40011 09950 76018 71 2 09950 60010 ...

Page 143: ...9 in Point 51 Inspection Use a vernier caliper to measure the thickness of the damper Standard 6 6 mm 0 260 in Limit 5 0 mm 0 197 in Point 61 Disassembly Use a wire with the end bent into an L shape to remove the valve lifter Note Bendthe end of the wire about 1 mm 0 04 in and insert the wire into the center hole of the valve lifter to hook the valve lifter Clean the wire thoroughly first Linethe ...

Page 144: ...use the SST to move the plunger up and down several times SST 09276 76001 71 09276 71010 Caution The diesel oil is used only for the test When installing the valve lifter perform bleeding again in engine oil 2 Use a tester and apply 196 N 20 kgf 44 1 Ibfl of force to the plunger of the air bled lifter After the plunger has dropped about 2 mm 0 08 in measure the time taken for the plunger dropping ...

Page 145: ...38 629 to 38 729 mm 1 5208 to 1 5248 in Limit IN 38 26 mm 1 5063 in EX 38 27 mm 1 5067 in Inspection Inspectthe bending of the camshaft Bending runout of the dial gauge12 Limit 0 06 mm 0 0024 in Inspection Inspect the oil clearance of the camshaft bearing 1 Measure the outside diameter of the camshaftjournal Standard No 46 459 to 46 475 mm 1 8291 to 1 8297 in No 2 46 209 to 46 225 mm 1 8192 to 1 8...

Page 146: ...l clearance Standard 0 025 to 0 081 mm 0 0010 to 0 0032 in Limit 0 1 mm 0 0039 in If it exceeds the limit replace the bearing Point 111 Disassembly Use the SST to tap out the oil seal SST 09950 76018 71 1 09950 6001 0 09950 76020 71 2 09950 7001 0 Disassembly Remove the camshaft bearing 1 Remove the oil pump w strainer See P8 6 2 Use the SST to remove the rear tight plug SST 09215 76004 71 09215 0...

Page 147: ... 09215 76004 71 09215 00101 3 Use a new tight plug to apply ThreeBond 1386 to the outer circumference and drive the tight plug into the cylinder block until the surface is even SST 09215 76004 71 09215 00101 Point 141 Reassembly Using the SST drive the oil seal into the timing gear cover until the surface is even SST 09950 76018 71 1 09950 60010 09950 76020 71 2 09950 70010 Point 151 Reassembly Ta...

Page 148: ...timing chain camghaft sprocket and crankshaft sprocket 1 Positionthe crankshaft key exactly at the top 2 Align the camshaft key with the upper mark on the thrust plate 3 Assemble the timing chain camshaft sprocket and crankshaft sprocket at the same time Caution Be sure to align the marks of each sprocket with the marks on the timing chain 4Y E Repair Section 1 1 2 ...

Page 149: ... Point 181 Reassembly Use the SST to install the bearing SST 09950 76018 71 1 09950 60010 09950 76020 71 2 09950 70010 Point 191 Reassembly Tap the bearing inner race evenly around with a bar to fit it 4Y E Repair Section 1 1 2 ...

Page 150: ...CYLINDER BLOCK COMPONENTS Refer to Refer to FIG 1301 AH FIG 1302 I I 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 152: ...or each cylinder are assembled in their correct combinations 9 10 11 12 Disassembly See P2 10 See P2 22 Rear oil seal Measuring the thrust clearance of the connecting rod Connecting rod cap W1bearing Piston Wl connecting rod Piston disassembly Measuring the thrust clearance of the crankshaft Crankshaft cap bearing thrust washer Crankshaft Inspection t t Point 41 Reassembly t t Point 51 Point 81 Po...

Page 153: ...surement with a Plastigage and tighten the connecting rod cap set nut to the specified torque Do not turn the crankshaft during the measurement Standard 0 020 to 0 051 mm 0 0008 to 0 0020 in Limit 0 10 mm 0 0039 in Caution When using STD bearings use a bearing with the same reference number 6 7 8 as that punched into the connecting rod cap Removethe Plastigage completely after measuring Point 41 D...

Page 154: ...n SST 09221 76002 71 09221 25018 Note The removal should be performed at room temperature Sort out the removed parts for each cylinder and be sure not to mix them up during reassembly Point 61 Inspection lnspect the cylinder block 1 lnspect for any distortions on the upper face of the cylinder block Limit 0 05 mm 0 0020 in Checkthat there are no considerablescratcheson the cylinder wall surface If...

Page 155: ...cylinder bore and calculate the piston clearance Standard 0 065 to 0 085 mm 0 0026 to 0 0033 in If the value exceeds the limit replacethe piston or rebore the cylinder and install an 01s piston Boring dimension P C H P Outside diameter of the piston C Piston clearance H Honing margin 0 02 mm 0 0008 in or less Inspection Inspect the piston and the connecting rod 1 Measure the gap between the piston...

Page 156: ... Install each compression ring with the punch mark at the top using the piston ring tool Punch mark Top ring 1 T Second ring 2 T Align the ring gaps as shown in the illustration Point 71 Inspection Measure the thrust clearance of the crankshaft Standard 0 020 to 0 220 mm 0 0008 to 0 0087 in Limit 0 30 mm 0 0118 in If it exceeds the limit replace the thrust washer Point 81 Disassembly Evenly loosen...

Page 157: ...ng the measurement Standard 0 02 to 0 051 mm 0 0008 to 0 0020 in Limit 0 10 mm 0 0039 in If it exceeds the limit replace the bearing Or if necessary replace the crankshaft Note When using STD bearings replace with a bearing with the same reference number 1 to 3 as that punched into the cylinder block Inspection Inspect the bending of the crankshaft Inspect the bending when turning the crankshaft o...

Page 158: ...0 0008 in Taper degree 0 02 mm 0 0008 in If it exceeds the limit replace the crankshaft Point 101 Reassembly Installthe bearing cap 1 Install with the oil groove of the thrust washer facing the crankshaft 2 Check the front mark and install in the same place as before it was disassembled Disassembly Evenly tighten the bearingcap bolts in several times following the order shown in the illustration P...

Page 159: ...ngine oil to the inner surface of the bearing Assemble the upper bearing to the locking groove of the connecting rod Install the lower bearing to the locking groove of the bearing cap Reassembly Attach a vinyl hose or similar to the connecting rod bolt to protect the cylinder inner wall and the crankshaft Reassembly When reinstalling the piston to the cylinder be sure to install it in the same cyl...

Page 160: ...on angles of the punched alphabet marks differs Be sure to align them when installing 3 Make sure that no foreign matter or oil etc becomes attached to the back surface of the bearing 4 Apply engine oil to the inner surface of the bearing 5 Tighten the left and right bolts alternately in two or three times Point 141 Reassembly Use the SST to knock in the oil seal SST 09950 76019 71 1 09950 60020 0...

Page 161: ...ndard When installing a new part Apply the standard of When inspecting for the inspection of the belt if it is usedfor five minutes or more When reassembling the belt that is used for 5 minutes or more adjust to the mean value of the standard in When inspecting Tension standard when using SST SST 09216 76001 71 09216 00020 When installing a new part 392 to 588 N 38 to 62 kgf 84 to 137 Ibfl When in...

Page 162: ...lt and rotate the distributor to adjust to the standard value 4 Tighten the set bolt and inspect the ignition timing again T 17 5 N m 178 kgf cm 12 9 ft lbfl 5 If the ignition timing has been adjusted seal the distributor set bolt with sealing tape INSPECTIONlADJUSTMENTOF IDLE UP SPEED Warm up the engine Standard Coolant temperature 75 C 167 F or above Hydraulic oil temperature 50 C 122 F or above...

Page 163: ...nnected to the idle up actuator rod and the idle speed does not reduce loosen the idle up adjusting screw See P2 43 Standard Idle speed Refer to repair manual for each vehicle model Vacuum 400 mmHg or more NO LOAD MAXIMUM SPEED INSPECTION AND ADJUSTMENT See P4 24 COMPRESSION INSPECTION Note When there is a drop in power output or excessive oil consumption or if the fuel consumption is extremely hi...

Page 164: ...Pressure difference between cylinders 98 kPa 1 O kgflcm2 114 psi 5 If some cylinders have a compression pressure less than the limit or if their pressure differences are more than the limit add a small amount of engine oil from the spark plug hole and repeat the above operations 1 to 3 a If the pressure goes up by adding oil there may be wear or damage to the piston ring and the cylinder wall b If...

Page 165: ......

Page 166: ...11 TIMING GEAR 3 20 COMPONENTS 3 20 DISASSEMBLY1INSPECTION REASSEMBLY 3 23 CYLINDER BLOCK 3 32 COMPONENTS 3 32 DISASSEMBLY INSPECTION REASSEMBLY 3 34 ENGINE ADJUSTMENT 3 43 V BELT INSPECTION ADJUSTMENT 3 43 IDLE SPEED INSPECTION 3 44 INSPECTIONlADJUSTMENTOF IGNITION TIMING 3 44 NO LOAD MAXIMUM SPEED MEASUREMENT 3 45 COMPRESSION INSPECTION 3 45 4Y E Repair Section 1 1 3 ...

Page 167: ...t No Part name Oil pan seal cutter Valve guide bushing remover replacer Valve spring compressor Camshaft bearing remover replacer Belt tension gauge Piston pin remover replacer Oil filter wrench Sub harness 4Y E Repair Section 1 1 3 ...

Page 168: ...I Illustration Part No Part name Rocker arm support tool set Valve lifter tool Bearing remover Puller B set Replacer set qeplacer B set iandle set 4Y E Repair Section 1 1 3 ...

Page 169: ...I Item Removal Inspection Installation I I I 1 IFan pulley V belt I I I See P3 43 t t I I I I I 2 1Alternator I I I I I 3 1Spark plugs 1 4 5 6 7 8 9 10 11 Throttle body and adapter Fuel filter and hose Delivery pipe injector Intake exhaust manifolds Oil level gauge Oil filter Water pump Distributor Point I Point 21 Point41 Point31 Point61 Point51 4Y E Repair Section 1 1 3 ...

Page 170: ...uel into the receptacle tray Caution Do not allow any fire to come close during the operation Take measuresto prevent the fuel from scattering Point 21 Removal Remove the delivery pipe and the injectors 4 pieces at the same time Note Draw the delivery pipe out perfectly straight with respect to the injectors Take good care that the injectors do not fall Point 31 Inspection Using a straight edge ru...

Page 171: ...he crank pully with the notch of the timing gear cover Set the position of the groove in the oil pump driveshaft at about 30 when seen from above Align the housing groove with the drill mark of the gear and insert the distributor Note Do not confuse the drill mark and the straight pin When installing the distributor align the screw hole for attaching the block with the center of the groove in the ...

Page 172: ...n O ring and tighten the oil filter to the bracket by hand first and then use the SST to further tighten by 314 turn SST 09228 76001 71 09228 06501 Caution Apply a small amount of engine oil to the O ring Clean the surface to which the O ring will be attached 4Y E Repair Section 1 1 3 ...

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 176: ...res 1 to 11 on page P3 4 Cylinder head cover Rocker shaft ASSY Valve stem cap Valve push rod 7 8 9 10 Disassembly Point I Point 41 Cylinder head gasket Valve spring and valve Valve stem oil seal Valve guide bushing Inspection Reassembly Point 21 Point 31 Point 51 Point 81 Point 101 Point 181 Point 171 Point 71 Point 91 Point 111 Point 151 Point 141 Point 131 Point 121 4Y E Repair Section 1 1 3 ...

Page 177: ...ween the rocker arm and the shaft If the clearance is large disassemble and inspect it Inspection Inspect the oil clearance between the rocker arm and the rocker shaft 1 Measure the rocker arm inside diameter with a caliper gauge Standard 18 500 to 18 515 mm 0 7283 to 0 7289 in Measure the rocker shaft outside diameter with a micrometer Standard 18 474 to 18 487 mm 0 7273 to 0 7278 in Calculate th...

Page 178: ...ush rod 1 lnspect the runout in the push rod Limit 0 30 mm 0 0118 in If it exceeds the limit replace the push rod 2 lnspect for blockage of the push rod oil hole If there is a blockage remove it with an air gun Point 61 Disassembly Loosen the cylinder head bolts in two or three times following the order shown in the illustration Point 71 Inspection Use a straight edge ruler and a thickness gauge t...

Page 179: ...e the valve guide bushing inside diameter with a caliper gauge Standard IN 8 010 to 8 030 mm 0 3154 to 0 3161 in 2 Measure the outside diameter of the valve stem Standard IN 7 970 to 7 985 mm 0 3138 to 0 3144 in EX 7 965 to 7 980 mm 0 3136 to 0 3142 in 3 Calculate the oil clearance Standard IN 0 025 to 0 060 mm 0 0010 to 0 0024 in EX 0 030 to 0 065 mm 0 0012 to 0 0026 in Limit IN 0 10 mm 0 0039 in...

Page 180: ...valve onto the valve seat Do not rotate the valve while it is pressed onto the valve seat 3 lnspect the width of the contact surface to see whether it is within the standard along the entire circumference Standard Contact width 1 2 to 1 6 mm 0 047 to 0 063 in If the width is not within the standard replace the valve or correct the valve seat 4 Correct the valve seat Caution Use a carbide tip cutte...

Page 181: ...is on the inward side grind using a 60 cutter on the IN side and a 65 cutter on the EX side Inspection Inspectthe valve spring Measurethe squareness at the top end of the spring Limit IN EX 2 0 mm 0 079 in Measure the free length Standard IN EX 46 0 mm 1 81 in Limit IN EX 45 5 mm 1 79 in Point 101 Disassembly Remove the valve guide bushing 1 Use a bar and hammer to break off the valve guide bushin...

Page 182: ...ore correct the inside diameter of the bushing bottom hole with a reamer Bushing bottom hole inside diameter 13 050 to 13 077 mm 0 5138 to 0 5148 in Bushing insidediameter mm in 13 000to 13 027 0 5118to 0 5129 If the bushing bottom hole inside diameter is 13 077 mm 0 5148 in or more replace the cylinder head Point 121 Bushing size STD bushing Reassembly Install the valve guide bushing 1 Gradually ...

Page 183: ...ft Point 141 Reassembly Use the SST to reassemble the valve spring and valve SST 09202 76002 71 09202 70020 Point 151 Reassembly Check the direction of the gasket and install the gasket Point 161 Reassembly Tighten the cylinder head bolts in two or three times following the order shown in the illustration Point 171 Reassembly Use the SST to position and install the push rod SST 09270 76001 71 0927...

Page 184: ...rt set bolts in two or three times following the order shown in the illustration Reassembly Check the direction of the rocker arm shaft then use the SST to position the rocker arm and install the rocker arm ASSY SST 09270 76001 71 09270 71010 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 188: ...1 1 No 1 2 3 Item Fan pulley V belt alternator Cylinder head ASSY Crankshaft pulley 5 6 7 8 Disassembly See P3 43 See P3 11 Timing gear cover and gasket Crankshaft bearing Pump drive sprocket and drive chain crankshaft sprocket Chain tensioner Inspection t t Point I Point 21 Reassembly t t Point 31 Point 191 Point 181 4Y E Repair Section 1 1 3 ...

Page 189: ...t Point 21 If you remove the parts other than the camshaft you do not need to remove the cylinder head Timing gear case Front oil seal Camshaft bearing Disassembly Use the SST to remove the bearing case side SST 09320 23000 71 Disassembly Point 61 Point 81 Point 91 Disassembly Use the SST to remove the bearing gear side SST 09950 76014 71 1 09950 40011 09950 76018 71 2 09950 60010 Inspection Point...

Page 190: ...g gear inspection Measure the outside diameter of the sprocket with the chain on Limit Crankshaft 59 mm 2 32 in Camshaft 114 mm 4 49 in Point 51 Inspection Use a vernier caliper to measure the thickness of the damper Standard 6 6 mm 0 260 in Limit 5 0 mm 0 197 in Point 61 Disassembly Use a wire with the end bent into an L shape to remove the valve lifter Note Bend the end of the wire about 1 mm 0 ...

Page 191: ...eds the limit replace the valve lifter Inspection Valve lifter leak down test 1 Bleed the air from the valve lifter Immersethe valve lifter in a containerfull of diesel oil and use the SST to move the plunger up and down several times SST 09276 76001 71 09276 71010 Caution The diesel oil is used only for the test When installing the valve lifter perform bleedingagain in engine oil 2 Use a tester a...

Page 192: ...straight to avoid damaging the camshaft bearing Point 101 Inspection Measure the thrust clearance of the camshaft Standard 0 07 to 0 22 mm 0 0028 to 0 0087 in Limit 0 3 mm 0 012 in Inspection Measure the height of the cam Standard IN 38 620 to 38 720 rnm 1 5205 to 1 5244 in EX 38 629 to 38 729 mm 1 5208 to 1 5248 in Limit IN 38 26 mm 1 5 063 in EX 38 27 mm 1 5067 in Inspection Inspect the bending ...

Page 193: ...1 8323 in No 2 46 250 to 46 290 mm 1 8209 to 1 8224 in No 3 46 000 to 46 040 mm 1 8110 to 1 8126 in No 4 45 750 to 45 790 mm 1 8012 to 1 8028 in NOS 45 500 to 45 540 mm 1 7913 to 1 7929 in Calculate the oil clearance Standard 0 025 to 0 081 mm 0 0010 to 0 0032 in Limit 0 1 mm 0 0039 in If it exceeds the limit replace the bearing Point 111 Disassembly Use the SST to tap out the oil seal SST 09950 7...

Page 194: ...block and the bearing Use the SST and install the bearing SST 09215 76004 71 09215 00101 Use a nevj tight plug to apply ThreeBond 1386 to the outer circumference and drive the tight plug into the cylinder block until the surface becomes even SST 09215 76004 71 09215 00101 Point 141 Reassembly Using the SST drive the oil seal into the timing gear cover until the surface becomes even SST 09950 76018...

Page 195: ...y FlPG to the seal section of the oil pan FIPG 08826 76001 71 For handling of FIPG See PO 19 Point 171 Reassembly Install the timing chain camshaft sprocket and crankshaft sprocket 1 Position the crankshaft key exactly at the top 2 Align the camshaft key with the upper mark on the thrust plate 4Y E Repair Section 1 1 3 ...

Page 196: ...rocket with the marks on the timing chain Point 181 Reassembly Use the SST to install the bearing SST 09950 76018 71 I 09950 60010 09950 76020 71 2 09950 70010 Point 191 Reassembly Tap the bearing inner race evenly around with a bar to fit it Point 201 Reassembly Apply engine oil to the entire circumference of the O ring then assemble 4Y E Repair Section 1 1 3 ...

Page 197: ...CYLINDER BLOCK COMPONENTS Refer to Refer to FlG 1301 AH 43A FIG 1302 I I I Referto FIG 1302 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 199: ...iner Rear oil seal retainer WI oil seal 8 9 10 11 12 Disassembly See P3 11 See P3 23 Rear oil seal Measuringthe thrust clearance of the connecting rod Connecting rod cap WI bearing Point I PistonW1connecting rod Piston disassembly Measuring the thrust clearance of the crankshaft Crankshaft cap bearing thrust washer Cranksha Inspection t t Point 141 Point 31 Reassembly t t Point41 Point 51 Point 71...

Page 200: ...surement with a plastigage and tighten the connecting rod cap set nut to the specified torque Do not turn the crankshaft during the measurement Standard 0 020 to 0 051 mm 0 0008 to 0 0020 in Limit 0 10 mm 0 0039 in Caution When using STD bearings use a bearing with the same reference number 6 7 8 as that punched into the connecting rod cap Remove the plastigagecompletely after measuring Point 41 D...

Page 201: ...pin SST 09221 76002 71 09221 25018 Note The removalshould be performed at room temperature Sort out the removed parts for each cylinder and be sure not to mix them up during reassembly Point 61 Inspection Inspect the cylinder block 1 Inspect for any distortions on the upper face of the cylinder block Limit 0 05 mm 0 0020 in Check that there are no considerablescratcheson the cylinder wall surface ...

Page 202: ...the cylinder bore and calculate the piston clearance Standard 0 065 to 0 085 mm 0 0026 to 0 0033 in If the value exceeds the limit replace the piston or rebore the cylinder and install an 01s piston Note Boring dimension P C H P Outside diameter of the piston C Piston clearance H Honing margin 0 02 mm 0 0008 in or less Inspection Inspect the piston and the connecting rod Measure the gap between th...

Page 203: ...tall each compression ring with the punch mark at the top using the piston ring tool Punch mark Top ring 1 T Second ring 2 T Align the ring gaps as shown in the illustration Point 71 Inspection Measure the thrust clearance of the crankshaft Standard 0 020 to 0 220 mm 0 0008 to 0 0087 in Limit 0 30 mm 0 0118 in If it exceeds the limit replace the thrust washer Point 81 Disassembly Evenly loosen the...

Page 204: ...ankshaft during the measurement Standard 0 02 to 0 051 mm 0 0008 to 0 0020 in Limit 0 10 mm 0 0039 in If it exceeds the limit replace the bearing Or if necessary replace the crankshaft Note When using STD bearings replace with a bearing with the same reference number 1 to 3 as that punched into the cylinder block Inspection lnspect the bending of the crankshaft lnspect the bending when turning the...

Page 205: ... 0008 in Taper degree 0 02 mm 0 0008 in If it exceeds the limit replace the crankshaft Point 101 Reassembly Install the bearing cap 1 Install with the oil groove of the thrust washer facing the crankshaft 2 Check the front mark and install in the same place as before it was disassembled Disassembly Evenly tighten the bearing cap bolts in several times following the order shown in the illustration ...

Page 206: ...gine oil to the inner surface of the bearing Assemble the upper bearing to the locking groove of the connecting rod Install the lower bearing to the locking groove of the bearing cap Reassembly Attach a vinyl hose or similar to the connecting rod bolt to protect the cylinder inner wall and the crankshaft Reassembly When reinstallingthe pistonto the cylinder be sure to install it in the same cylind...

Page 207: ...n angles of the punched alphabet marks differs Be sure to align them when installing 3 Make sure that no foreign matter or oil etc becomes attached to the back surface of the bearing 4 Apply engine oil to the inner surface of the bearing 5 Tighten the left and right bolts alternately in two or three times Point 141 Reassembly Use the SST to knock in the oil seal SST 09950 76019 71 1 09950 60020 09...

Page 208: ...ing a new part Apply the standard of When inspecting for the inspection of the belt if it is usedfor five minutes or more When reassembling the belt that is used for 5 minutes or more adjust to the mean value of the standard in When inspecting Tension standard when using SST SST 09216 76001 71 09216 00020 When installing a new part 392 to 588 N 38 to 62 kgf 84 to 137 Ibfl When inspecting 294 to 49...

Page 209: ...ADJUSTMENTOF IGNITION TIMING 1 Warm up the engine Standard Coolanttemperature 75 to 80 C 167 to 176 F or more 2 Attach a rev counter to the terminal for measuring engine speed Rev terminal 3 lnspect the idle speed Standard Referto repair manual for each vehicle model Note If the idle speed is outside the standard value refer to the section on ldle speed adjustment in the repair manual for each veh...

Page 210: ...measuring engine speed Rev terminal 3 Fully depress the accelerator pedal and measure the maximum speed Standard Refer to the repair manual for each vehicle model COMPRESSION INSPECTION 1 Warm up the engine Standard Coolant temperature 75 to 80 C 167 to 176 F or more 2 Disconnect the battery negative terminal 3 Remove the spark plug 4 Remove the IGN fuse and EFI fuse 5 Remove the throttle body set...

Page 211: ...compression pressure of all four cylinders and inspect the difference Limit of pressure difference between cylinders 98 kPa 1 0 kgflcm2 I4 psi If some cylinders have a compression pressure less than the limit or if their pressure differences are more than the limit add a small amount of engine oil from the spark plug hole and repeat the operations 1 to 3 above a If the pressure goes up by adding o...

Page 212: ...AM 4 6 COMPONENTS 4 7 ON VEHICLE INSPECTION 4 8 REMOVAL INSTALLATION 4 9 DISASSEMBLY 4 9 INSPECTION 4 13 REASSEMBLY 4 15 CARBURETORADJUSTMENT 4 17 FAST IDLE CAM ADJUSTMENT 4 19 CHOKE VALVE ADJUSTMENT 4 19 AIR GOVERNOR 4 20 COMPONENTS 4 20 REMOVALlINSTALLATION 4 21 DISASSEMBLY 4 21 INSPECTION 4 22 REASSEMBLY 4 23 ADJUSTMENT 4 24 4Y E Repair Section 1 1 4 ...

Page 213: ...SST TO BE USED r Illustration Part No I Part name 09860 76001 71 09860 11011 Carburetor screwdriver set 4Y E Repair Section 1 1 4 ...

Page 214: ...FUEL PUMP COMPONENTS 4Y E Repair Section 1 1 4 ...

Page 215: ...gthe pipe and check the arm travel and play Note The arm travel and play checked in the preparation shall be used as the basis for later inspections 2 Diaphragm inspection 1 Block the inlet pipe and outlet union with fingers and operate the arm to check that the arm movement becomes heavy Caution Do not operate the arm forcibly 3 Inlet valve inspection Block the outlet union with a finger and oper...

Page 216: ... the vent hole with a finger and operate the arm to check that the operating force becomes heavy Caution Do not operate the arm forcibly INSTALLATION 1 Fuel pump ASSY installation Install the fuel pump ASSY and insulator to the cylinder block by using two set nuts T 21 N m 214 kgfcm 15 5 ftdbfl Caution Surely bring the rocker arm into contact with the camshaft 2 Fuel pump piping connection 4Y E Re...

Page 217: ... pump nozzle 4 5 6 7 8 9 10 11 12 13 Choke valve Main nozzle Choke breaker Main air bleed Slow jet Float Slow air bleed No 2 Power piston Strainer Needlevalve 15 16 17 18 Solenoidvalve Economizer jet Idle adjusting screw Throttle valve 19 20 21 Idle upactuator Slow air bleed No 1 Mainjet 4Y E Repair Section 1 1 4 ...

Page 218: ...COMPONENTS 4Y E Repair Section 1 1 4 ...

Page 219: ...th similar parts Make sure to avoid gasoline to attach on rubbers Accelerator pump nozzle Accelerator pump lever lnspection in Cold State Choke breaker system inspection 1 Start the engine 2 Check that the rod returns when the choke breaker vacuum hose is disconnected lnspection in Hot State Choke valve full opening inspection Check that the choke valve is fully opened Accelerator pump inspection ...

Page 220: ...not disassemble the following parts Choke valve set screws Throttle valve set screws Throttle arm Automatic choke mechanism Small venturi tube Power valve Air Horn Disassembly Caution Do not separate the wax body from the air horn Air horn ASSY removal 1 Set screw 2 Air horn 3 Gasket Choke breaker disassembly 1 Set screw 2 Cover 3 Spring 4 Diaphragm with lever 5 Gasket Float removal Remove the flo...

Page 221: ...ower piston stopper 3 Power piston 4 Spring Needle valve seat removal 1 Needlevalve seat 2 O ring Carburetor Body Disassembly 1 Carburetor body removal 1 Remove two screws and disconnect the carburetor body and the flange 2 Remove the gasket and insulator 2 Hot idle compensator removal 1 Hot idle compensator 2 O ring 4Y E Repair Section 1 1 4 ...

Page 222: ...oval 1 Remove set screws and the idle up actuator Main jet removal 1 Removethe main passage plug and gasket 2 Remove the main jet and gasket from the main passage plug hole Accelerator pump diaphragm removal 1 Remove set screws and remove the accelerator pump cover 2 Remove the diaphragm and spring Throttle adjusting screw removal 1 Throttle adjusting screw 2 Spring 4Y E Repair Section 1 1 4 ...

Page 223: ...ever set nut and then remove the throttle lever ASSY throttle arm ASSY bushing and spring Caution When removing the throttle lever set nut put the rotation stopper at the accelerator pump cam side in order not to add force on the throttle valve 2 Remove the idle adjusting screw 1 Idle adjusting screw 2 Spring 4Y E Repair Section 1 1 4 ...

Page 224: ...he holes may be deformed 1 Choke valve and choke shaft inspection Push the choke valve with a finger and check that it is fully opened smoothly 2 Needlevalve inspection 1 Check the sliding motion of the needle valve 2 Install the float reverse the air horn and check if air is leakingwhen sucked from the fuel inlet pipe side 3 Power piston sliding status inspection 1 Installthe spring and power pis...

Page 225: ...ly Accelerator pump diaphragm inspection 1 Check the diaphragm for any damage 2 Push the plunger rod with a finger Check that it moves smoothly Power valve sliding inspection Push the power valve rod lightlywith a finger and check that it slides smoothly Idle adjusting screw inspection Checkthat the tapered portionof the idleadjusting screw is not stepped and that the threaded portion is not damag...

Page 226: ...bling it pin Clearance between the float and the air horn I I I clearance 1 Install to the valve seat in the following order of the needle valve spring and needle valve bushing pin 2 Install the float and float lever pin 3 Turn the air horn upside down and measure the gap between the tip of the float and the air horn using SST when the float goes down by its own weight SST 09240 76002 71 09240 000...

Page 227: ...alue is outside the standard in procedure 3 adjust by bending the float lever section A If the value is outside the standard in procedure 4 adjust by bending the float lever section B 4Y E Repair Section 1 1 4 ...

Page 228: ...ct the idle up actuator rod Measure throttle valve idle opening angle SST 09240 76002 71 09240 00014 Standard from horizontal level 13 5 For adjustment turn the throttle adjusting screw A Inspection and adjustment of fast idle With the condition of an ambient temperature 25 2 C 77 35 6 F adjust the fast idle cam See P4 19 then align the I mark on the fast idle cam to the center of the roller and m...

Page 229: ...inspection and adjustment Apply a pressure of 400 mmHg or more to the choke breaker diaphragm chamber and measure the choke valve opening angle SST 09240 76002 71 09240 00014 Standard from horizontal level 39 to 41 For adjustment bend the choke breaker rod end Check if the choke valve opens and the reading does not drop when a negative pressure is applied Unloader inspection and adjustment Measure...

Page 230: ...he adjust screw so I mark of the fast idle cam will come to the center of the roller pin of the fast adjust lever and fix with the lock nut After completing the above I mark adjustment adjust the fast idle opening angle See P4 18 CHOKE VALVE ADI Caution JUSTME Do not adjust unless it is necessary 1 After completing the adjustment of the I mark of the fast idle cam adjust the positions of the rack ...

Page 231: ...AIR GOVERNOR COMPONENTS 4Y E Repair Section 1 1 4 ...

Page 232: ...Bush wl adjusting screw removal 1 Remove the lock bolt 2 Turn the adjusting screw counterclockwise Remove the bush wl adjusting screw Note Note the screwed in depths of the screw and bush 3 Spring SUB ASSY removal Remove the snap ring Remove the spring SUB ASSY 4 Throttle valve and valve shaft removal 1 Remove valve set screws Remove the throttle valve 2 Remove the throttle valve shaft 4Y E Repair...

Page 233: ...d 2 Replacethe governor ribbon if any bending deformation crack or other abnormality is found 3 Throttle valve and the valve shaft inspection 1 Check for damage and deformation of the throttle valve 2 Assemble the throttle valve shaft to the governor body Turn the cam manually and check for any sticking or loosenesscaused by wear 3 Check for wear loosenesswhen the shaft is inserted or rusting of t...

Page 234: ...haft apply MP greasethinly to the governor body needle bearing After completing the throttle valve shaft and valve reassembly check for smooth operation Temporarily installthe air governor spring to the following dimension I Effective spring turns B I 11turns 1 13 turns I Adjusting screw protrusionA 1 ton vehicle 16 8 mm 0 661 in 2 to 3 ton vehicle 21 9 mm 0 862 in 4Y E Repair Section 1 1 4 ...

Page 235: ...rew Counterclockwise turn reduces the relief down when the tilt lever of the oil control valve is operated From the condition where the relief down is within the specified value 1 10 clockwise turn will correct kinks in the spring Clockwise turn reduces hunting during no load or load maximum speed Turning the adjusting screw clockwise 114 counterclockwise turn from the position where there is no h...

Page 236: ...wise B Note Refer to adjustment procedures of each section 4 Loaded maximum speed adjustment 1 Fully depress the accelerator pedal and maintain the speed at the no load maximum speed 2 Operate the tilt lever backward and measure the relief down Relief down 300 rpm or less 3 If the relief down exceeds 250 rpm turn the adjusting screw counterclockwise for adjustment Note Refer to adjustment procedur...

Page 237: ......

Page 238: ...SPECTION INSTALLATlON 5 4 INJECTOR 5 6 COMPONENTS REMOVAL INSPECTION INSTALLATION 5 7 FUEL PRESSURE REGULATOR 5 10 FUEL PUMP 5 11 COMPONENTS 5 11 REMOVAL INSPECTION INSTALLATlON 5 12 INTAKE TEMPERATURE SENSOR 5 15 REMOVAL 5 15 INSPECTION 5 15 INSTALLATION 5 15 4Y E Repair Section 1 1 5 ...

Page 239: ...SST TO BE USED Part name Illustration Injectionmeasuring tool set Part No EFI inspection wire 4Y E Repair Section 1 1 5 ...

Page 240: ...THROTTLE BODY COMPONENTS 4Y E Repair Section 1 1 5 ...

Page 241: ...se Intakepipe Air intake connector Throttle body Inspection lnspection of the throttle body Inspection Point I 1 Make sure that the throttle shaft is not loose 2 Firmly press the throttle valve with your finger to open and close 3 When the throttle valve is in a free condition there must be an appropriate angle and clearance between the air horn and the throttle valve Reference Throttle angle is a...

Page 242: ...Inspection Inspectionof the throttle motor Measurethe resistancevalue between the terminals Standard Between M and M 0 3 to 100 R 4Y E Repair Section 1 1 5 ...

Page 243: ...INJECTOR COMPONENTS 4Y E Repair Section 1 1 5 ...

Page 244: ...on and eliminate the fuel pressure by slowly loosening the union bolt Note During the reassembly use new gaskets and O rings Throttle body Elimination of fuel pressure in fuel system Pressure regulator Delivery pipe spacer and injector Injector spacer Caution Put waste cloth in order to prevent the fuel from splashing Removal DO not allow any fire to come close during the operation See P3 4 See P3...

Page 245: ...elay box 3 Short circuit the terminal 1 and terminal 2 in the disconnected relay block 4 Connect SST to the injector SST 09842 76001 71 09842 30070 5 Turn the ignition key switch on to activate the fuel pump 6 Connect SST to the battery and measurethe injection amount of the injector Standard 41 to 42 cc115 seconds Caution Fuelwill be splashed when injecting so put a vinyl hose with the inside dia...

Page 246: ...s firmly attached Point 41 Installation Apply gasoline to the O ring and firmly insert the injectorto the delivery pipe as far as it will go Note Whileturning the injector to left and right firmly insert the injector to the delivery pipe Align all the four connector sections of the injectorto face upward After the reassembly check that the injector rotates smoothly Point 51 Installation Install th...

Page 247: ...e fuel pressure See P5 7 3 Installthe fuel pressure indicator between the fuel filter and the delivery pipe via SST SST 09268 76007 71 09268 41047 4 Turn the ignition key switch on to activate the fuel pump and measure the fuel pressure at that moment Standard 284 5 kPa 2 9 f 0 1 kgflcm2 41 2 1 4 psi Note The above standard is applied when the vacuum port of the pressure regulator is an atmospheri...

Page 248: ...FUEL PUMP COMPONENTS COOLER I I FUEL CAP WIKEY I 4Y E Repair Section 1 1 5 ...

Page 249: ...I Point 61 1 3 4 1 6 1Fuel pump I Point31 Point41 1 Point51 1 Point Operations Battery set plate Fuel hose Point I Point I Removal Place waste cloth and a fuel tray under the fuel filter and then disconnect the fuel hose Caution Take measures to prevent the fuel from splashing Do not allow any fire to come close during the operation Drain the fuel from the filter and the hoseside thoroughly 4Y E R...

Page 250: ...aution Inspection should be performed in a short period of time within 5 seconds Bring the pump away from the battery as far as possible Carry out the switching operation at the negative side of the battery Inspection Using the tester measure the resistance between the terminals Standard 0 2 to 3 0 R Point 51 Installation Install the fuel pump to the tank cover Caution The hose connecting the main...

Page 251: ...pump adjust with the dimensions of the inserted pipe and the hose at the top of the pump Point 61 Installation Install the fuel hose to the fuel pipe of the tank cover Caution Make sure to tighten using two wrenches There should be no interference with other parts by a kinked hose 4Y E Repair Section 1 1 5 ...

Page 252: ...NSPECTION INSTALLATION Measure the resistance value between the terminals Firmly press the intake temperature sensor into the grommet section of the air cleaner inlet hose Note After the installation check its condition Make sure that it is firmly inserted and not installed at an angle 80 I761 0 32 Temperature OC OF Resistance kQ 20 41 16 2 20 68 2 45 4Y E Repair Section 1 1 5 ...

Page 253: ......

Page 254: ...PCV DEVICE Page VENTILATION VALVE 6 2 COMPONENTS 6 2 REMOVAL 6 3 INSPECTION 6 3 INSTALLATION 6 3 4Y E Repair Section 1 1 6 ...

Page 255: ...VENTILATION VALVE COMPONENTS 4Y E Repair Section 1 1 6 ...

Page 256: ...Shake the ventilation valve with your hand and inspect whether the rattling sound can be heard If you can hear the rattling sound then it is normal 2 lnspection of the PCV device rubber hose Inspect for any damages cracks or deterioration on the PCV device rubber hose lf there are any abnormalities replace with a new one INSTALLATION The installation procedure is the reverse of the removal procedu...

Page 257: ......

Page 258: ...STEM Page WATER PUMP 7 2 COMPONENTS 7 2 REMOVAL INSPECTION INSTALLATION 7 3 DISASSEMBLY4NSPECTION REASSEMBLY 7 4 WATER TEMPERATURE SENSOR 7 6 REMOVAL 7 6 INSTALLATION 7 6 INSPECTION 7 6 4Y E Repair Section 1 1 7 ...

Page 259: ...WATER PUMP COMPONENTS 4Y E Repair Section 1 1 7 ...

Page 260: ...rocedure The installation procedure is the reverse of the removal procedure No 1 1 5 Radiatoroutlet hose I 1 I I 2 3 4 6 1Water pump Item Drain coolant V belt Fan Fan pulley Removal See P3 4 Inspection Installation t t 4Y E Repair Section 1 1 7 ...

Page 261: ...pection I Reassembly I Point Operations 1 2 3 Point I Inspection Inspectthe temperaturewhen the valve starts to open and the temperature when it is fully open 1 Insert the thermostat into water and raise the temperature of water while stirring Water inlet Thermostat Water pump cover Point I Point 21 Point 31 4Y E Repair Section 1 1 7 ...

Page 262: ...open at roomtemperature or if it does not seal well Point 21 Inspection lnspect the water pump Inspect the water pump rotor section for cracks damage and obvious rust Manually rotate the water pump rotor to inspect for abnormal bearing noise and to see that it turns smoothly 0 Point 31 Reassembly Install the gasket to the thermostat and then install it to the water inlet Caution Make sure that the...

Page 263: ...cylinder head T 29 10 f 5 0 N m 296 f 50 kgfmcm 21 4 3 6 ft lbfj INSTALLATION The installation procedure is the reverseof the removal procedure INSPECTION Using the circuit tester measure the resistancevalue between the terminals according to temperature changes Note By disconnecting the harness connector from the water temperature sensor you can also measure the resistance while the engine is mou...

Page 264: ...e SST TO BE USED 8 2 OIL PRESSURE INSPECTION 8 3 ENGINE OILmOIL FILTER REPLACEMENT 8 4 OIL PUMPmSTRAINER 8 5 COMPONENTS 8 5 REMOVAL INSPECTION INSTALLATlON 8 6 DISASSEMBLYmINSPECTION REASSEMBLY 8 8 4Y E Repair Section 1 1 8 ...

Page 265: ...SST TO BE USED Illustration I I Part No Part name 4Y E Repair Section 1 1 8 ...

Page 266: ...soline 2 Measure the oil pressure 1 Remove the pressure switch and install the oil pressure gauge 2 Warm up the engine and measure the oil pressure Standard Coolant temperature 75 to 85 C 167 to 185 F Operating oil temperature 50 C or more 122 F Standard Idle speed 29 42 kPa 0 3 kgflcm2 4 3 psi or more 2000 rpm 196 to 441 kPa 2 0 to 4 5 kgflcmz 28 4 to 64 0 psi or more 3 Install the pressure switc...

Page 267: ...e surface to which the O ring will be attached 4 Pour in engine oil 1 Install the oil drain plug with a new gasket Caution Befolre attaching the plug remove the old gasket stuck on the oil pan and clean the surface to which the new gasket will be attached 2 Pour in engine oil Oil pan capacity 4 0 1 1 1 US gal 3 Attach the oil filler cap 5 lnspect the oil level Check using the oil level gauge 6 lns...

Page 268: ...OIL PUMPmSTRAINER COMPONENTS 4Y E Repair Section 1 1 8 ...

Page 269: ...As shown in the left illustration soak the intake side strainer side of the oil pump in oil and turn the pump shaft clockwise with a flat blade screwdriver Checkthat oil is discharged from the oil discharge hole No 1 2 3 Item Engine oil Oil pan Oil pump w strainer Installation t t Point21 Removal See P8 4 See P2 22 Inspection t t Point I 4Y E Repair Section 1 1 8 ...

Page 270: ...mp shaft clockwise Check that the shaft does not rotate Point 21 Installation Install the oil pump w strainer to the cylinder block Caution Turn the pump shaft to align the position of the protruding portion at the tip of the distributor shaft and the slit at the tip of the oil pump shaft 4Y E Repair Section 1 1 8 ...

Page 271: ...ction I Reassembly 1 Point Operations 1 2 3 Point I Inspection lnspection of drive and driven rotors Oil strainer Drive and driven rotors Reliefvalve 1 Using the thickness gauge measure the clearance body clearance between the driven rotor and the pump body Standard 0 10 to 0 16 mm 0 0039 to 0 0063 in Limit 0 20 mm 0 008 in Point I Point 21 4Y E Repair Section 1 1 8 ...

Page 272: ...it 0 15 mm 0 0059 in 3 Using a thickness gauge measure the tip clearance of the drive rotor and the driven rotor Standard 0 06 to 0 15 mm 0 0024 to 0 0059 in Limit 0 2 mm 0 008 in Point 21 Reassembly Install the drive and driven rotors with the punch marks on the drive rotor and the driven rotor facing the pump body 4Y E Repair Section 1 1 8 ...

Page 273: ......

Page 274: ...4Y M Page CIRCUIT DIAGRAM 9 2 SPARK PLUGS 9 3 INSPECTION 9 3 DISTRIBUTOR 9 4 COMPONENTS 9 4 ON VEHICLE INSPECTION 9 5 REMOVAL INSPECTION INSTALLATION 9 7 DISASSEMBLYllNSPECTlON REASSEMBLY 9 8 4Y E Repair Section 1 1 9 ...

Page 275: ...CIRCUIT DIAGRAM Ignition key Switch Black with two orange stripes 4Y E Repair Section 1 1 9 ...

Page 276: ...PECTION 1 Clean the spark plugs using the spark plug cleaner 2 Inspect the spark plugs and replace any that are abnormal 3 Inspection of the plug gap Standard 0 7 to 0 8 mm 0 028 to 0 031 in 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 278: ...e cord Limit less than 25 kwone cord 2 lnspection of the ignition coil 1 Measurement of the primary coil resistance Standard 1 2 to 1 5 R 2 Measurement of the secondary coil resistance Standard 7 7 to 10 4 kR 3 lnspection of the igniter Remove the distributor cap the rotor and the dust cover 1 lnspection of the input voltage a Turn the ignition key switch on b Measurethe voltage between the positi...

Page 279: ... 008 to 0 016 in If it is outside the standard replace the signal generator 2 lnspection of the governor process Turn the rotor to the right and inspect whether the rotor returns smoothly 3 lnspection of the vacuum advancer Disconnect the vacuum hose and apply approx 400 mmHg negative pressure to the diaphragm and check that the vacuum advancer moves If the vacuum advancer does not move replace th...

Page 280: ...ure The installation procedure is the reverse of the removal procedure 1 3 1Connector I I I I No 1 2 Removal Item Battery negative terminal Resistive cord 4 5 Inspection Vacuum advancer hose Distributor Installation See P2 4 4Y E Repair Section 1 1 9 ...

Page 281: ...rcap I I I I 1 2 1 Distributorrotor 1 3 4 5 6 Dust cover Ignition coil 7 8 9 Point 151 Igniter Vacuum advancer 10 11 12 13 Distributorwire Signal rotor Signal generator ASSY Point I Governor spring Signal rotor shaft Governor weight Governor shaft Point 141 Point 131 Point21 Point41 Point61 Point71 Point 31 Point I21 Point 51 Point 81 Point 111 Point 101 Point 91 4Y E Repair Section 1 1 9 ...

Page 282: ...he breaker plate Rotate the breaker plate and check that there are no drags or jamming If there are any drags or jamming replacethe signal generator ASSY Point 41 Disassembly Remove the signal rotor shaft 1 Remove the cam cap 2 Remove the screw and remove the signal rotor shaft Point 51 Inspection lnspection of the signal rotor shaft Installthe signal rotor shaft to the governor shaft and check fo...

Page 283: ...punch knock out the straight pin 3 Remove the spiral gear and the thrust washer 2 Remove the governor shaft and the thrust washer Point 81 Inspection Inspection of the governor shaft 1 Rotate the governor shaft and check the condition of the governor shaft rotation 2 Using the thickness gauge measure the governor shaft thrust clearance Standard 0 15 to 0 50 mm 0 0059 to 0 0197 in If it is outside ...

Page 284: ...r pin is at the position shown in the illustration lnstall the straight pin Using the thickness gauge measure the governor shaft thrust clearance Standard 0 15 to 0 50 mm 0 0059 to 0 0197 in If it is outside the standard adjust with the thrust washer Thrust washer thickness 0 3 mm 0 012 in 0 4 mm 0 016 in 0 5 mm 0 020 in 0 6 mm 0 024 in Pinch the both ends of the straight pin with the vise and cau...

Page 285: ...Insert the signal rotor into the rotor shaft and adjust the notches 2 Inspection of the air gap 1 Measurethe air gap Standard 0 2 to 0 4 mm 0 008 to 0 016 in If it is outside the standard as a result of the inspection replace the signal generator ASSY 2 During the replacement wash the new magnet holding screw and the threaded portion of the coil with non residue solvent and then apply ThreeBond 13...

Page 286: ... not attach to the screw and the threaded portion of the coil Make sure to remove any residue of ThreeBond 1324 Do not start the engine untilThreeBond 1324 is hardened Point 131 Reassembly lnstall the vacuum advancer 1 Insert the breaker plate pin to the advancer link hole 2 Install the advancer and the wire clamp Point 141 Reassembly lnstall the igniter 1 lnstall the igniter and tighten two screw...

Page 287: ... Point 151 Reassembly Install the ignition coil 1 Install the ignition coil and the gasket 2 Installthe wire to the ignition coil terminal 4Y E Repair Section 1 1 9 ...

Page 288: ...E Page SPARK PLUGS 10 2 INSPECTION 10 2 DISTRIBUTOR 10 3 COMPONENTS 10 3 ON VEHICLE INSPECTION 10 4 REMOVAL 10 4 INSTALLATION 10 5 IGNITER 10 6 GENERAL 10 6 REMOVAL INSPECTION INSTALLATlON 10 7 4Y E Repair Section 1 1 10 ...

Page 289: ...PECTION 1 Clean the spark plugs using the spark plug cleaner 2 Inspect the spark plugs and replace any that are abnormal 3 Inspection of the plug gap Standard 0 7 to 0 8 mm 0 028 to 0 031 in 4Y E Repair Section 1 1 10 ...

Page 290: ...DISTRIBUTOR COMPONENTS Refer to Refer to 4Y E Repair Section 1 1 10 ...

Page 291: ... the resistive cord Limit 25 kR or less cord 2 lnspection of the ignition coil 1 Measurement of the primary coil resistance Standard 1 2 to 1 5 R 2 Measurementof the secondary coil resistance Standard 7 7 to 10 4 kR 3 Measurementof the pickup coil resistance Standard 460 k 50 fl Note Pickup coil is measured by the total resistance value of the two serially connected coils measured at the connector...

Page 292: ...pump driveshaft at about 30 when viewed from the upper side 3 Align the housing groove with the drill mark of the gear and m insert the distributor Note Do not confuse the drill mark and the straight pin When installing the distributor align the screw hole for attachingthe block with the center of the flange groove to install When the distributor is completely set the direction of the rotor must b...

Page 293: ...shooting in the repair manualfor each vehicle model Note For the judgment of the igniter quality the following items will be the observation points The ignition coil is normal and the wiring to the igniter and the connecter are also normal There is a normal output of IGt signal from the ECUto the igniter as well as IGt signal from the igniter to the ECU and the wiring and connector are normal Igni...

Page 294: ...stallation Procedure The installation procedure is the reverse of the removal procedure 1 2 1Battery I I I I No 1 1 3 1 Battery set plate I I I I 4 1Igniter I Item Relay box Removal Inspection Installation 4Y E Repair Section 1 1 10 ...

Page 295: ......

Page 296: ...SYSTEM Page SST TO BE USED 11 2 STARTER MOTOR 11 3 COMPONENTS 11 3 REMOVAL INSPECTION INSTALLATlON 11 4 DISASSEMBLY INSPECTION REASSEMBLY 11 5 STARTER MOTOR ASSY UNIT INSPECTION 11 10 4Y E Repair Section 1 1 11 ...

Page 297: ...SST TO BE USED Part name I Injection pump spline shaft puller Illustration Part No 4Y E Repair Section 1 1 11 ...

Page 298: ...STARTER MOTOR COMPONENTS 4Y E Repair Section 1 1 11 ...

Page 299: ...on Procedure The installation procedure is the reverse of the removal procedure I N o Item Removal Inspection Installation 1 2 3 4 Battery Battery set plate Disconnectthe connectors and the terminals Starter ASSY 4Y E Repair Section 1 1 11 ...

Page 300: ...Lead wire 3 4 5 6 7 8 I 11 IRetainer roller I I I Disassembly End frame Brush Armature ASSY Bearing 9 10 1 12 1 Return spring I I I Housing ASSY Clutch ASSY Steel ball Idler gear Caution Apply grease to the steel ball idler gear starter clutch and return spring on reassembly Inspection Point 21 Point 51 Point 61 Point 71 Reassembly Point 31 Point41 Point 101 Point 91 Point 81 4Y E Repair Section 1...

Page 301: ...p the brush spring on the plus side with long nose pliers Take care not to damage the brush or the commutator Point 31 Inspection lnspect the brush 1 lnspect for roughness of the contact surface and the length of the brush Measure the brush length in the center section concave part Standard 20 5 mm 0 807 in Limit 13 0 mm 0 512 in 2 When correcting the contact surface and replacing the brush wrap s...

Page 302: ...ion Inspect the insulation between the commutator and the armature coil Standard 1 Ma or more Inspection Perform a short circuit test on the armature coil 1 Remove completely any deposits on the surface of the armature 2 Using an armature tester place an iron piece in parallel contact to the armature and turn the armature Standard The iron piece should not be attracted or vibrate Inspection lnspec...

Page 303: ...14 in 3 Measure the undercut depth between the segments Standard 0 5 to 0 8 mm 0 020 to 0 031 in Limit 0 2 mm 0 008 in Point 51 Disassembly Use the SST to remove the bearing SST 09286 76001 71 09286 46011 Point 61 Inspection lnspect the magnetic switch 1 lnspect for continuity between the 50 terminal and the C terminal Standard Continuity exists 4Y E Repair Section 1 1 11 ...

Page 304: ...on left and rotates smoothly when rotated in the opposite direction right Point 81 Reassembly Use a press to press fit the bearing Point 91 Reassembly Reassemble the brushes 1 Lift the brush spring up with a screwdriver etc and reassemble the brush holder into the starter yoke 2 Pull the brush spring up and reassemble the brush into the brush holder Point 101 Reassembly Align the notch a in the en...

Page 305: ...l in test status check that the pinion gear remains popped out even after the C terminal wire is disconnected 3 Plunge r return test check that the pinion gear returns from the holding test status of the holding coil when the terminal is disconnected as shown in the illustration on the left 4 No load test 1 Secure the starter motor with a vice 2 During a no load test a large current will flow thro...

Page 306: ...CHARGING SYSTEM Page SST TO BE USED 12 2 ON VEHICLE INSPECTION 12 3 ALTERNATOR 12 4 ELECTRICAL CIRCUIT DIAGRAM 12 4 COMPONENTS 12 4 DISASSEMBLY INSPECTION REASSEMBLY 12 5 4Y E Repair Section 1 1 12 ...

Page 307: ...SST TO BE USED Illustration F Part No Part name HST pump bearing replacer Alternator rear bearing puller Alternator rear bearing replacer Replacer set qandle set 4Y E Repair Section 1 1 12 ...

Page 308: ...r when the engine is running 7 Perform a no load test Adjustment voltageadjustment current inspection 1 Connect an ammeter and voltmeter as shown in the illustration on the left 2 Gradually increase the engine speed to 1500 rpm and measure the voltage Standard 12 V 13 5 to 14 3 V when warm 3 Measure the current with the engine speed at 1500 rpm Standard 10 A or less Note Directly after the engine ...

Page 309: ...ALTERNATOR ELECTRICAL CIRCUIT DIAGRAM COMPONENTS 4Y E Repair Section 1 1 12 ...

Page 310: ... 6 7 8 9 10 I Terminal insulators Rear end cover Brush holder WI brush Point I IC regulator Rectifier holder Alternator pulley Rear end frame Rotor ASSY Rear bearing spring washer Bearing cover front bearing Point 151 Point41 Point 51 Point61 Point81 Point91 Point21 Point 31 Point71 Point 141 Point 131 Point 121 Point Ill Point 101 4Y E Repair Section 1 1 12 ...

Page 311: ... the soldered section Caution Brush replacement should be carried out for both sides at the same time Point 21 Inspection lnspect the diode of the IC regulator Perform a continuity test on the diode between the B terminal and F terminal with the tester set in the kR range Standard When the polarity is changed between F and B there should be continuity on one side and no continuity on the other Poi...

Page 312: ...resistance is large the rectifier is judged to be functioning Caution A 500 V mega tester should never be used as this will destroy the rectifier Point 41 Disassembly Set the alternator pulley in a vice and remove the set nut Caution Always use aluminum pads in the vice Point 51 Disassembly After removing the set nut and bolt hold the rear end frame and apply a shock to the tip of the rotor shaft ...

Page 313: ...ip rings 1 If the slip rings are damaged correct them with sand paper MOO 2 Measure the outside diameter of the slip rings Standard 14 4 rnrn 0 567 in Limit 14 0 rnrn 0 551 in Inspection Inspect the stator coil of the drive end frame Measure the resistance between the phases Standard Approx 1 0 R Point 81 Disassembly Remove the rear bearing and spring washer SST 09820 76002 71 09820 0002 1 4Y E Re...

Page 314: ...k to the bearings Point 101 Reassembly Install the front bearing SST 09950 76018 71 1 09950 60010 09950 76020 71 2 09950 70010 Point 111 Reassembly Reassemble the rear bearing and spring washer SST 09820 76003 71 09820 00030 Point 121 Reassembly Insert a plate washer or similar into the clearance between the SST and the rear end frame so that pressure is applied uniformly to the rear end frame SST...

Page 315: ...s of the stator coil have been securely inserted into the end frame terminal holder 2 Temporarily tighten all the terminal attachment bolts before fully tightening them 3 Tighten the rectifier attachment bolt Point 151 Reassembly Check that the brush holder boot is correctly fitted 4Y E Repair Section 1 1 12 ...

Page 316: ...RVICE STANDARDS 13 5 ENGINE BODY 13 5 FUEL SYSTEM 13 8 COOLING SYSTEM 13 8 LUBRICATIONSYSTEM 13 8 IGNITION SYSTEM 13 9 STARTING SYSTEM 13 9 CHARGING SYSTEM 13 1O TIGHTENING TORQUE FOR EACH PART 13 11 4Y E Repair Section 1 1 13 ...

Page 317: ...ection Oil pan seal cutter Valve guide bushing remover replacer Valve spring compressor Camshaft bearing remover replacer Belt tension gauge Piston pin remover replacer Oil filter wrench Zarburetor adjusting gauge set 4Y E Repair Section 1 1 13 ...

Page 318: ...ation Wire gauge set Rocker arm support tool set Valve lifter tool Injection pump spline shaft puller Bearing remover HST pump bearing replacer Alternator rear bearing puller Alternator rear bearing replacer 4Y E Repair Section 1 1 13 ...

Page 319: ...Illustration Part No Part name Section Carburetor screwdriver set Puller B set Replacer set Replacer B set Handle set Injection measuring tool set EFI inspection wire 4Y E Repair Section 1 1 13 ...

Page 320: ...Limit 1Squareness I I mm in I 2 0 0 079 108 2 4 260 108 5 4 272 107 7 4 240 108 0 4 252 IN EX Free length mrn in Rocker arm shaft 7 970 to 7 985 0 3138to 0 3144 7 965 to 7 980 0 3136to 0 3142 IN EX IN EX IN EX IN EX 0 025 to 0 060 0 0010to 0 0024 0 030 to 0 065 0 0012to 0 0026 0 10 0 0039 0 12 0 0047 1 0to 1 4 0 039to 0 055 1 3to 1 7 0 051 to 0 067 0 5 0 020 0 8 0 031 Standard Push rod Face runout...

Page 321: ...o 4 No 5 No 1 No 2 No 3 No 4 No 5 Timing chain stretch limit tension 5 kg mm in Crankshaft timing gear outside diameter limit with the chain mm in Cam shaft timing gear outside diameter limit with the chain mm in Limit Standard Limit 291 4 11 472 59 2 32 114 4 49 Tension damper Wall thickness of the tensioner head section mm in Damper wall thickness mm in Valve lifter Lifter outside diameter mm in...

Page 322: ...0to 0 220 0 0008to 0 0087 0 30 0 0118 57 985 to 58 000 2 2829to 2 2835 0 020to 0 051 0 0008to 0 0020 0 10 0 0039 47 985 to 48 00 1 8892to 1 8898 0 020to 0 051 0 0008to 0 0020 0 10 0 0039 Coolant capacity Refer to repair manual for each vehicle model Lubricating oil capacity L US gal I Oil pan capacity Specific gravity of the electrolyte electrolyte temperature20 C 4 0 I I 1 28 7 to 9 0 28 to 0 35 ...

Page 323: ...rom horizontal position 39 to 41 from horizontal position 19 5 from horizontal position 5 5 0 217 Fuel pressure regulator 4Y E only Leakagefrom the nozzle Fuel pressure kPa kgf cm2 psi 1 284 5 2 9 0 1 i41 2 1 41 1 Float declining position 1 drop or less 3 minutes COOLING SYSTEM 1 I to 1 3 0 043to 0 051 LUBRICATIONSYSTEM Thermostat Oil pump Temperature when startingto open C OF Temperature when ful...

Page 324: ...50 1500 2000 2500 1lgnitioncoil secondary coil resistance I I Standard 7 7 to 10 4k C 2 I 0 2 76 13 5 100 120 240 320 or more Pickupcoil resistance Resistive cord resistance Ignition coil primary coil resistance STARTING SYSTEM 0 0 4 to 5 14to 18 18 to 22 Starter motor Standard Limit Standard Motor model DC series woundreduction model I 460 50 R 25 kmcord 1 2to 1 5 C2 I Nominal voltage V I 12 I No...

Page 325: ...volutionspeed I rPm 1500 1 Alternator Nominalvoltage V 12 10 5 0 413 1 5 0 059 14 4 0 567 14 0 0 551 Brush length mm in mm in Slip ring outside diameter Maximumoutput A Standard Limit Standard Limit 60 4Y E Repair Section 1 1 13 ...

Page 326: ...nkshaft bearing cap Cylinder head x Rocker shaft I 24 244 I7 71 Cylinder head x Cylinder head cover Cylinder head x Spark plug I 18 183 13 2 5 51 3 7 Cylinder head x Manifold I 49 500 36 2 Connecting rod x Connecting rod cap I 49 500 36 2 Cylinder head x Water pump Crankshaft x Crankshaft pulley Timing gear case x Timing gear cover Camshaft x Camshaft timing gear 21 214 15 5 140 1427 I03 21 21 214...

Page 327: ... This Page Intentionally Left Blank ...

Page 328: ...SECTION INDEX NAME I SECTION GENERAL ENGINE OVERHAUL I FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM STARTING SYSTEM 1 1 APPENDIX 1DZ II Repair ...

Page 329: ... This Page Intentionally Left Blank ...

Page 330: ...SPECIAL PRECAUTIONS 0 9 GENERAL PRECAUTIONS 0 9 INSPECTION OF ELECTRIC PARTS 0 12 BOLT AND NUT TIGHTENING TORQUE 0 14 BOLT STRENGTH TYPE IDENTIFICATION METHOD AND TIGHTENING TORQUE 0 14 TIGHTENING TORQUE OF HEXAGON HEAD BOLTS WITH FLANGE SEATS 0 16 PRECOAT BOLTS BOLTS WlTH SEAL LOCK AGENT COATING ON THREADS 0 16 SI UNITS 0 17 HANDLING THE FlPG LIQUID GASKET 0 18 1DZ II Repair Section 1 2 0 ...

Page 331: ...air manual for each model No load static maximum speed N m kgf cm ft lbfllrpm See the repair manual for each model See the repair manual for each model IIdling speed rPm Number of piston rings ICylinder liner type Compression ring Oil ring 2 1 Exhaust valve opening closing timing Intake valve opening closing timing Open BBDC 52 Open Close Close BTDC 14 ABDC 44 ATDC 14 Engine oil amount Ignition sy...

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 335: ...times partially omitted in illustrations When a part requiring tightening torque instruction is not indicated in the 1 illustration the part name is described in the illustration frame Disassembly and reassembly procedure Reassembly procedure is the reverse of the disassembly procedure 1 2 1Timing gear cover I I I I Number 1 1 3 1 1 d l e e a r o l I I point I I I Item Crank pulley with set bolt o...

Page 336: ...ribed IFR 1 Front 1 Front side I Abbreviation RH LH IRR 1 Rear 1 Rear side I 1STD Standard Original term Right hand Left hand lndicates that the standard size is the size of the parts that were used for assembly at the manufacturer Meaning Right side Left side 1 Over size Under size For items that have worn over a long time or where the fit ting has loosened due to repeated removal and reassembly ...

Page 337: ...ts that are put together ISUBIASSY Sub assembly Two or more individual parts that are welded cast or caulked together The item following is attached Example wlwasher with an attached washer 1 MIT I Manual transmission 1 lndicates a manual transmission ITorque converter I lndicates a automatic transmission 1 LWR Lower Lower side 1DZ II Repair Section 1 2 0 ...

Page 338: ...tely after stopping the engine to prevent scalding 3 Do not bring clothes tools and others close to rotating parts during engine operation 4 Turn the ignition switch OFF and remove the ignition key unless engine operation is necessary 2 Preparation before disassembly 1 Prepare general tools SST measuring tools greases and non reusable parts 2 When disassembling a complicated assembly put punch or ...

Page 339: ...so much that it will cause you to slip c Do not use electric equipment such as power pumps and working lamps because they could cause sparks or high temperatures d Do not use tools such as iron hammers because they could cause sparks during work e Dispose separately cloths that are saturated with fuel 7 Reassembly position and direction 1 Reassemble the parts in the position and direction they wer...

Page 340: ...g disposal by specialized companies Further always recover or wipe up any waste fluid that is spilt 11 Protection of function parts After completing inspection and maintenance work for the vehicle before reconnecting the battery terminal fully check each connector to make sure that no connections have been forgotten and that no connections are incomplete Be especially careful of connectors related...

Page 341: ...te values can be obtained from the measurements However sometimes difficult to understand when viewing operations or movements 1 Differences between the measurement results of the analog and digital systems Sometimes there are differences between the measurement results of the analog and digital systems See the instruction manual when using a circuit tester The information below describes the prec...

Page 342: ...ured the measurement results are different This manual mainly uses the measurement results obtained using an analog circuit tester with a source voltage of 3 0 V 3 Differences in measurement results due to measurement ranges Resistance Meter 0 R Variable resistance Resistance Voltage 1 5 V 1 b Red 2 Black When the measurement range in an analog circuit tester is changed the internal circuit change...

Page 343: ...ng the torque in the tightening torque table 2 Determine the tightening torque of hexagon flange bolts by identifying the strength type and checking the torque in the tightening torque table 3 Determine the tightening torque of nuts by applying the method in item 1 above to the connecting bolt BOLT STRENGTH TYPE IDENTIFICATION METHOD AND TIGHTENING TORQUE Identification by bolt shape Shape and str...

Page 344: ...gon head bolt Tightening torque table 91611 40625 Length mm Diameter mm Strength type Stud bolt Shape 92132 40614 L L e n g t h mm Diameter mm Strength type iameter Lengt L Strength type Diameter Standard tightening torque N m kgf cm ftdbfl 1DZ II Repair Section 1 2 0 ...

Page 345: ...by bolt shape Hexagon flange bolt Hexagon flange bolt No mark 0 No mark 0 TIGHTENING TORQUE TABLE Hexagon flange bolt Strength type I Diameter mm Pitch mm Specified torque N m kgfcm ftdbfl 1DZ II Repair Section 1 2 0 ...

Page 346: ... previously used in different countries It is an international unit system established to ensure the smooth exchange of technology NEW UNITS ARISING FROM SI UNIT INTRODUCTION Conversion value I 1 previous unit SI unit Item 1 New unit Force 2 1 N Newton I kgf I 1 kgf 9 80665 N Previous unit Pressure 2 1 Pa Pascal 1 kgf cm2 I 1 kgflcm2 98 0665 kPa 0 0980665 MPa Torque 2 Moment 1 N m kgfxm Rotation s...

Page 347: ... THREEBOND or seal packing black for the FIPG The part number is set as 08826 76001 71 Example of coating location description Coating method and parts reassembly procedure CAUTION When removing the gasket make sure that shreds from the gasket do not enter the engine Clean the connection surface of parts and their connecting parts with a cloth to eliminate any oil moisture or dirt Coat the part to...

Page 348: ...L 1 4 ENGINE MALFUNCTIONS OR STOPS WHILE IDLING 1 5 CANNOT ACCELERATE SMOOTHLY 1 5 INSUFFICIENT OUTPUT 1 6 ENGINE OVERHEATING 1 6 HIGH FUEL CONSUMPTION 1 7 FREQUENT DIESEL KNOCKING 1 8 LARGE AMOUNT OF EXHAUST SMOKE WHILE DRIVING 1 8 UNUSUAL ENGINE SOUNDS AND NOISES 1 9 HIGH ENGINE OIL CONSUMPTION 1 12 1DZ II Repair Section 1 2 1 ...

Page 349: ...ection timing Idling speed condition List of described items I Engine does not crank normally I P l 3 I Engine does not start easily or does not start at all I P l 4 Page Condition I I 1 Engine malfunctions or stops while idling 1 P l 5 Malfunction description I Insufficient output including hunting I P l 6 IEngine malfunction I Cannot accelerate smoothly including breathing I P l 5 I High fuel co...

Page 350: ... Starter unit 5 Neutral safety switch 1 Battery Cranking operation is delayed or there is a clattering sound 1 Starter clutch Rasping sound 2 Ring gear 3 Magnet switch Point I To judge whether the defect is in the circuit to the starter or in the starter motor itself directly connect terminal 30 and terminal 50 of the starter to the battery with a lead wire If the starter operates the defect is in...

Page 351: ...operation of the glow indicator lamp Turn the engine switch to the ON position and check the operation of the glow indicator lamp in the combination meter 4 Cylinder Point 31 Check the operation of the preheating timer The power supply time for the glow plugs is determined in accordance with the engine coolant temperature If the power supply time is extremely short it can cause a starting defect P...

Page 352: ...he accelerator lever and perform the following inspection while the engine speed is high While the engine is idling loosen the high pressure nuts on the nozzle side for each cylinder in turn and check whether or not there are changes in the engine speed condition When there no changes in the engine speed while the nuts are loosened it means that there is an abnormality in the cylinder CANNOT ACCEL...

Page 353: ...elief down engine speed inspection Inspection for determining whether the insufficient output is in the engine unit or in the drive system If the Classification 2 Injection pump Main inspection or adjustment areas 1 lnjection timing 3 lnjection nozzle 1 Cylinder head gasket Compression 2 Cylinder head 3 Cylinder block Cooling Point I Radiator internal bubble inspection 1 Coolant 2 V belt 3 Radiato...

Page 354: ... environment driving method altitude etc 4 Engine and vehicle maintenance conditions injection timing compression pres sure etc 5 Differences in specifications supplied equipment mast height attachments air conditioning 1 1 lnjection pump I Areas for inspection or adjustment when the fuel consumption increases Fuel Classification 1 2 Fuel system leak I Main inspection or adjustment areas 1 3 lnjec...

Page 355: ...OKE WHILE DRIVING 4 Cylinder 1 Clogging of the air cleaner Large amount of black smoke is generated Symptom Main inspection or adjustment areas Constantly generated At low speeds only Po int 11 nearly fully open 1 Clogging of the air cleaner 1 Injection pump Also generated at speeds other than low speeds 1 lnjection timing early 2 lnjection pump 3 lnjection nozzle 1 1 Defective fuel Point I Black ...

Page 356: ...ls gritty to your hand there is a bearing defect Pour in engine oil from the outside of the oil seal or apply a noise damper solution with compressed air The sound gets smaller or stops Check by placing a sound scope in the area of the timing gear cover Sound is heard clearly when the engine warms up After the engine has warmed up and the engine speed changes from idling to a high speed the sound ...

Page 357: ...en nozzle injection is stopped the sound changes and generally gets smaller Heard clearly from the bottom of the engine during or immediately following acceleration after the engine has warmed up If nozzle injection is stopped at the engine speed where the knocking sound is generated about 1000 rpm the sound changes and generally gets smaller Heard clearly from the bottom of the engine during or i...

Page 358: ...he valve The sound gets smaller or stops when engine oil or a noise damper solution is applied with compressed air Check by blocking with a wet cloth the likely location of the leak in the exhaust system When the engine speed is increased the sound gets louder Stop the nozzle injection and check After it is stopped the sound gets smaller or stops Check by coating with oil the installation areas of...

Page 359: ... the combustion chamber from the clearance between the valve stem and valve guide Check the exhaust gas condition when the engine is raced at about 2000 rpm after warming up If a large amount of whitish purple exhaust gas is emitted as the engine speed is increased the emission will get steadily larger I 1 Cylinder head Symptom Leak to outside the engine Main inspection or adjustment areas 1 Engin...

Page 360: ...MBLY 2 22 CYLINDER BLOCK 2 33 COMPONENTS 2 33 DISASSEMBLY INSPECTION AND REASSEMBLY 2 35 CYLINDER BLOCK BORE DIMENSIONS 2 47 ENGINE TUNE UP 2 48 V BELT TENSION INSPECTION AND ADJUSTMENT 2 48 VALVE CLEARANCE INSPECTION AND ADJUSTMENT 2 49 IDLING SPEED INSPECTIONAND ADJUSTMENT 2 49 MAXIMUM ENGINE SPEED INSPECTION AND ADJUSTMENT 2 50 INJECTION TIMING INSPECTIONAND ADJUSTMENT 2 50 COMPRESSION INSPECTI...

Page 361: ...t name Oil pan seal cutter Valve guide bush remover replacer Valve stem oil seal replacer Valve spring compressor Camshaft bearing remover replacer Belt tension gauge Oil filter wrench Plunger stroke measuring tool 1DZ II Repair Section 1 2 2 ...

Page 362: ...Illustration Part number Part name Bearing remover Drive pinion bearing replacer Puller C set Puller B set Replacer set Replacer B set Handle set Variable pin wrench set 1DZ II Repair Section 1 2 2 ...

Page 363: ...dure The installation procedure is the reverse of the removal procedure I Procedure 1 1 Removal 1 Inspection Installation 1 1 1Fan pulley V belt 1 See P 2 48 1 t 1 2 1Alternator adjusting bar 3 4 1 7 1Injection pipe Water pump Intake pipe 5 6 Glow plug Fuel hose 1DZ II Repair Section 1 2 2 ...

Page 364: ...inder number errors during installation Installation Oil filter Intake and exhaust manifold Point 21 Removal Remove the injection pump 1 Remove the injection pipe hose 2 Remove the service cover located on the front of the timing gear cover 1 Set bolt 2 Cover 3 Gasket Point I Point 21 3 While the rotation of the crankshaft is stopped remove the injection pump drive gear set nut Point 71 Point 61 P...

Page 365: ...drive gear can be seen in the service opening 5 Disconnect the injection pump drive gear from the pump using the SST SST 09950 76003 71 09950 50012 6 Remove the injection pump assembly 1 Pump stay bolt 2 Pump nut set 3 Injection pump assembly 4 0 ring Caution Do not turn the crankshaft after removing the injection Pump Be sure the pump shaft key position after removing the injection pump 1DZ II Re...

Page 366: ...he exhaust manifold for distortion Limit 0 4 mm 0 016 in Point 51 Installation Fit an 0 ring to the oil filter and attach the oil filter to the bracket by turning it by hand Using the SST retighten the oil filter by 314 of a turn SST 09228 76004 71 09228 07501 Caution Coat a small amount of the engine oil on the 0 ring Clean the fitting surface 1DZ II Repair Section 1 2 2 ...

Page 367: ...was removed Coat a small amount of the MP grease on the 0 ring Use a new gasket for the service cover located on the front of the timing gear cover Check and adjust the injection timing after installation See P 2 45 Point 71 Installation The nozzle gasket must be replaced with a new one If it is not defective reuse the nozzle seat after fully removing the carbon 1DZ II Repair Section 1 2 2 ...

Page 368: ...CYLINDER HEAD COMPONENTS 1DZ II Repair Section 1 2 2 ...

Page 369: ...1DZ II Repair Section 1 2 2 ...

Page 370: ...move items 1 to 9 and 12 shown under See P 2 4 1 Ip 2 4 t 1 7 1Cylinder head assembly I I Point 71 1 I Inspection Disassembly Procedure 2 3 4 5 6 Reassembly Item Cylinder head cover Rocker shaft assembly Valve stem cap Valve push rod Cylinder head bolt Point I Point 41 Point 61 Point 21 Point 31 Point 51 Point 151 Point 141 1DZ II Repair Section 1 2 2 ...

Page 371: ... the valve stem cap If light damage is found reface with an oil stone If there is significant wear or damage replace it Inspection Move the rocker arm as shown and check the clearance between the rocker arm and the shaft If the clearance is too large disassemble and check the parts Inspection Check the oil clearance between the rocker arm and the rocker shaft Measure the inside diameter of the roc...

Page 372: ...o 1 49 mm 0 0516 to 0 00587 in 2 If light damage is found in the contact areas with the rocker arm reface with an oil stone If there is significant wear or damage replace the valve stem cap Point 41 Disassembly Sort the removed push rods carefully so they can be reassembled in the correct order Point 51 Inspection Check the push rods for bend Measure the amount of bend per full turn of the push ro...

Page 373: ...nd along the diagonal lines at the bottom of the cylinder head Limit 0 15 mm 0 0059 in 2 Check the distortion in the manifold fitting surface Limit INlEX 0 20 mm 0 008 in If the limit is exceeded reface or replace it Inspection Check the cylinder head for cracks Using the color check method dye detection method look for cracks in the combustion chamber intake port exhaust port and the lower and up...

Page 374: ...oint 91 Inspection Check the valve 1 Measure the thickness of the valve head Limit IN 0 9 mm 0 035 in EX 1 0 mm 0 039 in 2 Measure the overall length of the valve Standard IN 108 54 mm 4 2732 in EX 108 24 mm 4 2614 in Limit IN 107 90 mm 4 2480 in EX 107 60 mm 4 2362 in 1DZ II Repair Section 1 2 2 ...

Page 375: ...he contact position is deviated outside use a 20 cutter and if the contact position is deviated inside use a 75 cutter for refacing Use a cutter with a cemented carbide tip on the EX side Cut while constantly checking the valve contact position and contact width Cut the face evenly without undulation by gradually reducing the pressure toward the end of refacing Correct after checking the valve gui...

Page 376: ...38 to 0 3146 EX 7 96 to 7 97 mm 0 3134 to 0 3138 3 Calculate the oil clearance Standard IN 0 02 to 0 06 mm 0 0008 to 0 0024 in EX 0 04 to 0 07 mm 0 0016 to 0 0028 in Limit IN 0 10 mm 0 0039 in EX 0 12 mm 0 0047 in If the limit is exceeded replace the valve or the valve guide bushing Further reface the inside diameter using the reamer as required to bring the oil clearance between the bushing and t...

Page 377: ... Reassembly Coat the engine oil on the lips of the new valve stem oil seal and the valve stem and reassemble them SST 09201 76004 71 09201 56010 Point 121 Reassembly Reassemble the valve spring and valve SST 09202 76002 71 09202 70020 Point 131 Reassembly Check that the direction is correct when installing the gasket 1DZ II Repair Section 1 2 2 ...

Page 378: ...y Tighten the cylinder head bolts evenly in several steps in the order shown to the left Point 151 keassembly Tighten the support set bolts evenly in several steps in the order shown to the left 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 382: ...sembly Remove the crankshaft pulley SST 09950 76003 71 09950 50012 Point 21 Disassembly If cover ishard to remove apply a screwdriver to the slit in the cover and pry off the cover At this time be careful not to damage areas around the slit 1DZ II Repair Section 1 2 2 ...

Page 383: ... If the limit is exceeded replace each idle gear or thrust washer Point 41 Inspection Check the idle gear oil clearance 1 Measure the inside diameter of the idle gear Standard No 1 45 000 to 45 025 mm 1 77165 to 1 77264 in No 2 50 000 to 50 025 mm 1 96850 to 1 96948 in 2 Measure the outside diameter of the idle gear shaft Standard No 1 44 950 to 44 975 mm 1 76969 to 1 77067 in No 2 49 930 to 49 94...

Page 384: ...65 to 0 0984 in Point 51 Disassembly Remove the injection pump drive gear SST 09950 76003 71 09950 50012 Point 61 Disassembly Remove the bearing Case side SST 09320 23000 71 Gear side SST 09950 76014 71 09950 40011 1 SST 09950 76018 71 09950 60010 2 1DZ II Repair Section 1 2 2 ...

Page 385: ...to 22 221 mm 0 87402 to 0 87484 in 3 Calculate the valve lifter oil clearance Standard 0 010 to 0 051 mm 0 00039 to 0 00201 in Limit 0 1 mm 0 004 in If the limit is exceeded replace the valve lifter If an 01s valve lifter is to be used correct the inside diameter of the bore to standard OIS valve lifter bore inside diameter standard 22 245 to 22 271 mm 0 87579 to 0 87681 in Point 91 Disassembly Do...

Page 386: ...1 59102 in Limit IN 39 47 mm 1 5539 in EX 39 85 mm 1 5689 in Inspection Check the camshaft for bend Bend Dial gauge deflection I 2 Limit 0 04 mm 0 0016 in Inspection Check the camshaft bearing oil clearance 1 Measure the outside diameter of the camshaft journal Standard No 1 front 47 159 to 47 175 mm 1 85665 to 1 85728 in No 2 center 46 959 to 46 975 mm 1 84878 to 1 84941 in No 3 rear 46 759 to 46...

Page 387: ...m 0 0039 in If the limit is exceeded replace the bearing If a serious streak or damage is found on the camshaft journal reface the camshaft journal and replace the bearing with a UIS bearing Point 111 Disassembly Remove the camshaft timing gear set bolt SST 09960 76001 71 09960 10010 Disassembly Remove the timing gear from the camshaft using a press Point 121 Disassembly Remove the key for cranksh...

Page 388: ...09215 76004 71 09215 00101 Point 141 Reassembly Install the camshaft bearing Align the oil holes of the bearing and of the cylinder block 1 Install the camshaft bearing No 2 SST 09215 76004 71 09215 00101 2 Install the camshaft bearing No 1 and No 3 SST 09215 76004 71 09215 00101 3 Coat THREEBOND 1386 to the outer periphery using a new tight plug and drive the bearings until they are flush with th...

Page 389: ...o 1 83169 Point 151 Reassembly Drive in the oil seal using the SST until it becomes flush with the timing gear cover surface SST 09950 76019 71 09950 60020 1 SST 09950 76020 71 09950 70010 2 Note Coat MP grease on the oil seal lips No 1 Point 161 Reassembly Coat the FlPG on the timing gear case seal FIPG 08826 76001 71 For handling the FIPG see P 0 18 Point 171 Reassembly Reassemble the crankshaft...

Page 390: ...facing the gear side 2 Install the camshaft timing gear set bolt SST 09960 76001 71 09960 10010 Point 191 Reassembly Coat the FIPG on the oil pan seal FIPG 08826 76001 71 For handling the FIPG see P 0 18 Point 201 Reassembly Install the bearing Case side gear side SST 09950 76018 71 09950 60010 1 SST 09950 76020 71 09950 70010 2 1DZ II Repair Section 1 2 2 ...

Page 391: ...nched marks with the marks on the other gears Point 221 Reassembly Coat the FIPG on the timing gear cover seal FIPG 08826 76001 71 For handling the FIPG see P 0 18 Point 231 Reassembly Reassemble the crankshaft pulley SST 09950 76018 71 09950 60010 1 SST 09950 76020 71 09950 70010 2 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 394: ...3 1Oil strainer I I I 4 1Rear oil seal retainer with oil seal I I I 5 Rear oil seal I I point 121 6 1Measure the thrust clearance of the connecting rod 1 7 1Connecting rod cup with bearing I I Point 21 1 Point 111 10 1Measure the thrust clearance of the crankshaft point 51 1 8 9 13 1oil regulator I I I Piston with connecting rod Piston disassembly 11 12 Point 31 Crankshaft cap bearing thrust washe...

Page 395: ...ting rod bearing Measure using the plastigage and tighten the connecting rod cap set nut to specified torque Do not turn the crankshaft during measurement Standard 0 044 to 0 080 mm 0 00173 to 0 00315 in Limit 0 110 mm 0 043 in If the limit is exceeded replace the bearing If a serious streak or damage is found on the bearing reface the crankshaft and replace the bearing with a UIS bearing Bearing ...

Page 396: ...on the piston pins and the connecting rods sorted by cylinder groups Point 41 Inspection Check the cylinder block 1 Check the cylinder block for distortion in the upper surface Limit 0 1 mm 0 004 in Make sure that the cylinder wall is free of serious scratches 2 Measure the six dimensions as shown to the left and determine the difference between the maximum and minimum dimensions Limit 0 2 mm 0 00...

Page 397: ...iston bottom skirt Standar d 85 950 to 85 980 mm 3 3839 to 3 3850 in 2 Calculate the piston clearance from the cylinder inside diameter measured in inspection 2 Standard 0 040 to 0 060 mm 0 00157 to 0 00236 in Limit 0 15 mm 0 0059 in 5 If the limit is exceeded in inspection 2 3 or 4 bore the cylinder and install an O S piston If there is a wear larger than the limit for O S piston use a repair lin...

Page 398: ...e in inside diameter and piston clearance 2 When using the repair liner Liner fitting code A B Cylinder bore diameter mm in Cylinder liner outside diameter mm in L a Bore the cylinder for press fitting the liner After boring wash the area thoroughly and clean it using compressed air For the bored dimensions see P 2 47 b Coat the engine oil on the liner surface c Install the liner using the SST and...

Page 399: ...iston ring end gap Standard No 1 0 27 to 0 39 mm 0 0106 to 0 0154 in No 2 0 45 to 0 60 mm 0 0177 to 0 0236 in Oil ring 0 20 to 0 40 mm 0 0079 to 0 0157 in 3 Measure the oil clearance of the connecting rod bushing 1 Measure the inside diameter of the bushing Standard 27 011 to 27 023 mm 1 06343 to 1 06390 in 2 Measure the outside diameter of the piston pin Standard 27 000 to 27 012 mm 1 06299 to 1 ...

Page 400: ...ved cap bearing and washer carefully so they can be installed in the correct positions Point 71 Inspection Check the crankshaft 1 Measure the oil clearance of the crankshaft using the plastigage Do not turn the crankshaft during measurement Standard 0 028 to 0 048 mm 0 00110 to 0 00189 in Limit 0 1 mm 0 004 in If the limit is exceeded replace the bearing If a serious streak or damage is found on t...

Page 401: ...ng thickness mm in UIS 0 25 2 54843 to 0 08283 to 2 54921 0 08307 2 Check the crankshaft for bend Measure the amount of bend per full turn of the crankshaft Bend Dial gauge deflection 2 Limit 0 05 mm 0 0020 in 1DZ II Repair Section 1 2 2 ...

Page 402: ...kshaft and replace the bearing with a UIS bearing 3 Measure the dimensions of the crankshaft pin as shown Standard 50 48 to 50 50 mm 1 9874 to 1 9882 in 4 Calculate ellipticity and taper Limit Ellipticity 0 02 mm 0 0008 in Taper 0 05 mm 0 0020 in If the standard is not met or if the limit is exceeded or if a serious streak or damage is found reface the crankshaft and replace the bearing with a UIS...

Page 403: ...fore disassembly with reference to the front mark 3 Tighten evenly in several steps in the order as shown Point 91 Reassembly Reassemble the connecting rod 1 Install the snap ring on one side 2 Warm the piston to about 60 C 140 F 3 Align the front marks on the piston and the connecting rod 4 lnstall the piston pin 5 Install the snap ring 1DZ II Repair Section 1 2 2 ...

Page 404: ... Reassemble the bearing Prevent foreign matter oil etc from adhering to the bearing surface and coming into contact with the connecting rod Coat the engine oil on the bearing bore lnstall the upper bearing by matching the connecting rod lock groove lnstall the lower bearing by matching the bearing cap lock groove Point 101 Reassembly Reassemble the piston in the same cylinder from which it was dis...

Page 405: ... of the engine 2 Prevent foreign matter oil etc from adhering to the bearing back surface 3 Coat the engine oil on the bearing bore 4 Tighten left and right bolts alternately in several steps Point 121 Reassembly Reassemble the rear oil seal SST 09950 76019 71 09950 60020 1 SST 09950 76020 71 09950 70010 2 1DZ II Repair Section 1 2 2 ...

Page 406: ...te Upon press fitting the cylinder liner reface the cylinder liner so that the liner will be flush with the upper surface of the cylinder block At the time the maximum limit for the cylinder block must be less than 0 1 mm 0 0039 in 1DZ II Repair Section 1 2 2 ...

Page 407: ... standard for belts in use When reassembling a belt that has been used for 5 minutes or longer adjust the tension to the median of the standard for belts in use Standard tension when using the SST SST 09216 76004 71 09216 00020 New belts 520 to 755 N 53 to 77 kg 116 9 to 169 8 Ibfl Belts in use 324 to 559 N 33 to 57 kg 72 8 to 125 7 Ibfl Note Fit the belt tension gauge hooks to the belt crests to ...

Page 408: ... as shown Standard IN 0 18 to 0 22 mm 0 0071 to 0 0087 in hot engine EX 0 33 to 0 37 mm 0 0 130 to 0 0146 in hot engine 3 Turn the crankshaft in the forward direction to set cylinder No 4 to the TDC 4 Measure the valve clearance of the remaining valves 3 Adjust the valve clearance 1 Loosen the lock nut and turn the adjusting screw for adjustment Standard IN 0 18 to 0 22 mm 0 0071 to 0 0087 in hot ...

Page 409: ...er is touching the maximum adjusting screw 2 Start the engine depress the accelerator pedal fully and check the engine speed no load static maximum speed Standard See the repair manual for each model 4 Adjust the no load static maximum speed Unseal the maximum adjusting screw and turn it for adjustment 5 Check the maximum speed while there is a load 1 With the engine running at the maximum speed o...

Page 410: ...pump body A are aligned with each other If they are not aligned check the amount of offset Loosen the injection pump connections of the following pipes Fuel inlet pipe Injection pipe Overflow pipe Loosen the injection pump mounting nut and lower bracket Move the pump body for adjusting a Move the pump body in direction A when the measured value in step 7 was smaller than 0 87 mm 0 034 in b Move th...

Page 411: ... each cylinder For example if ten compression strokes are necessary to obtain the maximum pressure for No 1 cylinder also use ten strokes for the other cylinders Use a fully charged battery to maintain the specified engine speed 3 Measure the compression pressure for each cylinder Limit of difference between cylinders 200 kPa 2 kgf cm2 28 psi 4 If the compression pressure in any cylinder is below ...

Page 412: ...Y INSPECTION AND REASSEMBLY 3 6 INJECTION NOZZLE 3 8 COMPONENTS 3 8 REMOVAL AND INSTALLATION 3 9 INJECTION PUMP 3 13 SPECIFICATIONS 3 13 COMPONENTS 3 13 REMOVAL AND INSTALLATION 3 15 DISASSEMBLY 3 16 INSPECTION 3 22 REASSEMBLY 3 26 AIRTIGHTNESS TEST 3 38 ADJUSTMENT 3 39 1DZ II Repair Section 1 2 3 ...

Page 413: ...USED SSTs Part number Part name Fuel filter wrench Injection pump arm njection pump tool set Vozzle holder retaining nut wrench Steering warm bearing puller 1DZ II Repair Section 1 2 3 ...

Page 414: ...1DZ II Repair Section 1 2 3 ...

Page 415: ...leed air from the fuel system after installingthe fuel pump The installation procedure is the reverse of the removal procedure Number 1 2 3 4 Item Disconnect the wiring Fuel hose Fuel filter set bolt Fuel filter Removal Inspection Installation 1DZ II Repair Section 1 2 3 ...

Page 416: ...Bleeding air from the fuel system Operate the priming pump knob up and down to bleed air Air bleeding has finished when the knob operations feel heavy 1DZ II Repair Section 1 2 3 ...

Page 417: ... procedure is the reverse of the disassembly procedure 1 bolt 0 ring 1 2 1 Sedimenter 0 ring Inspection Disassembly Number Point I Disassembly and reassembly Replace the fuel filter SST 09228 76010 71 09228 64010 Reassembly Item 3 Fuel filter element Point I Point I 1DZ II Repair Section 1 2 3 ...

Page 418: ...Reassembly Coat a small amount of light oil on the 0 ring of the fuel filter element 1DZ II Repair Section 1 2 3 ...

Page 419: ...3 8 INJECTION NOZZLE COMPONENTS 1DZ II Repair Section 1 2 3 ...

Page 420: ...rocedure is the reverse of the removal procedure Number 1 2 5 lnjection nozzle assembly I Item Intake pipe Injection pipe 3 4 I Point I Fuel hose Nozzle leakage pipe Caution The nozzle gasket must be replaced with a new one Removal Inspection Installation 1DZ II Repair Section 1 2 3 ...

Page 421: ... the washer If it is below the standard use a thicker washer and if it is above the standard use a thinner washer 43 types of washers are provided in 0 025 mm 0 00098 in steps in a range of 0 900 to 1 950 mm 0 0354 to 0 0768 in The injection pressure changes by about 0 49 MPa 5 kgf cm2 71 psi as the washer thickness changes by 0 05 mm 0 00197 in 2 Check the oil seal at the valve seat 1 Slowly push...

Page 422: ...e a small piece of hard wood and a brass brush Clean the nozzle with clean light oil 2 Clean the carbon deposit at the nozzle needle tip using a small piece of hard wood 3 Clean the carbon deposit on the outside of the nozzle body using a brass brush 3 Check the nozzle appearance 1 Check the nozzle body for cracks and corrosion 2 Check the nozzle needle for damage and corrosion If necessary replac...

Page 423: ...a little at a time If the needle does not sink at any point in the test replace the body and needle as a set 5 Perform reassembly with the same procedures as disassembly and using the SST SST 09268 76003 71 09268 64010 Retaining nut tightening torque T 58 8 to 78 5 N m 600 to 800 kgf cm 43 4 to 57 9 ft lbfl 1DZ II Repair Section 1 2 3 ...

Page 424: ...interval Clockwise as viewed from the drive side Plunger diameter mm in Feed pump Cam lift mm in Governor type Timer Vane type built in type 2 2 0 087 Centrifugal all speed Hydraulic Lubrication method Fuel lubrication Fuel cut Fuel cut by a solenoid COMPONENTS 1DZ II Repair Section 1 2 3 ...

Page 425: ...1DZ II Repair Section 1 2 3 ...

Page 426: ...d installation procedure The installation procedure is the reverse of the removal procedure 1 Removal I Inspection 1 Installation 1 I Intake pipe I I I 2 3 lnjection pipe hose Injection pump assembly See P 2 4 t t 1DZ II Repair Section 1 2 3 ...

Page 427: ... for any sign of deformation damage roughening and scratches Arrange the removed parts in an orderly manner and distinguish partsto be replacedfrom those to the reused n 1 Overflow screw 1 Remove the overflow screw and drain the fuel 2 Attach the pump to the pump mounting bench using the SST SST 09245 76001 71 09245 54010 3 Remove the governor cover 1 Socket bolt 2 Lift the governor cover and disc...

Page 428: ... lock nut and the governor shaft have left handed threads 3 While extracting the governor shaft remove the following parts as an assembly a Flyweight holder b Flyweight c Flyweight washer d Governor sleeve 4 Washer 5 Adjusting washer 6 Remove the solenoid 1 Boot 2 Solenoid assembly 3 0 ring 7 Remove the distributor head plug 1 Head plug SST 09260 76003 71 09260 54012 2 0 ring 1DZ II Repair Section...

Page 429: ...the same cylinders Note Cylinder marks A 6 C D are punched on the distributor heads 9 Remove the distributor head 1 Distributor head 2 Lever support spring Note When removing the distributor head do so carefully while holding the plunger end with a pair of tweezers or similar tool 10 Remove the plunger 1 Plunger spring guide 2 Plunger spring shim 3 Plunger spring upper seat 4 Plunger spring 5 Spil...

Page 430: ...ernor lever 1 Support bolt 2 Governor lever 12 Remove the cam plate and the coupling 1 Plunger adjusting shim 2 Cam plate 3 Coupling spring 4 Coupling 13 Remove the timer spring lmer cover 1 T 2 Timer spring 3 Adjusting washer 2 pieces 4 0 ring 1DZ II Repair Section 1 2 3 ...

Page 431: ...r ring Note Offset the drive shaft pawl by 90 from the timer slide pin 4 Roller ring Caution Do not drop the roller ring as the four rollers are installed in special heights Reinstall them in the same combination and position 5 Timer piston 6 Timer sub piston Caution Do not drop the timer sub piston 1DZ II Repair Section 1 2 3 ...

Page 432: ...ed pump parts 1 Feed pump cover set screw 2 Feed pump cover 3 Liner Caution Make sure that the rotor and the blade remain inside at this time Do not slant or pry 4 Rotor blade Caution Do not alter the relative positions of the four blades and the rotor When replacement is necessary replace the rotor blades and liner as a group 17 Remove the regulating valve 1 Regulating valve SST 09260 70003 71 09...

Page 433: ...und at the plunger lead replace the plunger spill ring and distributor head as a group 2 Check the plunger sliding contact surfaces as follows Slide the plunger several times in clean light oil Incline the distributor head 60 and pull out the plunger by about 15 mm 0 59 in When the plunger is released gently it must drop at least 3 mm 0 12 in by its own weight Secure the spill ring and distributor...

Page 434: ...en released c Replace the valve if it falls to the seat 3 Check the roller ring 1 If flaking local wear or other flaws that prevent reuse are found on the roller and roller pin replace the roller ring assembly 2 Measure the height of four rollers using a dial gauge and calculate the dispersion Limit 0 02 mm 0 0008 in If the limit is exceeded change the roller positions with one another and check t...

Page 435: ... vernier caliper Limit L 4 2 mm 0 165 in 6 Check the flyweight Measure the amount of stepped wear on the flyweight surface that comes into contact with the washer Limit A 0 2 mm 0 008 in If the limit is exceeded replace all four parts as a group 7 Check the feed pump Check the sliding surface for excessive wear or damage If necessary replace the feed pump assembly 1DZ II Repair Section 1 2 3 ...

Page 436: ...springs at the same time 2 Squareness of the spring Limit A 2 0 mm 0 08 in 10 Check the pump housing 1 Check the feed pump for wear or scratches on the sliding surface 2 Check the threads for damage 3 Wear on the housing bushing a Fit the nut on the drive shaft as shown to the left Lightly shake the drive shaft in the direction of the wear lightly pushing by hand and measure the amount of wear Bus...

Page 437: ... the lever shaft 2 Reassemble parts in the lever shaft cover first 3 Return spring 4 Adjusting lever Note Align the matching marks on the adjusting lever and the lever shaft One serration of the adjusting lever corresponds to a lever angle of 7 5 When replacing the adjusting lever select a new one that has the same punched number 5 Spring guide 6 Nut T 4 90 to 9 81 N m 50 to 100 kgf cm 3 62 to 7 2...

Page 438: ... and back it will block fuel passage The step at the side must be positioned at the top as shown in the illustration 2 Rotor blade Caution Reassemble the rotor and the blades with the grooved side facing inward as shown to the left Check that the rotor and the blades slide smoothly When feed pump replacement is required replace the entire assembly rotor blades and liner 3 Feed pump cover Caution C...

Page 439: ...ve key and thrust washer to the shaft and reassemble them along the rotor key groove Check that the parts rotate smoothly after reassembling 7 Reassemblethe roller ring 1 Insert the timer slide pin into the roller ring assembly Caution Make sure that the curved surface of the washer at the roller of the roller ring is facing the periphery Make sure that the slide pin is inserted to the center as s...

Page 440: ...le the stopper pin and fit the clip Caution Make sure that the timer piston slides smoothly 3 Reassemble the following parts a 0 ring b Washers c Timer spring d Timer cover Caution Install washers at both ends of the spring to a thickness of 0 5 mm 0 020 in or more 9 Reassemble the coupling and cam plate 1 Coupling 2 Reassemble the cam plate with the pin in the same direction as the key groove in ...

Page 441: ...g parts to the cylinder head a Plunger spring guide b Upper spring seat c Plunger spring d Lower spring sheet e Plunger upper plate f Plunger lower plate g Plunger Caution Do not reassemble the plunger spring shim at this point Leave the spill ring removed 3 Selecting the plunger spring shim Measure dimension KF when the plunger spring is released and calculate the necessary plunger spring shim th...

Page 442: ...equired replace both as a pair 11 Adjust the plunger shim measuring dimension K 1 Dimension K is the distance from the end surface of the distributor cylinder as assembled to the end surface of the plunger head at the BDC of the plunger Dimension K can be altered by selective use of the plunger adjusting shim 2 Insert a plunger shim of an appropriate thickness and reassemble the plunger with the c...

Page 443: ... plunger to the BDC and measure dimension K Standard K 3 3 f 0 1 mm 0 130 f 0 004 in Caution Make sure that the plunger is not raised during measurement 5 Selecting the plunger shim Compare the measured value with the standard and select the appropriate plunger shim thickness accordingly Shim thickness mm tl t2 3 3 in tl t2 0 13 t Shim thickness during measurement t2 Measured dimension 6 Remove th...

Page 444: ...h an oil groove c Plunger spring lower seat d Spill ring Caution Install the spill ring in such away as the end surface with a hole faces the cam plate 2 Reassemble the following parts to the plunger spring lower seat a Plunger spring b Spring upper seat c Plunger spring shim selective use d Plunger spring guide 3 Plunger shim selective use Caution Do not coat grease on the plunger shim 4 Reassemb...

Page 445: ...upport spring Note Coat grease Denso grease No 50 or timer grease on the spring to adhere it to the distributor head 2 Reassemble the distributor head Note The lever support spring must face the governor lever Push the distributor head by hand until it touches the 0 ring 3 Distributor head set bolts T 10 79 to 12 75 N m 110 to 130 kgf cm 8 0 to 9 4 ft lbfl Note Tighten the four bolts evenly and al...

Page 446: ...pring seat 5 Valve holder SST 09260 76003 71 09260 54012 T 53 94 to 63 74 N m 550 to 650 kgf cm 39 8 to 47 0 ft lbfl Caution Always use new gaskets When replacement is required always replace the delivery valve and the valve seat as a group 19 Reassemble the solenoid 1 Reassemble the 0 ring to the solenoid 2 Solenoid T 19 61 to 24 52 N m 200 to 250 kgf cm 14 5 to 18 1 ftlbfl Caution When assemblin...

Page 447: ...assemble the 0 ring to the governor shaft 4 Reassemble the following parts a Governor shaft b Adjusting washer c Washer d Governor flyweight assembly Caution Note that the governor shaft has left hand threads 5 Measure the thrust clearance of the weight holder using a thickness gauge Thrust clearance 0 15 to 0 35 mm 0 0059 to 0 0138 in over the entire circumference If the standard is not met chang...

Page 448: ... the end surface of the pump housing Standard L 1 5 to 2 5 mm 0 059 to 0 098 in Caution Note that the governor shaft has left hand threads 7 Governor shaft lock nut SST 09260 76003 71 09260 54012 T 24 51 to 29 42 N m 250 to 300 kgf cm I8 1 to 21 7 ft lbfl Caution Note that the lock nut has left hand threads 1DZ II Repair Section 1 2 3 ...

Page 449: ...new governor cover gasket 3 Socket bolt AIRTIGHTNESS TEST After reassembly is completed carry out an airtightness test with the following steps 1 Install a blind plug to the overflow screw opening Apply air pressure of about 147 kPa 1 5 kgflcm2 21 33 psi from the fuel inlet hole Insert the pump into the oil until the overflow screw is in the oil and check that air does not leak from any part of th...

Page 450: ... check 10 High speed lever setting 11 Load sensing timer adjustment 12 Low speed lever setting Nozzle valve 0 to 590 kPa 0 to 980 kPa opening pressure 14 71 k 0 49 MPa 0 to 6 kgf cm2 0 to 10 kgf cm2 0 to 90 psi 0 to 140 psi a Feed pump b Fuel filter c Adjusting valve d Pressure gauge for feed pressure measurement e Pressure gauge for internal pressure measurement 150 k 5 kgf cm2 2130 k 70 psi f No...

Page 451: ... gauge for internal pressure measurement 1 Inlet hose 2 Overflow hose Note Do not confuse the overflow screw with the inlet screw The overflow screw has OUT stamped on it 3 Pressure gauge Note The pressure gauge used is one that is integrated with a timer measuring device Pipes may be taken from the overflow hose connection 4 High pressure pipe Use a high pressure pipe of the following specificati...

Page 452: ...that injection occurs at 1200 rpm Wipe oil off the pump surface so that oil leakage can be detected easily 5 Carry out a run in operation of the pump in this condition at 1200 rpm for 5 minutes Caution Turn the switch off immediately and check the pump if oil leakage injection failure unusual sounds or other problems are found during operation Set the key groove of the drive shaft at the angle sho...

Page 453: ...y adjustment of the full load standard injection rate Measure the injection rate at pump speed 900 rpm Other than 2TD 20 25 900 rpm for 2TD 20 25 only 800 rpm If the standard is not met turn the full load set screw as necessary 1DZ II Repair Section 1 2 3 ...

Page 454: ...erence point 0 472 to 0 497 High speed lever set 1 310 1 0 80to2 40 point 0 049 to 0 146 Full load reference point 7 7 to 8 1 8oo 0 470 to 0 494 High speed lever set 2 2 to 4 0 point 1 l3lo 1 0 134to0 244 Remarks Adjust with the full load set screw Adjust with the maximum speed adjusting screw Adjust with the full load set screw Adjust with the maximum speed adjusting screw A d j u s t z h the ful...

Page 455: ...t full position Measure the overflow rate at pump speed 1200 rpm Standard 283 to 533 cm3 min 17 27 to 32 53 cu in min Caution Always use the overflow screw attached to the pump Timer adjustment Lever at full position 1 Remove the cover from the high pressure side without a timer spring of the timer Attach the timer measuring device Denso part number 95905 10110 and set the zero point 2 Measure the...

Page 456: ...the injection rate at pump speed 900 rpm Except for 2TD 20 25 900 rpm only for 2TD 20 25 800 rpm If the standard is not met adjust the rate by turning the full load set screw as necessary Standard Model Deviation 0 6 cm3 0 037 cub or less 8FDlO to 15 8FDK20 to 30 for DPF Starting injection rate adjustment Lever at full position rpm Pump peed i easure the injection rate at pump speed 100 rpm Standa...

Page 457: ...f the injection rate by 1 6 cm3 0 098 cu in 200 st Size variation of governor sleeve plugs Dimension L mm in 2 5 0 098 2 7 0 106 2 9 0 114 3 1 0 122 3 3 0 130 3 5 0 138 3 6 0 142 Dimension L mm in 3 7 0 146 3 9 0 154 4 1 0 161 4 3 0 169 4 5 0 177 4 7 0 185 If the deviation limit is not satisfied replace the delivery valve delivery valve spring etc 1DZ II Repair Section 1 2 3 ...

Page 458: ... 509 to 0 533 1 0 6 0 037 or less Lever angle 18 5 7 74 to 8 14 at Full position 1 1 0 472 to 0 497 0 6 0 037 or less Pump speed rPm 14 5 7 94 to 8 34 at Full position 1 1 0 485 to 0 509 15 5 1 900 7 94 to 8 34 at Full position 1 0 485 to 0 509 1 0 6 0 037 or less 0 6 0 037 or less 20 k 5 6 74 to 8 26 at Full position 1 500 1 0 411to0 504 0 5 0 031 or less In ection rate B cm 1200 st I cyl cu 200 ...

Page 459: ...in 1200 st 1cyl 1275 1 06 to 2 66 I4l01 0 065 to 0 162 High speed lever setting Remarks 0 80 to 2 40 0 049 to 0 146 I I 3 34 to 6 14 375 1 0 204 to 0 375 1Confirmation High speed lever setting 5 22 to 8 02 0 319 to 0 489 1400 1500 1 0 90 0 055 or less I Confirmation Confirmation 0 90 0 055 or less Confirmation 1310 1275 0 80 to 2 40 0 049 to 0 146 I I High speed lever setting 5 22 to 8 02 0 319 to...

Page 460: ... position A where the pump internal pressure begins to drop as shown to the left Check if the standard injection rate is obtained at that position 2 If the standard is not met adjust the rate by turning the governor shaft Set the lever again as in step 1 above and check the standard injection rate Method of adjustment When the injection rate is low Turn the governor shaft clockwise When the inject...

Page 461: ...wly switch the adjusting lever from idle to full position and maintain the adjusting lever at position B where the pump internal pressure begins to rise see the relative positions of the lever position and pump internal pressure Check if the standard injection rate is obtained at that position In ection rate cm I200 st I cyl cu in 1200 st 1cyl By governor shaft q full 2 4 2 0 4 effect 1 I 3 2 q fu...

Page 462: ...tion of adjustment reduce the fuel cut solenoid voltage to 0 V and confirm that the injection rate is zero at that voltage At pump speed 100 rpm 2 Check that the lever angle is 38 5 2TD 20 25 36 k 5 8FD10 to 15 8FDK20to 30 included DPF vehicle model 32 k 5 8FD20 to 30 29 k 5 8FD20 to 30 for DPF between the idle and full positions 3 Seal the full load set screw and the maximum speed set screw Pump ...

Page 463: ...1DZ II Repair Section 1 2 3 ...

Page 464: ...COOLING SYSTEM WATER PUMP 4 2 COMPONENTS 4 2 REMOVAL AND INSTALLATION 4 3 DISASSEMBLY INSPECTION AND REASSEMBLY 4 4 1DZ II Repair Section 1 2 4 ...

Page 465: ...WATER PUMP COMPONENTS Refer to 5701 30 1DZ II Repair Section 1 2 4 ...

Page 466: ...nstallation procedure is the reverse of the removal procedure Number 1 5 lternator adjusting bar 2 3 4 6 1 Water pump I I Item Drain the coolant 7 1 Water pump inlet I I V belt Fan Fan pulley Removal See P 2 43 Inspection Installation t t 1DZ II Repair Section 1 2 4 ...

Page 467: ... I I I I 1 3 1 Water pump rotor Reassembly umber 1 Item 1 I I I I 1 4 Water pump cover Water outlet Point operation Point I Check the valve opening temperature and the fully opened temperature 1 Put the thermostat in water and increase the water temperature while agitating Disassembly Point I 2 Inspection Thermostat 1DZ II Repair Section 1 2 4 ...

Page 468: ...ature 95 O C 203 O F Fully opened lift 10 mm 0 39 in or more Note If the valve is open at normal temperatures or if the valve tightness is impaired replace the valve Point 21 Check the water pump 1 Check the water pump rotors for cracks damage and excessive rust 2 Check the bearing for unusual sound and resistance when the water pump rotor is rotated by hand 1DZ II Repair Section 1 2 4 ...

Page 469: ...1DZ II Repair Section 1 2 4 ...

Page 470: ...LUBRICATION SYSTEM USED SSTS 5 2 OIL PRESSURE INSPECTION 5 3 ENGINE OIL AND OIL FILTER REPLACEMENT 5 3 OIL STRAINER 5 4 OIL PUMP 5 5 1DZ II Repair Section 1 2 5 ...

Page 471: ...USED SSTs I Illustration Part number I Part name 09032 76001 71 09032 00100 Oil pan seal cutter 09228 76004 71 09228 07501 Oil filter wrench 1DZ II Repair Section 1 2 5 ...

Page 472: ...e 75 to 85 O C 167 to 185 OF Standard At idle speed 78 kPa 0 8 kgflcm2 11 4 psi or more At 1600 rpm 343 kPa 3 5 kgflcm2 49 8 psi or more 3 Mount the bolt ENGINE OIL AND OIL FILTER REPLACEMENT 1 Drain the engine oil 1 Remove the oil filler cap 2 Remove the oil drain plug and drain the oil 2 Remove the oil filter SST 09228 76004 71 09228 07501 3 Install the oil filter Fit an 0 ring to the oil filter...

Page 473: ... Start the engine and check the system for oil leakage 7 Check the oil amount Recheck the oil amount after the oil leakage check Note Stop the engine and wait for 3 minutes before performing the inspection OIL STRAINER REMOVAL AND INSTALLATION 1 Remove the oil pan See P 2 21 SST 09032 76001 71 09032 00100 2 Remove the oil strainer 3 Install the oil strainer T 14 51 to 21 77 N m 148 to 222 kgf cm 1...

Page 474: ...OIL PUMP COMPONENTS 1DZ II Repair Section 1 2 5 ...

Page 475: ...erse of the disassembly procedure 1 I Fan V belt 1 See P 2 43 1 Number 2 I Crank pulley I see p 2 21 I t Disassembly Item 5 1 Idle gear No 1 I Point 21 I Inspection 3 4 Reassembly Timing gear cover Measure the oil pump gear backlash 6 See P 2 21 Oil pump assembly t Point 11 Point 31 t t 1DZ II Repair Section 1 2 5 ...

Page 476: ...Position the matching marks at the point of engagement between the idle gear and each gear Point 31 Inspection Check the body clearance Measurement position Clearance between the rotor and the body Standard 0 10 to 0 17 mm 0 0039 to 0 0067 in Limit 0 20 mm 0 0079 in 1nspection Checkthe tip clearance Measurement position Clearance between the rotor and the gear Standard 0 05 to 0 15 mm 0 0020 to 0 ...

Page 477: ... rotor protrusion from the oil pump body using the straightedge and dial gage Reference value 3 91 to 3 97 mm 0 1539 to 0 1563 in Reassembly The rotor is symmetric and may be installed on either side Caution Do not drop the rotor 1DZ II Repair Section 1 2 5 ...

Page 478: ... 3 INSPECTION OF GLOW PLUG 6 4 INSPECTION OF PREHEATING TIMER 6 4 INSPECTION OF WATER TEMPERATURE SENSOR 6 5 STARTER MOTOR 6 6 COMPONENTS 6 6 REMOVAL INSPECTION AND INSTALLATION 6 7 DISASSEMBLY INSPECTION AND REASSEMBLY 6 8 STARTER ASSEMBLY INDIVIDUAL INSPECTION 6 14 1DZ II Repair Section 1 2 6 ...

Page 479: ...USED SSTs Illustration Part number Part name 09286 76001 71 09286 46011 Injection pump spline shaft puller 1DZ II Repair Section 1 2 6 ...

Page 480: ...PREHEATING SYSTEM ELECTRIC CIRCUIT DIAGRAM COMPONENTS 1DZ II Repair Section 1 2 6 ...

Page 481: ...ion switch is turned to the ON position Standard See the chart on the left 2 Measure the voltage of the preheating timer when the ignition switch is turned to the ON position Measurementterminals REL to E01 Standard The battery voltage approx 12 V should be indicated immediately after the switch is turned ON and go off soon after 3 Start the engine while the battery voltage is being applied across...

Page 482: ...TER TEMPERATURE SENSOR Measure the resistance across both terminals of the water temperature sensor Standard 15 C 5 OF 11 I6 to 13 62 kR 20 C 68 OF 2 21 to 2 69 kR 50 C 122 OF Approx 0 43 kR 1DZ II Repair Section 1 2 6 ...

Page 483: ...STARTER MOTOR COMPONENTS 1DZ II Repair Section 1 2 6 ...

Page 484: ...ion procedure The installation procedure is the reverse of the removal procedure 1 I Battery lumber 2 Battery set plate 3 1 Oil catcher Item Removal 4 5 Disconnect the connector and terminal Starter assembly Inspection Installation 1DZ II Repair Section 1 2 6 ...

Page 485: ...1 Inspection I Reassembly 1 1 Lead wire 2 Yoke assembly 1 Point I Point 111 3 1 End frame 1 Point 101 10 1 Snap retainer 4 5 6 7 8 9 Brush Armature assembly Bearing Housing assembly Clutch assembly Steel ball 11 12 13 Idle gear Retainer roller Return spring Point 21 Point 51 Point 31 Point 41 Point 61 Point 71 Point 91 Point 81 1DZ II Repair Section 1 2 6 ...

Page 486: ...he field Standard 0 1 MQ or more Point 21 Disassembly Lift the side brush spring using radio pliers Do not damage the brush and commutator Point 31 Inspection Check the brush 1 Check the brush for roughened contact surfaces and measure the brush length Measure the brush length at the center recess Standard 20 5 mm 0 807 in Limit 13 0 mm 0 512 in 2 When the contact surface is roughened or when repl...

Page 487: ... holders Standard 0 1 MR or more Point 41 Inspection Check the insulation between the commutator and the armature coil Standard I MR or more Inspection Perform a short circuit test of the armature coil 1 Thoroughly clean the armature surface before the test 2 Put a piece of iron piece parallel to the armature using an armature tester and turn the armature Standard The piece of iron is not pulled i...

Page 488: ...all segments Inspection Check the commutator 3 Measure the radial runout Limit 0 05 mm 0 0020 in or less 4 Measure the outside diameter Standard 36 mm 1 42 in Limit 35 mm 1 38 in 5 Measure the undercut depth between the segments Standard 0 7 mm 0 028 in Limit 0 2 mm 0 008 in 1DZ II Repair Section 1 2 6 ...

Page 489: ... Continuity 2 Check the continuity between the terminal 50 and magnet switch body Standard Continuity Point 71 Inspection Check the clutch and the gear 1 Check the gear for wear and damage 2 Make sure that the gear is locked when turned in the drive direction counterclockwise and that it turns smoothly when turned in the opposite direction clockwise 1DZ II Repair Section 1 2 6 ...

Page 490: ...a screwdriver reassemble the brush holder to the starter yoke 2 Pull up the brush spring and reassemble the brush to the brush holder Point 101 Disassembly Align the notch a on the end frame with the grommet b on the lead wire Point 111 Disassembly Reassemble the felt washer to the armature shaft bearing 1DZ II Repair Section 1 2 6 ...

Page 491: ...ll in test Check that the pinion gear comes out when wired as shown 2 Holding coil retention test Disconnect the test lead wire from terminal C as shown after the pull in test Make sure that the pinion gear remains protruding 3 Plunger return test Disconnect the terminal as shown after the holding coil retention test Make sure that the pinion returns at this time 1DZ II Repair Section 1 2 6 ...

Page 492: ... 1 Secure the starter in a vise Use adequately large lead wires for a no load test as large current is involved Read the ammeter after the pointer becomes stabilized Standard 90 A or less 1DZ II Repair Section 1 2 6 ...

Page 493: ...1DZ II Repair Section 1 2 6 ...

Page 494: ...CHARGING SYSTEM USED SSTS 7 2 ON VEHICLE INSPECTION 7 3 ALTERNATOR 7 4 ELECTRIC CIRCUIT DIAGRAM 7 4 COMPONENTS 7 4 DISASSEMBLY INSPECTION AND REASSEMBLY 7 5 1DZ II Repair Section 1 2 7 ...

Page 495: ...USED SSTs I Illustration Part number Part name HST pump bearing replacer Alternator rear bearing puller Alternator rear bearing replacer Replacer set Handle set 1DZ II Repair Section 1 2 7 ...

Page 496: ...the alternator when the engine is running 7 Perform a no loadtest Regulated voltage and current check I Connect the ammeter and voltmeter as shown 2 Gradually increase the engine speed to 1500 rpm and measure the voltage Standard 12 V 13 5 to 14 3 V hot engine 3 Measure the current at engine speed of 1500 rpm Standard 10 A or less Note The current reading instantly goes above 10 A immediately afte...

Page 497: ...ALTERNATOR ELECTRIC CIRCUIT DIAGRAM COMPONENTS 1DZ II Repair Section 1 2 7 ...

Page 498: ... Point 121 Point 111 Point 101 Inspection Point I Point 21 Point 31 Point 71 Disassembly Point 41 Point 51 Point 61 Point 81 Point 91 Number 1 2 3 4 5 6 7 8 9 10 Item Terminal insulator Rear end cover Brush holder with brush IC regulator Rectifier holder Alternator pulley Rear end frame Rotor assembly Rear bearing spring washer Bearing cover front bearing 1DZ II Repair Section 1 2 7 ...

Page 499: ... lead wires Coat insulation paint to the solder Caution Always replace both brushes at the same time Point 21 Inspection Check the IC regulator diode Check the continuity of the diode between terminals B and F with the kR range of the circuit tester Standard Test two times with different polarities The diode must be continuous in one polarity and not continuous in the other Point 31 Inspection Che...

Page 500: ...n Caution Do not use a 500 V megohmmeter since it will damage the rectifier Point 41 Disassembly Set the alternator pulley in a vise and remove the set bolts Caution Always use pads to protect the components Point 51 Disassembly After set nuts and set bolts are removed hold the rear end frame and separate it by applying a shock to the rotor shaft end Caution When applying a shock put the parts on ...

Page 501: ... the rotor core Standard oo R Inspection Check the slip rings 1 If the slip ring is damaged repair it using abrasive paper 400 2 Measure the outside diameter of the slip ring Standard 14 4 mm 0 567 in Limit 14 0 mm 0 551 in Inspection Check the stator coil in the drive end frame Measure the resistance between phases Standard Approx 1 0 R 1DZ II Repair Section 1 2 7 ...

Page 502: ...e bearing Caution High speed bearings x2 are used Be sure to use the specified type marked with a Denso part number when replacing the bearings and do not subject the bearings to impacts Point 101 Reassembly Reassemble the front bearing SST 09950 76018 71 09950 60010 1 09950 76020 71 09950 70010 2 Point 111 Reassembly Reassemble the rear bearing and the spring washer SST 09820 76003 71 09820 00030...

Page 503: ...tighten set nuts Caution Always use pads to protect the components Point 141 Reassembly Reassemble the rectifier holder 1 Make sure that the ends of the four stator coil terminals fit in position in the terminal holders of the end frame 2 First tighten all the terminal mounting bolts temporarily and then tighten them properly 3 Mount the rectifier mounting bolt Point 151 Reassembly Make sure that ...

Page 504: ... SST LIST 8 2 SERVICE STANDARDS 8 6 ENGINE OVERHAUL 8 6 FUEL SYSTEM 8 12 COOLING SYSTEM 8 16 LUBRICATION SYSTEM 8 16 STARTING SYSTEM 8 17 CHARGING SYSTEM 8 17 TIGHTENING TORQUE 8 18 1DZ II Repair Section 1 2 8 ...

Page 505: ...on Part number Oil pan seal cutter Valve guide bush remover replacer Valve stem oil seal replacer Valve spring compressor Camshaft bearing remover replacer Belt tension gauge Oil filter wrench Fuel filter wrench 1DZ II Repair Section 1 2 8 ...

Page 506: ... Plunger stroke measuring tool lnjection pump arm Injection pump tool set Nozzle holder retaining nut wrench lnjection pump spline shaft puller Bearing remover Drive pinion bearing replacer HST pump bearing replacer 1DZ II Repair Section 1 2 8 ...

Page 507: ... Part name Section Part number Steering warm bearing puller Alternator rear bearing puller Alternator rear bearing replacer Puller C set Puller B set Replacer set Replacer B set Handle set 1DZ II Repair Section 1 2 8 ...

Page 508: ...Illustration rPart number Part name Variable pin wrench set Section 1DZ II Repair Section 1 2 8 ...

Page 509: ...LVE SPRING IN 1 2to 1 6 0 0472 to 0 0630 EX 1 6 to 2 0 0 0630 to 0 0787 45 VALVE IN 108 54 4 2732 Standard EX 108 24 4 2614 Overall length mm in IN 107 90 4 2480 Limit EX 107 60 4 2362 Overall length mm in IN 7 97 to 7 99 0 3138 to 0 3146 Stem outside diameter mm in EX 7 96 to 7 97 0 3134 to 0 3138 0 02 to 0 06 0 0008 to 0 0024 Standard Valve guide bushing oil clearance 0 04 to 0 07 0 0016 to 0 00...

Page 510: ...nside diameter mm in Oil clearance between shaft and arm mm in Standard Limit 18 470 to 18 490 0 72717 to 0 72795 18 44 0 7260 Standard Limit Standard Limit 18 500 to 18 520 0 72835 to 0 72913 18 60 0 7323 0 007 to 0 049 0 00028 to 0 00193 0 16 0 0063 1DZ II Repair Section 1 2 8 ...

Page 511: ...51 0 00039 to 0 00201 0 1 0 004 I Standard 0 05 0 0020 ldle gear No 1 x oil pump gear Limit 0 3 0 0118 ldle gear thrust clearance Standard 0 0012 to 0 0043 mm in No 2 0 100 to 0 260 0 0039 to 0 0102 I Limit I No 1 0 3 0 012 No 2 0 5 0 020 ldle gear inside diameter I I No 1 45 000 to 45 025 I I No 1 44 950 to 44 975 1 76969 to 1 77067 ldle gear shaft outside diameter mm in I Standard I No 2 49 930 ...

Page 512: ...rtion limit mm in 0 025 to 0 066 0 00098 to 0 00260 0 1 0 0039 1 Taper ellipticity Top surface distortion limit Cylinder inside diameter mm in 0 02 0 0008 or less 0 1 0 004 Difference between maximum and minimum I Boring margin 0 02 0 0008 or less Cylinder liner outside diameter mm in Cylinder liner bore diameter mm in A B Valve lifter bore inside diameter mm in 89 030 to 89 045 3 50512 to 3 50571...

Page 513: ...OD BUSHING 0 27 to 0 39 0 0106 to 0 0154 0 45 to 0 60 0 0177 to 0 0236 Oil ring mm in 0 20 to 0 40 0 0079 to 0 0157 No 2 I I Bushing inside diameter standard mm in 1 27 011 to 27 023 1 06343 to 1 06390 0 04 to 0 08 0 0016 to 0 0031 Oil ring I Connecting rod thrust clearance mm in Bushing oil clearance 0 03 to 0 07 0 0012 to 0 0028 Limit 0 15 0 0059 Standard Limit 0 08 to 0 30 0 0031 to 0 0118 0 40...

Page 514: ...TUNE UP U S 0 50 Journal pin and crank pin mm in V belt tension 49 99 to 50 00 1 9681 to 1 9685 I New belt 1 520 to 755 53 to 77 116 9 to 169 81 Ellipticity limit Taper limit 0 02 0 0008 0 05 0 0020 Tension gauge N kgf Ibfl V belt deflection Lubricant oil capacity Pressure 98 1 N 10 kgf 22 Ibfl mm in Belts in use New belt 324 to 559 33 to 57 72 8 to 125 71 7 to 9 0 28 to 0 35 Belts in use t US gal...

Page 515: ... pressure MPa kgf cm2 psi 1 14 71 f 0 49 150 f 5 2133 to 22041 ITest oil SAE J967 IS0 4113 IFeed oil pressure kPa kgf cm2 psi I High pressure pipe Inside diameter x outside diameter x length mm in 1 0 2 x 0 6 x 840 00 079 x 00 236 x 033 071 I Test oil temperature O C OF I 40 to 45 104 to 113 2 Temporary adjustment Lever at full position In ection rate 5 cm 1200 st I cyl cu in 200 st I cyl Referenc...

Page 516: ...8 31 4 Overflow rate inspection Lever at full position 1200 I t o n stroke mm in 1 0 45 to 1 25 0 0177 to 0 0492 1 2 35 to 3 15 0 0925 to 0 1240 1 I Pump speed rPm 700 6 Full load injection rate adjustment Lever at full position 5 Timer adjustment Lever at full position 283 to 533 17 27 to 32 53 1200 Pump speed rpm Use overflow screw on each pump Injection rate Variation cm3 200st l c y cm3 cu in ...

Page 517: ...cyl cu in 1200 st 1cyl In ection rate B cm 1200 st I cyl Variation cm3 cu in 100 Variation cm3 cu in Pump speed Lever angle 7 7 to 8 1 0 470 to 0 494 cuh 1200 st 1cyl 18 5 at Full position 0 073 or less 0 6 0 037 or less Gain in weight at the start 14 5 5 at Full position 0 6 0 037 or less 8FDlO to 15 8FDK20 to 30 for DPE 18 5 at Full position 0 6 0 037 or less 8FD20 to 30 for DPF 15 5 at Full pos...

Page 518: ...o 6 14 0 204 to 0 375 1275 1410 I 1500 1 0 90 0 055 or less 1 Confirmation confirmation 15 k 5 at Full position 5 22 to 8 02 0 319 to 0 489 1 06 to 2 66 0 065 to 0 162 at Full position confirmation High speed lever setting 1375 20 k 5 I 1400 1 0 90 0 055 or less I Confirmation 3 34 to 6 14 0 204 to 0 375 1310 4 6 to 7 4 1275 1 0 281 to 0 452 10 Load sensing timer adjustment confirmation Confirmati...

Page 519: ...ss Model 1 See the repair manual for each model Low speed lever setting Confirmation Low speed lever setting COOLING SYSTEM THERMOSTAT Idling speed rpm IOpening temperature c OF I 80 to 84 176 to 183 I No load maximum speed rpm Fully opened temperature c OF I 95 203 I I Fully opened lift mm in I 10 0 39 LUBRICATION SYSTEM OIL PUMP IOil pump type Trochoid pump Body clearance Tip clearance mm in Sta...

Page 520: ...0 0020 or less Mica depth mm in Standard Limit 36 1 42 35 1 38 Standard Limit mm in CHARGING SYSTEM ALTERNATOR 0 7 0 028 0 2 0 008 Spring installed load N gf W Standard Limit Brush length 20 5 0 807 13 0 512 Standard Limit Rated voltage V Maximum output A Output speed rPm 31 4 to 39 2 3200 to 4000 7 1 to 8 81 21 6 2200 4 9 12 60 1500 Slip ring outside diameter mm in Standard Limit mm in 10 5 0 413...

Page 521: ...er support x nozzle holder x water pump Crank shaft x crankshaft pulley Camshaft x camshaft timing gear Connecting rod x connecting rod cap Injection pump x timing gear case x pump drive gear x injection pipe riming gear case x timing gear cover Alternator bracket x alternator Uater pump x fan fan pulley Valve rocker support x rocker shaft Uater outlet x outlet housing Vozzle holder x nozzle leaka...

Page 522: ... SECTION SECTION INDEX GENERAL OPERATION DESCRIPTION LPG REGULATOR OVERHAUL ELECTRICAL TROUBLESHOOTING APPENDIX SEC INDEX fm 1 ページ２００７年２月２２日木曜日午後４時５０分 1 3 0 1 3 1 1 3 2 1 3 3 1 3 4 4Y E LPG Device Repair ...

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Page 524: ... VEHICLE 0 7 ABBREVIATIONS 0 7 GENERAL RULES OF SERVICING WORK 0 8 BOLT NUT TIGHTENING TORQUES 0 9 BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE 0 9 PRECOATED BOLTS BOLTS WITH SEAL LOCK AGENT COATING ON THREADS 0 12 PERIODIC MAINTENANCE 0 13 INSPECTION METHOD 0 13 PERIODIC REPLACEMENT PARTS 0 13 00 book 1 ページ２００７年２月２２日木曜日午後４時４５分 LPG Device for 4Y E Engine Section 1 3 0 ...

Page 525: ... and quick coupling OPT 20 kg 44 1 lb 797 mm 31 4 in General purpose STD With level gauge and quick coupling OPT Cylinder Removal installation method Bracket opening direction Fuel hose connecting position Weight External diameter 20 0 kg 44 1 lb 797 mm 31 4 in Sinple type STD Swing down type OPT Right Bottom 15 0 kg 33 1 lb 637 mm 25 1 in n n n 00 book 2 ページ２００７年２月２２日木曜日午後４時４５分 LPG Device for ...

Page 526: ...E ENGINE PERFORMANCE CURVES 4Y Engine 8FGU15 to 25 8FGCU20 to 32 Gasoline Exclusive Convertible LPG Exclusive Convertible Engine speed Fuel consumption ratio Shaft output Shaft torque 00 book 3 ページ２００７年２月２２日木曜日午後４時４５分 LPG Device for 4Y E Engine Section 1 3 0 ...

Page 527: ...soline Convertible with LPG Engine speed Fuel consumption ratio Shaft output Shaft torque LPG Exclusive Convertible Gasoline Exclusive Convertible LPG Exclusive Convertible 00 book 4 ページ２００７年２月２２日木曜日午後４時４５分 LPG Device for 4Y E Engine Section 1 3 0 ...

Page 528: ...0 21 E 4Y Engine 8FGU15 to 32 series 8FGCU15 18 and 8FGCSU20 Gasoline Exclusive Convertible LPG Exclusive Convertible Engine speed Fuel consumption ratio Shaft output Shaft torque 00 book 5 ページ２００７年２月２２日木曜日午後４時４５分 LPG Device for 4Y E Engine Section 1 3 0 ...

Page 529: ...6 3 160 16 3 m m rpm 2100 m m 2570 m 2200 2100 m m Maximum shaft output kW PS 38 51 m m 44 59 43 58 42 57 36 48 m m rpm 2570 m m 2570 m m 2250 m m Minimum fuel consumption ratio g kW h g PS h 298 219 m 233 171 233 171 m 310 228 298 219 m m rpm 2000 m m 2000 m 1600 2000 m m Idle speed rpm 750 m m 750 m m 750 m m No load maximum governed speed rpm 2570 m m 2570 m m 2250 m m 00 book 6 ページ２００７年２月２２日 ...

Page 530: ...line For LPG For gasoline Solenoid valve For LPG For LPG Not provided Abbreviation code Meaning Abbreviation code Meaning ASSY Assembly O S Oversize ABDC After bottom dead center OPT Option ATDC After top dead center RH Right hand BBDC Before bottom dead center rpm Revolution per minute BTDC Before top dead center SST Special service tool BDC Bottom dead center STD Standard EX Exhaust SUB ASSY Sub...

Page 531: ...e parts to be reused 4 Cleaning of disassembled parts Parts to be reused shall be cleaned and washed thoroughly 5 Inspection and measurement Detailed inspection and measurement shall be carried out as required for parts to be reused 6 Installation Install good parts according to the correct procedure and observing the determined standards tightening torques adjustment values etc Be sure to use gen...

Page 532: ...e hexagon flange bolt based on the threading diameter 3 The nut tightening torque can be judged from its corresponding bolt type by using procedure 1 BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE Identification by Actual Part Type Shape and Strength class Strength class Hexagon head bolt standard bearing surface 4 4T 5 5T 6 6T 7 7T 8 8T 4T 5T 7T 8T Welded bolt 4T Stud bolt 4T 6T ...

Page 533: ... 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 8 19 39 72 108 172 80 195 400 730 1100 1750 5 8 14 1 28 9 52 7 79 4 126 6 7T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 11 25 52 95 147 226 110 260 530 970 1500 2300 7 9 18 8 38 3 70 0 108 3 166 1 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 12 29 61 108 172 265 125 300 620 1100 1750 2700 9 0 21 7 44 9 79 4 126 6 195 3 91611 40625 Nominal length mm No...

Page 534: ... 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 5 19 39 71 110 170 80 190 400 720 1120 1730 6 14 29 52 81 125 8 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 12 29 61 110 175 270 120 300 620 1120 1780 2750 9 22 45 81 129 199 10 9T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 15 5 38 80 145 230 360 160 390 820 1480 2350 3670 12 28 59 107 170 266 11 9T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 17 5 42 89...

Page 535: ...lt at the lower limit of the allowable tightening torque range if the bolt moves retighten it according to the steps below 2 How to reuse precoated bolts 1 Wash the bolt and threaded hole The threaded hole must be washed even when replacing the bolt with a new one 2 Completely dry the washed parts by blowing with air 3 Apply the specified seal lock agent to the bolt threaded portion Seal lock agen...

Page 536: ...tor adjustment status I m m m Regulator function I m m Adapter I m m Filter clogging C m m Loosened installation and functioning of solenoid valve I m m Gas cylinder I m m m Looseness and damage of gas cylinder mounting I m m m Item Replacement timing O ring for LPG cylinder valve Every 24 months LPG high and low pressure rubber hoses Every 24 months LPG regulator diaphragm and O ring Every 36 mon...

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Page 538: ... 21 E OPERATION DESCRIPTION Page OUTLINE OF LPG DEVICE 1 2 FUEL FILTER FOR LPG 1 3 SOLENOID VALVE 1 3 ADAPTER 1 4 REGULATOR 1 5 SPECIFICATIONS 1 5 REGULATORS SYSTEM COMPONENTS 1 11 01 book 1 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 1 ...

Page 539: ...ified in the regulator and supplied to engine with its pressure kept at a certain rate Engine coolant is led to the regulator for use as the heat source for LPG gasification Battery Ignition switch Fuse LPG filter Main solenoid valve Valve LPG Cylinder Regulator set Regulator Injector path Main path Coolant path Slow solenoid valve Engine Adapter Injector 01 book 2 ページ２００７年２月２２日木曜日午後４時４６分 LPG D...

Page 540: ...ted between the LPG filter and the regulator and controls gas flow according to the engine condition For example when the engine is running the solenoid valve is ON and supplies fuel Once the engine stops running it turns OFF and cuts off the gas flow When the current flows through the solenoid valve which consists of a slide valve back spring and solenoid coil magnetic force is generated The slid...

Page 541: ...r shaped needle valve that moves right or left based on the engine ECU signal This sliding of the valve changes the opening space of the fuel path Specifications FCM specifications Seat diameter Needle valve Ventury FCM Electronic governor Ventury diameter Seat angle Ventury diameter mm in 24 0 9 Needle valve seat diameter mm in 11 0 4 Needle valve seat angle G 60 Magnetized way 1 2 magnetized typ...

Page 542: ... maintaining the pressure at a fixed level SPECIFICATIONS First chamber pressure kPa psi 24 5 to 34 3 3 6 to 5 0 First seat inner diameter mm in 3 2 0 1 Secondary seat inner diameter mm in 6 0 0 2 Slow system flow shut off method Solenoid valve Drain cock Optionally available 01 book 5 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 1 ...

Page 543: ...1 When LPG flows out to second reducing chamber C the first pressure drops and first valve lever is operated by first regulator spring to open elastic face valve 1 to cause fuel to flow into first reducing chamber B again Opening and closing of elastic face valve is repeated to maintain the first pressure at a fixed level The pressure of the fuel entering from chamber B into chamber C through elas...

Page 544: ...ric pressure LPG flows into chamber D The LPG entering chamber D flows through the slow path and main path into the adapter and is then supplied to the engine from the venturi nozzle to start initial explosion When the throttle valve at the electric governor is opened slightly then vacuum is generated in the venturi of the adapter The vacuum in the adapter acts on the secondary pressure reduction ...

Page 545: ... the adapter and then supplied to the engine fuel is also delivered to the engine by the LPG injector to compensate the air fuel ratio The idle adjusting screw controls main flow rate of fuel Since vacuum at the adapter is very low during idling elastic face valve 2 is not opened and the fuel is supplied not from the chamber C but from the slow path LPG injector Injector path Slow solenoid valve C...

Page 546: ...ed to the engine by the LPG injector through the injector path While the engine is running in medium load range LPG fuel is mostly supplied through the main path and LPG injector injects the shortage amount of fuel to the ideal air fuel ratio While the engine is in high load range the FCM at adapter changes the amount of fuel flow to adjust the overall fuel amount on the other hand the injector su...

Page 547: ...etween chambers B and D resulting in suspension of LPG supply through the slow path Since the vacuum at the adapter venturi does not exist LPG supply through the slow path also stops LPG injector Slow solenoid valve Chamber D Chamber B Adapter Slow path 01 book 10 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 1 ...

Page 548: ...signal etc detected by means of engine ECU When the ignition switch is ON with the engine not running the valve is closed not to flow LPG to the adapter Ignition switch ST ON AM EFI main relay Battery LPG Solenoid relay Slow solenoid Main solenoid Engine ECU Gasoline Starter relay Starter motor Igniter LPG Gasoline switch LPG 01 book 11 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section...

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Page 550: ...EGULATOR OVERHAUL Page PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR 2 2 REGULATOR 2 3 REMOVAL INSTALLATION 2 10 DISASSEMBLY REASSEMBLY 2 12 LPG LEAK INSPECTION 2 17 ENGINE ADJUSTMENT 2 18 02 book 1 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 551: ...use other device or liquid etc 6 To check gas leak at night be sure to light a flashlamp outside the chamber before approaching to the LPG forklift to prevent a hazard by switching spark 7 When gas should leak ventilate air after confirming that there is no fire 8 Pay special attention to keep the LPG cylinder Keep it in the place free from the fire and install a gas leak detector 9 When a LPG for...

Page 552: ...2 3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E REGULATOR General 02 book 3 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 553: ...ents Solenoid valve First valve ASSY Idle adjust screw O ring First cover First diaphragm Second valve ASSY Second diaphragm Second cover 02 book 4 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 554: ... 22000 71 Tool 4 80339 76026 71 Automatic choke pipe plug 5 09817 23600 71 Union 6 09819 23600 71 Gauge 7 09819 22000 71 Gauge 8 23627 22000 71 Spring 9 9 1 9 2 9 3 09820 23600 71 09823 23600 71 09822 22000 71 09821 22000 71 Tester SUB ASSY Union Gauge Bellows 1 2 3 4 5 6 7 8 9 3 9 9 1 9 2 02 book 5 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 555: ...ippers remove the ring Reassembly 1 Install the idle adjusting screw temporarily 1 Set the mixture adjust screw temporarily to the following dimension Temporal set value 6 2 mm 0 25 in 2 Make sure to install a new cap 21673 13370 71 after this adjustment is made on the vehicle Make sure to adjust the engine speed after installing the regulator on the vehicle 2 Install the regulator primary pressur...

Page 556: ...s 24 5 to 34 3 kPa 0 25 to 0 35 kgf cm2 3 6 to 5 0 psi SST SST Compressed air 12 V SST Inspection 3 1 Stop supllying the compressed air in state of Inspection 2 2 Read the SST gauge SST SST 12 V SST 24 5 to 34 3 kPa 0 25 to 0 35 kgf cm2 3 6 to 5 0 psi Other than 24 5 to 34 3 kPa 0 25 to 0 35 kgf cm2 3 6 to 5 0 psi In appropriate adjustment of first pressure Elastic face valve 1 defect Elastic face...

Page 557: ...ct Elastic face valve 2 in C chamber defect Leak from A or F Leak from A C D or E Re check after retightening each part Since the fitting at A is applied with a sealing agent reassemble it From Inspection 3 NG OK Normal OK NG Flow 1 from inspection 3 Leak from B Defect of idle adjusting screw O ring Leak from F Body defect Result 1 Result 2 OK NG Elastic face valve 2 contact defect First diaphragm...

Page 558: ... the operating sound is heard when applying 12 V to the slow solenoid 2 Inspect the main solenoid Check that the operating sound is heard when applying 12 V to the main solenoid 12 V 12 V 02 book 9 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 559: ...just the idling speed See page 2 17 Removal Procedure 1 Fully discharge LPG from the fuel piping Point 1 2 Disconnect the battery cable from the negative terminal 3 Drain engine coolant 4 Disconnect the wiring from the main and slow solenoid valves 5 Disconnect the fuel piping 6 Disconnect the coolant piping 7 Remove the filter and main solenoid 8 Remove the regulator ASSY Installation Procedure T...

Page 560: ...ding to the procedure below 1 Close the LPG supply piping valve 1 green 2 Close the LPG outlet valve 2 amber 3 Start the engine and run the engine in the idling state until it stops naturally 1 2 02 book 11 ページ２００７年２月２２日木曜日午後４時４６分 LPG Device for 4Y E Engine Section 1 3 2 ...

Page 561: ... troubleshooting given in this manual Disassemble the regulator carefully or defects such as diaphragm or valve contacts may occur T N m kgf cm ft lbf Disassembly Procedure 1 Remove the regulator second cover and diaphragm Point 1 2 Remove the second valve ASSY Point 2 3 Remove the first cover first diaphragm and spring Point 3 4 Remove the first valve ASSY Point 4 5 Remove the slow solenoid valve...

Page 562: ...second valve ASSY is replaced with a new one 1 Insert the seat 2 Install the spring washer 3 Install the snap ring 4 Perform valve airtightness test in the state of step 3 above See page 2 13 5 Apply adhesive agent Castle Super Cement on the snap ring and spring washer Do not let the adhesive agent adhere on the valve seat portion Inspection Inspect the second valve lever height Check contact with...

Page 563: ... 4 4 N m 36 to 45 kgf cm 2 6 to 3 5 ft lbf Disassembly Since the diaphragm hook is engaged with the first valve lever move the diaphragm in the direction of the arrow in the illustration for removal Reassembly Engage the diaphragm hook onto the first valve lever tip Point 4 Disassembly 1 Remove the first valve ASSY 2 Disassemble the first valve Reassembly 1 Reassemble the first valve ASSY Note Rep...

Page 564: ...e SST and no contact when passing through the T side SST 09813 26600 71 Reference height 11 8 to 12 3 mm 0 47 to 0 48 in from the regulator contact surface 5 Using SSTs adjust the first valve lever height if it is not within the specified range SST 09814 22000 71 1 09815 22000 71 2 Note Do not apply force to the valve seat or the valve seat will be damaged Be sure to set the SST with a cut on the ...

Page 565: ...regulator on the vehicle be sure to adjust the VF voltage See page 2 18 Second Valve Airtightness Check 1 Temporarily install the second valve ASSY 2 Remove the idle adjusting screw and install the SSTs SST union tightening torque T 0 2 to 0 3 N m 2 to 3 kgf cm 0 14 to 0 19 ft lbf SST 09817 23600 71 1 09820 23600 71 2 3 Put the SST to the injector port SST 80339 76026 71 3 4 Apply 12 V to the slow...

Page 566: ...night 1 Open the valve between the LPG cylinder and hose The LPG is led to the regulator by this operation 2 Remove the idle adjust screw and install the SST SST 09817 23600 71 3 Apply 12 V to the main and slow solenoid valves 4 Using soapy water or aqueous solution of a neutral detergent check no gas leakage from each joint illustrated below 5 Be sure to wipe the liquid off after the leak check 0...

Page 567: ...ion timing Standard 7G BTDC 750 rpm 4 Adjust the initial advaced ignition timing 1 If the ignition timing is not as specified above loosen the two distributor clamp bolts and turn the distributor for adjustment When delayed Turn counterclockwise When advanced Turn clockwise 2 After adjustment tighten the bolts and check the ignition timing again 5 Check LPG regurator primary pressure 1 Install the...

Page 568: ...m 3 Measure the VF voltage while engine idling Standard 2 5 0 5 V 4 If the standard condition is not satisfied adjust the VF voltage into the specified range by turning the idle adjust screw of the regulator slowly Reference 5 After racing the engine several times check that the VF voltage is within the specified range Note Adjust the VF voltage to the 2 5 V as possible If VF voltage is 2 5 V but ...

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Page 570: ...FORE BEGINNING TROUBLESHOOTING 3 4 DIAGNOSIS SELF DIAGNOSIS FUNCTION 3 5 GENERAL 3 5 HOW TO INTERPRET THE FLOW CHARTS 3 6 ANALYZER 3 7 EXPLANATION 3 7 ANALYZER MENU SCREEN LIST 3 8 ABOUT TROUBLE SHOOTING BY ERROR CODES 3 9 TABLE OF DIAGNOSIS CODES 3 10 TROUBLESHOOTING BY SYMPTOMS 3 12 PARTS INSPECTION AND ADJUSTMENT 3 37 03 book 1 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3...

Page 571: ...ROCEDURE When any trouble occurs first inspect the connectors and wire harness of the related circuit according to the following procedure Continuity Inspection 1 Disconnect connectors at both ends of the relevant harness 2 Measure the resistance between corresponding terminals of the connectors at both ends Standard 10 or less Note Move the wire harness slightly from side to side and up and down ...

Page 572: ...y tug the connector or wire harness to make sure that it cannot be pulled out 4 Insert a male terminal same as that of the terminal to a female connector and check the extracting force Defective contact may exist at a terminal where the extracting force is less than that of other terminals Note If a problem such as rust or foreign matter on the terminal or a drop in the contact pressure of male fe...

Page 573: ...fluctuation in idle speed 4 Engine stalling a Directly after startup when cold when warm b During reduction of speed c After reduction of speed d Without warning e After engine running rough f When steering g During material handling h Can be re started immediately 5 Defective operational status a Insufficient power output b Hesitation c Surging swaying forward and backward during acceleration d K...

Page 574: ...d the spanner lamp flashes as a warning When this happens stop the vehicle quickly and check the error code 2 Diagnosis display system The diag memory has a system using the hour meter and tilt lever a system using the option display and a system using a plug in analyzer Here the display system using the hour meter and tilt lever is described 1 Open the diag memory menu from the main menu Refer to...

Page 575: ...r code 31 1 Inspect the VF voltage Standard 2 5 0 5 V OK To next procedure depending on result Single frames indicate measurement using a circuit tester and normal procedures Double frames indicate items that can be inspected using mask function 03 book 6 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 576: ...e analyzer functions include the following functions 1 Diagnosis memory function DIAG MEMORY The controller stores a maximum of the past 10 error codes diagnosis codes for faults that have occurred in the electrical system The diagnosis function is the function that reads these error codes and displays them on the display The error code and its time of occurrence as a key ON hour meter time are di...

Page 577: ...OXHT O2 sensor heater drive signal THA Intake temperature sensor voltage THW Coolant temperature sensor voltage PIM Intake pipe negative pressure sensor voltage VPA1 Accelerator sensor 1 voltage VPA2 Accelerator sensor 2 voltage PA Accelerator opening angle VTA1 Throttle position sensor 1 voltage VTA2 Throttle position sensor 2 voltage TA Throttle opening angle IM Electronic throttle motor current...

Page 578: ... the controller Even if an error code appears only temporarily and then disappears due to a defective contact the error code will still be stored 3 This volume contains a flow chart relating to symptoms that are particular to LPG When an error code is showing refer to 8FGU 8FDU15 32 8FGCU20 32 Repair Manual Vol 1 Pub No CU053 and 8FGCU15 18 Repair Manual Vol 2 Pub No CU055 and perform inspection a...

Page 579: ...normality 05 4 05 4 Blinking 4Y ECS Throttle position sensor 2 short abnormality 05 5 05 5 Blinking 4Y ECS Throttle position sensor offset abnormality 05 6 05 6 Blinking 4Y ECS Throttle position sensor out of range abnormality 06 1 06 1 Blinking 4Y ECS Throttle motor drive circuit open abnormality Limited speed of traveling and materials handling due to limited engine power output 06 2 06 2 Blinki...

Page 580: ...mality Partial limitation of the drive control function C4 1 C4 1 Blinking 4Y ECS Accelerator sensor 1 open abnormality Limited speed of traveling and materials handling due to limited engine power output ASC C4 2 C4 2 Blinking 4Y ECS Accelerator sensor 1 short abnormality ASC C4 3 C4 3 Blinking 4Y ECS Accelerator sensor 2 open abnormality ASC C4 4 C4 4 Blinking 4Y ECS Accelerator sensor 2 short a...

Page 581: ...lity Knocking 3 19 Hesitation 3 20 Insufficient power output 3 22 Engine stall Engine stalling in general 3 25 Engine stalling a short time after start up 3 28 Engine stalling when A C lights or defogger are turned on or when the steering is operated 3 30 Engine stalling on releasing the accelerator 3 31 LPG injector system 3 33 Air fuel ratio control motor system 3 35 Slow solenoid valve system 3...

Page 582: ...gulator and the LPG injector at the regulator side 2 Connect the SST to the LPG regulator and inspect the pressure during cranking SST 09820 23600 71 Standard The pressure rises SST Replace LPG filter NG OK Replace main solenoid valve OK NG Inspect ignition Inspect LPG filter Inspect main solenoid valve operating noise Inspect the operation sound of the solenoid valve when the ignition switch is t...

Page 583: ...adjustment 1 Repair or replace LPG regulator OK NG NG Defect of ignitor or engine ECU Adjust primary pressure of LPG regulator Refer to parts inspection and adjustment 2 Check starting ability NG OK Finish 03 book 14 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 584: ...g tar Drain plug Close Open Replace spark plug NG OK Inspect power balance Cause one cylinder at a time to misfire by removing its resistive cord and inspect for a drop in idle speed Inspect distributor cap and resistive cord Refer to parts inspection and adjustment 10 11 Only a particular cylinder NG OK Inspect spark plugs 1 Check that there is no obvious deposition 2 Inspect the plug gap Standar...

Page 585: ...nd resistive cord Refer to parts inspection and adjustment 10 11 OK Replace ignition coil NG Inspect ignition coil Refer to parts inspection and adjustment 12 OK Clean or replace LPG filter NG Inspect LPG filter OK Adjust primary pressure of LPG regulator Refer to parts inspection and adjustment 2 NG Inspect LPG regulator primary pressure Refer to parts inspection and adjustment 1 OK Repair LPG re...

Page 586: ...spect to see that the throttle PA value changes smoothly Standard PA value changes smoothly The idle speed remains low and does not change NG Check throttle system Clean or replace electric throttle OK Inspect LPG regulator Check LPG regulator for tar accumulation and drain plug loosening cock opening Standard Tar is not accumulated and plug is not loosened cock is not opened NG Tighten drain plug...

Page 587: ...ENT IDLE SPEED HIGH Probable cause Throttle valve return defect Air leakage VF voltage abnormality Note Inspect parts related to the items listed above 03 book 18 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 588: ...on chamber or on piston head portion Replace spark plug NG Inspect spark plugs 1 Check that there is no obvious deposition 2 Inspect the plug gap Standard 0 7 to 1 0 mm 0 028 to 0 039 in Adjust initial advance timing Refer to page 2 16 NG Check initial advance timing Refer to page 2 16 OK 03 book 19 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 589: ...e Operate the accelerator pedal and inspect to see that the throttle PA value changes smoothly Standard PA value changes smoothly Replace LPG filter NG Inspect LPG filter OK NG OK Inspect VF voltage Refer to parts inspection and adjustment 14 Inspect changes in VF voltage and OX value 0 or 1 at 1800 r min idle OFF Standard 2 5 0 5 V NG OK NG Adjust initial advance timing Inspect repair or replace ...

Page 590: ...parts inspection and adjustment 2 To injector system 3 33 NG Inspect injector operation and inspect for blockages Refer to parts inspection and adjustment 6 7 OK O2 Sensor system defect NG OK Replace distributor cap and resistive cord NG OK Replace ignition coil NG Inspect ignition coil Refer to parts inspection and adjustment 12 OK To air fuel ratio control motor system Refer to page 3 35 NG Insp...

Page 591: ... temperature THW Inspect LPG filter OK NG Replace LPG filter Inspect identify fault and repair cleaning system NG OK Repair vacuum piping NG Inspect vacuum piping of vacuum sensor Standard No hoses disconnected blocked or bent OK Adjust initial advance timing Refer to page 2 16 NG Inspect initial advance timing Refer to page 2 16 OK O2 Sensor system defect NG OK Inspect electronic throttle system ...

Page 592: ...and resistive cord NG Inspect distributor cap and resistive cord Refer to parts inspection and adjustment 10 11 OK Replace ignition coil NG Inspect ignition coil Refer to parts inspection and adjustment 12 OK Replace vacuum sensor OK During idling measure the voltage between PIM E2 of the engine ECU Standard 3 0 to 4 0 V For engine stop Disconnect the vacuum sensor connector and measure the voltag...

Page 593: ...ed winter only Inspect and repair blockages in fuel piping system OK Repair wire harness connectors NG Inspect wire harness and connectors between engine ECU and vacuum sensor Refer to the wiring diagram at the back of the book NG Replace engine ECU OK Adjust primary pressure of LPG regulator Refer to parts inspection and adjustment 2 NG Standard value or below OK NG Finish 03 book 24 ページ２００７年２月２...

Page 594: ...harge warning lamp Light comes on during engine stall Check the check engine warning light Inspect and repair charging system Light comes on before engine stall Inspect LPG filter Clean or replace LPG filter Light comes on during engine stall Stays off Inspect the check engine warning light by short circuiting between the engine ECU MZL E1 terminals Standard Turns on NG Inspect and repair the chec...

Page 595: ...oltage Refer to parts inspection and adjustment 14 NG OK OK NG LPG regulator defect or unsuitable fuel used winter only Inspect slow solenoid valve Refer to parts inspection and adjustment 4 To slow solenoid valve system Refer to page 3 36 NG OK Inspect injector system operation and inspect for blockages Refer to parts inspection and adjustment 6 7 To injector system Refer to page 3 33 NG Non oper...

Page 596: ...inter only OK NG Outside standard value Adjust LPG regulator primary pressure Refer to parts inspection and adjustment 2 Inspect and repair blockages in fuel piping system NG OK Check that the engine restarts OK Finish Repair LPG regulator Refer to section 2 NG Airtightness defect 03 book 27 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 597: ...d repair the charger Replace main solenoid valve Inspect the charge warning light Inspect LPG injector piping internal pressure 1 Disconnect the fuel hose between the LPG regulator and the LPG injector at the regulator side 2 Connect the SST to the LPG regulator and inspect the pressure during cranking SST 09820 23600 71 Standard The pressure rises SST Repair or replace LPG regulator See section 2...

Page 598: ...y pressure of LPG regulator Refer to parts inspection and adjustment 2 NG Inspect LPG regulator primary pressure Refer to parts inspection and adjustment 1 OK Unsuitable fuel used Engine ECU defect 0 V 2 50 V or 5 0 V will be displayed when the plug in analyzer is used for the inspection Inspect repair or replace the feedback related components injectors O2 sensor etc and the relevant wire harness...

Page 599: ...ack related components injectors O2 sensor etc and the relevant wire harnesses and connectors Refer to parts inspection and adjustment Repair or replace NG Inspect inner vent system 1 Check inner vent tube for damage bent or disconnection 2 Check resonator for damage Charge or replace the battery NG Inspect battery voltage BATT Standard 10 to 14 V OK Adjust initial advance timing Refer to page 2 1...

Page 600: ...parts inspection and adjustment 12 YES Does knocking occur on racing of the engine NG Repair air leak NG Inspect the air intake system for air leaks OK Replace distributor pickup coil OK Inspect wire harness and connectors between engine ECU pickup coil Refer to wiring diagram NG Repair wire harness and connectors OK Inspect or replace engine ECU NO NG Replace main solenoid valve NG Inspect main s...

Page 601: ...inspect for blockages Refer to parts inspection and adjustment 6 7 OK Adjust LPG regulator primary pressure NG Inspect LPG regulator primary pressure Refer to parts inspection and adjustment 1 OK Replace LPG filter NG Inspect LPG filter 03 book 32 ページ２００７年２月２２日木曜日午後４時４７分 LPG Device for 4Y E Engine Section 1 3 3 ...

Page 602: ...ction and adjustment 6 OK Perform startup operation inspection and idle operation inspection of injectors Refer to parts inspection and adjustment 6 Inspect or replace engine ECU Inspect and repair the STA system OK To A NG Only during startup To B NG Measure the voltage between RES E1 terminals of the engine ECU Standard 10 to 14 V NG OK Inspect LPG injectors Refer to parts inspection and adjustm...

Page 603: ...een connector 1 terminal on vehicle wire harness side and body earth Standard 10 to 14 V Battery voltage OK Inspect and repair injector power supply system NG Repair wire harness and connectors NG Measure the voltage between the THW E1 terminals of the engine ECU Standard 4 5 to 5 5 V OK Replace engine ECU NG Inspect the coolant temperature sensor Refer to parts inspection and adjustment 9 NG Repl...

Page 604: ...f the engine control computer Standard 0 5 to 3 5 V When cold 0 2 to 1 0 V When warm OK NG Replace intake temperature sensor NG Inspect intake temperature sensor Refer to parts inspection and adjustment 8 OK Repair wire harness and connectors Inspect wire harness and connectors between the engine ECU and intake temperature sensor Refer to the wiring diagram at the back of the book OK Inspect or re...

Page 605: ...ect the voltage between the connector terminal 2 on the wire harness side and body earth when the ignition switch is turned ON Standard Momentarily 10 to 14 V Battery voltage OK Inspect and repair the power supply system for the slow solenoid valve NG Repair wire harness and connectors NG Inspect voltage between connector terminal 2 and terminal 1 on the slow solenoid valve wire harness side 1 Dis...

Page 606: ...he tamper proof ring Refer to 2 5 1 2 Turn the ignition switch ON 3 Loosen the adjust screw nut and adjust the primary pressure by turning the screw Standard 24 5 to 34 3 kPa 0 25 to 0 35 kgf cm2 3 6 to 5 0 psi 4 Adjust the VF voltage See step 14 3 Inspect main solenoid valve 1 Turn the ignition switch ON 2 Check the solenoid valve operating sound Standard Solenoid valve makes operating sound 3 Di...

Page 607: ...nd scope on the air fuel ratio control motor 3 Check the air fuel ratio control motor operating sound Standard Motor makes click sound for several seconds 4 Remove the air fuel ratio control motor Note Do not disconnect the connector 5 Put masking tape on the contact surface with the adaptor to prevent air from blowing 6 Measure the length A when the engine stops and is idling Standard 13 to 14 mm...

Page 608: ...ement Standard The needle valve gradually moves to the CLOSE side c Apply battery positive voltage to the terminal 5 negative voltage to terminals in the order of 1 3 4 and 6 d Check that the needle valve movement Standard The needle valve gradually moves to the OPEN side Notice Do net apply excessive force to the needle valve portion 1 2 3 4 5 6 Terminals Resistance 2 1 3 15 to 25 at cold temp 20...

Page 609: ... the idle condition when disconnecting the injector connector Standard The engine idle speed decreases when disconnecting the connector 6 Check air tightness of the LPG injector a Disconnect the LPG injector connector and remove the injector with the hose connected Note Do not disconnect the injector hose b Check for the leakage of LPG from the injector while turning the ignition switch ON and OFF...

Page 610: ... within the range of 20 mm 0 79 in 8 Inspect air temperature sensor 1 Remove the air temperature sensor 2 Measure the resistance of the sensor Standard 9 Inspect coolant temperature sensor 1 Remove the coolant temperature sensor 2 Measure the resistance of the sensor Standard Temperature Resistance 20qC 68qF 2 to 3 k 80qC 176qF 0 2 to 0 4 k Temperature Resistance 20qC 68qF 2 to 3 k 80qC 176qF 0 2 ...

Page 611: ...e distributor cap 3 Remove the distributor rotor 4 Remove the dust proof cover 5 Inspect the primary coil a Measure the resistance between the terminals A and C Standard 6 Inspect the secondary coil a Measure the resistance between the terminals B and C Standard 7 Inspect the insulation of the ignition coils a Measure the resistance between the terminal A and body ground D Standard 1 M or higher C...

Page 612: ... at 1800 rpm Standard The OX value alternates more than 4 times between 0 and 1 for 10 seconds 3 Measure the VF voltage while engine idling Standard 2 5 0 5 V 4 If the VF voltage is not within the specified range adjust the VF voltage to the specified value by turning the idle adjust screw slowly Reference 5 After racing the engine several times check that the VF voltage is within the specified ra...

Page 613: ...ndard 1000 to 1373 kPa 10 2 to 14 0 kgf cm2 145 to 199 psi Note The difference between each cylinder is within 196 kPa 2 0 kgf cm2 28 psi d If the cylinder compression in 1 or more cylinders is low pour a small amount of engine oil into the spark plug hole and perform steps a through c for the cylinders with low compression If the compression pressure increases piston rings and or cylinder bore ma...

Page 614: ... 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E APPENDIX Page SST LIST 4 2 SERVICE STANDARDS 4 4 WIRING DIAGRAM 4 5 04 book 1 ページ２００７年２月２２日木曜日午後４時４８分 LPG Device for 4Y E Engine Section 1 3 4 ...

Page 615: ...tion 2 3 09238 13130 71 Sub harness 09814 22000 71 Tool 09815 22000 71 Tool 09813 26600 71 Gauge 80339 76026 71 Automatic choke pipe plug 09817 23600 71 Union 09819 22000 71 Gauge 04 book 2 ページ２００７年２月２２日木曜日午後４時４８分 LPG Device for 4Y E Engine Section 1 3 4 ...

Page 616: ...17 18 19 20 21 E Illustration Part number Part name Section 2 3 09819 23600 71 Gauge 23627 22000 71 Spring 09820 23600 71 Tester SUB ASSY 09240 26600 71 Plug in Analyzer 04 book 3 ページ２００７年２月２２日木曜日午後４時４８分 LPG Device for 4Y E Engine Section 1 3 4 ...

Page 617: ...eight From first cover contact surface mm in 11 8 to 12 3 0 47 to 0 48 Second valve lever height From second cover contact surface mm in 0 to 2 0 0 to 0 08 Tightening Torque T N m kgf cm ft lbf Regulator first cover set screw 3 5 to 4 4 36 to 45 2 6 to 3 5 First valve set screw 3 5 to 4 4 36 to 45 2 6 to 3 5 First spring adjuster lock nut 3 5 to 4 4 36 to 45 2 6 to 3 5 Regulator second cover set s...

Page 618: ...4 5 WIRING DIAGRAM ...

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