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SERVICE INFORMATION

SPECIAL TOOLS (CONT.2)

LLUSTRATION

TOOL NO.

TOOL NAME

5-8840-0259-0

Nozzle Holder Wrench (4JG2 only)

5-8840-0253-0 (J-22700)

Fuel Filter Wrench

5-8840-2362-0

Front Oil Seal Remover (4JG2, Belt Drive only)

5-8840-2361-0

Front Oil Seal Installer (4JG2, Belt Drive only)

5-8840-2360-0

Rear Oil Seal Remover

5-8840-2359-0

Rear Oil Seal Installer

5-8840-2040-0

Cylinder Liner Installer (4JB1 only)

5-8840-2313-0

Cylinder Liner Installer (4JG2 only)

5-8840-2039-0

Cylinder Liner Remover (4JB1 only)

5-8840-2304-0

Cylinder Liner Remover Ankle (4JG2 only)

5-8840-2000-0

Pilot Bearing Remover

5-8840-0019-0

Sliding Hammer

5-8522-0024-0

Pilot Bearing Installer

Содержание 4JB1

Страница 1: ...r starter relay Repair or replace the magnetic switch Starter motor Defective starter motor Repair or replace the starter motor 2 STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Loose battery cab...

Страница 2: ...Defective feed pump Repair or replace the feed pump FUEL IS BEING DELIVERED TO THE INJECTION PUMP Use of the wrong fuel Use the correct fuel Water particles in the fuel Change the fuel Fuel Fuel syste...

Страница 3: ...timer Replace the quick on start timer Glow plug indicator light turns on the 0 3 seconds Defective quick on start timer Replace the quick on start timer Return the starter switch to the ON position...

Страница 4: ...properly adjusted Adjust the idling Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed control device Accelerator control system Accelerator control s...

Страница 5: ...the valve clearance Compression pressure Blown out cylinder head gasket Worn cylinder liner Piston ring sticking Replace the related parts 3 INSUFFICIENT POWER Checkpoint Possible cause Correction Air...

Страница 6: ...epair or replace the injection pump timer Weak governor spring Replace the governor spring Injection pump Worn plunger Replace the plunger assembly Compression pressure Blown out cylinder head gasket...

Страница 7: ...is fuel drippage after fuel injection Replace the delivery valve Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Compression pressure Blown out cylinder head gasket Wor...

Страница 8: ...tat Defective thermostat Replace the thermostat Cooling system Cooling system clogged by foreign material Clean the foreign material from the cooling system Fuel injection timing Fuel injection timing...

Страница 9: ...engine oil Replace the engine oil Correct the engine oil volume Oil pressure gauge or unit Oil pressure indicator light Defective oil pressure gauge or unit Defective indicator light Repair or replac...

Страница 10: ...pipes Broken exhaust pipes Tighten the exhaust pipe connections Replace the exhaust pipes Injection nozzles and or glow plugs Loose injection nozzles and or glow plugs Replace the washers Tighten the...

Страница 11: ...r damaged crankshaft and or thrust bearings Replace the crankshaft and or the thrust bearings Crankshaft and connecting rod bearings Worn or damaged crankshaft and or connecting rod bearings Replace t...

Страница 12: ...ty radiator cap Replace Low engine oil level or use of improper engine oil Replenish or change oil Replenish Damaged cylinder head gasket Replace Clogged exhaust system Clean exhaust system or replace...

Страница 13: ...ON HEAD LAMP AND STARTER SWITCH HEAD LAMP DOES NOT COME ON OR IT IS EXTREMELY DARK a LACK OF BATTERY CHARGING b SHORT CIRCUIT IN STARTER OIL c FAULTY STARTER PARTS a DISCONNECT STARTER CIRCUIT b DISCO...

Страница 14: ...CONDITION CHECK IF VOLTAGE OF CONNECTOR 3BW ON MAGNETIC SWITCH OF RESTART RELAY IS NORMAL YES NO DISCONNECTION OR FAULTY CONNECTION BETWEEN STARTER SWITCH AND MAGNETIC SWITCH CHECK IF VOLTAGE IS PRES...

Страница 15: ...YES YES NO REPAIR OR PINION SLIDING PART DOES NOT MOVE MAGNETIC SWITCH OR COIL IS DISCONNECTED OR BURNED OUT REPAIR OR REPLACE STARTER CHECK IF INDICATOR LAMP ON METER COMES ON NORMALLY YES NO DISCON...

Страница 16: ...NOT RUN CHECK GROUND CABLE YES NO REPAIR OR REPLACE GROUND CABLE FAULTY CONNECTION OF BRUSH AND COMMUTATOR BURNED OUT MAGNETIC STARTER SWITCH REPAIR OR REPLACE STARTER DISCONNECTION OR DAMAGE OF FIEL...

Страница 17: ...OP THOUGH STARTER SWITCH IS RETURNED TO ON FROM START REPLACE STARTER SWITCH DISCONNECTED STARTER SWITCH WIRING CONNECTOR AND CHECK STARTER SWITCH OPERATION KEY POSITION BATTERY B1 IGNITION IG1 BATTER...

Страница 18: ...pe and hose Restricted Clean or replace Compressor Intake manifold Loose Leaking Repair Exhaust manifold turbine inlet Loose Leaking Repair Exhaust piping and silencers Restricted Clean or replace Air...

Страница 19: ...int Trouble Cause Countermeasure Compressor wheel Impact damage Replace Turbine wheel Impact damage Replace Carbon build up Replace Rotating assembly Dragging or seized Replace Continued from the prev...

Страница 20: ...r replace Turbocharger oil seal Leakage Replace Turbocharger oil drain pipe Restricted Repair or replace Air breather Restricted Clean Boost compensator Injection pump Defective Repair or replace Comp...

Страница 21: ...SERVICE INFORMATION 00 23 Checkpoint Trouble Cause Countermeasure Center housing oil drain passage Restricted Clean or replace Continued from the previous page NG OK...

Страница 22: ...ost compensator Injection pump Defective Repair or replace Turbocharger oil seal Leakage Replace Turbocharger oil drain pipe Restricted Clean or replace Turbine wheel Impact damage Replace Compressor...

Страница 23: ...SERVICE INFORMATION 00 25 Checkpoint Trouble Cause Countermeasure Center housing oil drain passage Restricted Clean or replace Continued from the previous page NG OK...

Страница 24: ...r Intake and exhaust system gaskets Damaged Replace Turbocharger rotating parts Rough rotation Replace Rubbing against housing Repair or replace Damaged Replace Rubbing against housing Repair or repla...

Страница 25: ...vel Too low Correct Contaminated Replace oil Turbocharger oil feed pipe Restricted Repair or replace Turbine housing Carbon deposits Clean Compressor housing Dirty Clean Turbine shaft bearings Worn Re...

Страница 26: ...ange Wrong grade or type Change Turbocharger oil feed pipe Restricted Clean or replace Turbocharger oil seal Defective Replace Center housing oil drain passage Restricted Clean or replace Turbine shaf...

Страница 27: ...l filters have on oil cooler It is then delivered to the vital parts of the engine from the cylinder body oil gallery 4JB1 4JB1TC 4JG2 Oil Filter Oil Cooler kPa Kg cm 2 psi Oil filter relief valve ope...

Страница 28: ...ion pressure kPa kg cm 2 psi 3 038 31 441 3 334 34 483 8 For EC 2 363 24 1 531 Engine weight Dry N kg lb Approximately 2 245 229 505 4JB1 2 511 256 564 4JB1T 4JB1TC Approximately 2 403 245 540 Fuel in...

Страница 29: ...Water cooled Fuel system Injection pump type Bosch distributor Governor type Mechanical Partially variable speed For EC Variable speed Injection nozzle type Hole Pinttle Injection nozzle kPa kg cm 2...

Страница 30: ...en C F wax pellet with jiggle valve Without jiggle valve Thailand only 82 180 95 203 Coolant total capacity Iit Imp qt US qt 10 8 80 10 57 For EC 7 3 6 42 7 71 Starting System Manufacturer DENSO Engin...

Страница 31: ...LR150 449B DENSO Rated voltage V 12 12 Rated output A 50 40 Rotating direction As viewed from pulley Clockwise Clockwise Pulley effective diameter mm in 80 3 15 82 3 23 Weight with pump kg lb 6 0 13...

Страница 32: ...alve Spring Free height Squareness Spring tension N kg lb 48 0 1 891 296 30 2 66 4 47 10 1 856 1 7 0 067 257 9 26 3 57 9 At installed height 38 9 1 531 7 946 7 961 0 3128 0 3134 7 921 7 936 0 3118 0 3...

Страница 33: ...de diameter Oil clearance Between rocker arm and rocker shaft Rocker shaft runout 18 98 19 00 0 7472 0 7480 19 036 19 060 0 7494 0 7504 0 06 0 08 0 00235 0 00315 18 90 0 7440 19 10 0 7520 0 10 0 004 0...

Страница 34: ...0 0 125 0 0035 0 0049 0 050 0 075 0 0020 0 0030 1 5 0 0591 1 5 0 0591 1 5 0 0591 0 15 0 0059 Oil 0 03 0 07 0 0012 0 0028 0 15 0 0059 Piston pin diameter 33 995 34 000 1 3384 1 3386 30 995 31 000 1 220...

Страница 35: ...e Upper surface of the cylinder block 0 20 0 0079 Cylinder bore diameter 97 000 97 040 95 011 95 040 3 8189 3 7406 3 8205 3 7417 Cylinder liner projection 0 0 0 1 0 00 0 0039 Cylinder liner inside 95...

Страница 36: ...n of the element Dust fouled Element Rotate the element with your hand while applying compressed air to the inside of the element This will blow the dust free Compressed air pressure kPa kg cm 2 Psi 3...

Страница 37: ...ment Replacement Procedure 1 Loosen the used oil filter by turning it counterclockwise with the filter wrench 2 Clean the oil filter fitting face This will allow the new oil filter to seat properly 3...

Страница 38: ...ilter Wrench 5 8840 0253 0 J 22700 5 Loosen the bleeder plug on the injection pump overflow valve 6 Operate the priming pump until fuel begins to flow from the fuel filter 7 Retighten the bleeder plug...

Страница 39: ...on the injection pump overflow valve 2 Operate the priming pump until fuel mixed with foam flows from the bleeder screw 3 Tighten the bleeder screw 4 Operate the priming pump several times and check...

Страница 40: ...he system from completely filling up 4 Keep a filling rate of 9 liter min or less Filling over this maximum rate may force air inside the engine and radiator And also the coolant overflow will increas...

Страница 41: ...ntain coolant pressure in the cooling system at 1 05 kg cm 2 15 psi 103 kPa Check the radiator filler cap with a radiator filler cap tester The radiator filler cap must be replaced if it fails to hold...

Страница 42: ...ey Drive Belt Move the idler pulley as required to adjust the compressor drive belt tension If the vehicle is equipped with power steering move the oil pump as required Depress the drive belt mid port...

Страница 43: ...ection pump idling set bolt 2 Adjust the idling speed to the specified range by turning the idling set bolt 3 Lock the idling set bolt with the idling set bolt lock nut 4 Check that the idling control...

Страница 44: ...nal positions without fail VALVE CLEARANCE ADJUSTMENT 1 Bring the piston in either the No 1 cylinder or the No 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaf...

Страница 45: ...ck that the notched line on the injection pump flange is aligned with the front plate or the timing gear case notched line 2 Bring the piston in the No cylinder to TDC 1 on the compression stroke by t...

Страница 46: ...ming is outside the specified range continue with the following steps 11 Loosen the injection pump fixing nuts and bracket bolts 12 Adjust the injection pump setting angle When large than standard val...

Страница 47: ...3 038 31 441 2 157 22 313 4JG2 3 334 34 484 2 452 25 356 5 Repeat the procedure Steps 3 and 4 for the remaining cylinders If the measured value is less than the specified limit refer to Troubleshooti...

Страница 48: ...licking sound within seven seconds after the starter switch is turned on 3 Measure the glow plug terminal voltage with a circuit tester immediately after turning the starter switch to the ON position...

Страница 49: ...SERVICE INFORMATION 00 51 FIXING TORQUE CYLINDER HEAD COVER CYLINDER HEAD ROCKER SHAFT BRAKER N m kg m lb ft 011LX002 tif...

Страница 50: ...00 52 SERVICE INFORMATION Crankshaft Bearing Cap Connecting Rod Bearing Cap Crankshaft Damper Pulley Flywheel Oil Pan N m kg m lb ft 0051 1 tif...

Страница 51: ...SERVICE INFORMATION 00 53 Timing Pulley Housing Timing Pulley Timing Gear Camshaft Oil Seal Retainer N m kg m lb ft 014LX001 tif...

Страница 52: ...00 54 SERVICE INFORMATION Cooling System and Lubrication System N m kg m lb ft...

Страница 53: ...SERVICE INFORMATION 00 55 Intake Manifold Exhaust Manifold Exhaust Pipe N m kg m lb ft 150LX004 tif...

Страница 54: ...00 56 SERVICE INFORMATION N m kg m lb ft 036LX003 tif...

Страница 55: ...SERVICE INFORMATION 00 57 Engine Electricals N m kg m lb ft 0056 1 tif...

Страница 56: ...00 58 SERVICE INFORMATION Engine Fuel N m kg m lb ft 0057 1 tif...

Страница 57: ...SERVICE INFORMATION 00 59 Engine Mounting Bracket N m kg m lb ft 0058 1 tif...

Страница 58: ...8840 0202 0 Oil Filter Wrench 106 0 mm 4 2 in 5 8840 2209 0 Oil Filter Wrench 100 6 mm 4 0 in 9 8523 1423 0 J 29760 Valve Spring Compressor 5 8840 2033 0 Oil Seal Installer 5 8840 9018 0 Piston Ring...

Страница 59: ...531 7002 0 Gauge Adapter 5 8840 0145 0 Measuring Device 5 8522 0024 0 Crankshaft Timing Pulley Installer 4JG2 Belt Drive only 5 8840 0266 0 Angle Gauge 5 8840 9016 0 Injection Nozzle Tester 5 8840 203...

Страница 60: ...2361 0 Front Oil Seal Installer 4JG2 Belt Drive only 5 8840 2360 0 Rear Oil Seal Remover 5 8840 2359 0 Rear Oil Seal Installer 5 8840 2040 0 Cylinder Liner Installer 4JB1 only 5 8840 2313 0 Cylinder L...

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