804

@TOYOTA
1HD-FT
ENGINE
REPAIR MANUAL
Jan., 1995
..
Pub. No. RM437E
FOREWORD
This repair manual has been prepared to provide information
covering general service repairs for the 1HD-FT engine
equipped in the TQYOTA LAND CRUISER.
Applicable models:
HDJ80 series
Please note that the publications below have also been prepared as relevant service manuals for the components and
system in this engine.
Manual Name
0
1HDFT Engine Emission Control Repair

Manual
Pub. No.
ERM111E
All information in this manual is based on the latest product information at the time of publication. However, specifications
and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
1995 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be
reproduced or copied, in whole or in part,
without the written permission of Toyota
Motor Corporation.
INTRODUCTION
ENGINE
STARTING SYSTEM
CHARGING SYSTEM
~=
IN-1
INTRODUCTION
HOW TO USE THIS MANUAL
IN- 2
IDENTIFICATION INFORMATION
IN- 4
GENERAL REPAIR INSTRUCTIONS
IN- 5
ABBREVIATIONS USED IN THIS

MANUAL
IN- 8
STANDARD BOLT TORQUE

SPECIFICATIONS .................................. IN- 9
IN-2
INTROOUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
__ n
INDEX
IN
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist you in finding your way through the manual. the Section Title and major heading are
given at the top of every page.
GENERAL DESCRIPTION
At the beginning of each section. a General Description is given that pertains to all repaIr
operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause.
PREPARATION
Preparation lists the SST (Special Service Tools). recommended tools. equipment. lubricant and
SSM (Special Service Materials) which should be prepared before beginning the operation and
explains the purpose of each one.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
Plug
0'
R
riven otor
Gasket
~J r"'""
~--
Timing Gear Case

Non-reusable part
IN-3
INTROOUCTION - HOW TO USE THIS MANUAL
The
procedures are presented in a step-by-step format:

The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as
specifications and warnings.
Example:
Task heading:
6_
what to do
INSTALL CRANKSHAFT PULLEY

(a) Using SST, install the bolt.
SST 0921 ~54015 (90119-~' 26)
Illustration:
what to do and where
Set part No.
Component part No.
Detailed text:
how to do task
(b) Install the b".

Torque: 30 Nm (310 kgf.cm. 22 ft.lbf)
"
Specification
This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.
REFERENCES
References have been kept to a minimum. However. when they are required you are given the
page to refer to.
SPECIFICATlONS
Specifications are presented in bold type throughout the text where needed. You never have to
leave the procedure to look up your specifications. They are also found at the end of each section.
for quick reference.
IN-4
INTRODUCTION - IDENTIFICATION INFORMATION
CAUTIONS, NOTICES, HINTS:
IN
CAUTIONS are presented in bold type. and indicate there is a possibility of injury to you or
other people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the
components being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional
information to help you perform the repair efficiently.
SI UNIT
The UNITS given in this manual are primarily expressed according to the 51 UNIT(lnternational
System of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 Nm (310 kgf.cm. 22 ftlbf)
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
_.-
The engine serial number is stamped on the engine

block as shown.
..
"'
INTROOUCTION - GENERAL REPAIR INSTRUCTIONS
GENERAL REPAIR INSTRUCTIONS
IN-5
--,
1.
Use fender. seat and floor covers to keep the vehicle

clean and prevent damage.
2.
During disassembly, keep parts in the appropriate
3.
Observe the following:

(a) Before performing electrical work. disconnect
order to facilitate reassembly.
(b)
the negative cable from the battery terminal.

If it is necessary to disconnect the battery for
inspection or repair. always disconnect the cable
4.
5.
6.
Seal lock Adhesive

INOO:Ml
from the negative (-) terminal which is grounded

to the vehicle body.
(c) To prevent damage to the battery terminal post.
loosen the terminal nut and raise the cable straight up without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals with a clean shop rag. Do not scrape them
with a file or other abrasive objects.
(e) Install the cable terminal to the battery post with
the nut loose. and tighten the nut after installa
tion. Do not use a hammer to tap the terminal
onto the post.
(f) Be sure the cover for the positive (+) terminal is
properly in place.
Check hose and wiring connectors to make sure that
they are secure and correct.
Non-reusable parts
(a) Always replace cotter pins. gaskets. 0 -rings and
oil seals etc. with new ones.
(b) Non-reusable parts are indicated in the component illustrations by the .... symbol.
Pre coated parts
Pre coated parts are bolts and nuts. etc. that are
coated with a seal lock adhesive at the factory.
(a) If a pre coated part is retightened. loosened or
caused to move in any way. it must be recoated
with the specified adhesive.
(b) When reusing precoated parts. clean off the old
adhesive and dry with compressed air. Then
apply the specified seal lock adhesive to the bolt.
nut or threads.
(c) Precoated parts are indicated in the component
illustrations by the
symbol.
When necessary. use a sealer on gaskets to prevent
leaks.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
"'*.
7.
8.
IN-6
INTRODUCTION - GENERAL REPAIR INSTRUCTIONS
9.
Use of special service tools (SSn and special service

materials (SSM) may be required. depending on the
nature of the repair. Be sure to use SST and SSM

where specified and follow the proper work procedure. A list of SST and SSM can be found in the
preparation part at the front of each section in this

manual.
IN
10. When replacing fuses. be sure the new fuse has the
Fu",
EQual Amperage
10 )
correct amperage rating. 00 NOT exceed the rating or

use one with a lower rating.
Rali~
10
illustration
Abbreviation
Symbol
~
IE559-t
FUSE
FUSE
MEDIUM CURRENT FUSE
M.fUSE
HIGH CURRENT FUSE
HFUSE
FUSIBLE LINK
FL
-R-..,..
CIRCUIT BREAKER
CB
..,
85517
tnSM
11. Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at

the proper locations.
(a) If the vehicle is to be jacked up only at the front
or rear end. be sure to block the wheels at the
opposite end in order to ensure safety.
INTROOUCTION - GENERAL REPAIR INSTRUCTIONS
IN.'
(b)
WRONG
After the vehicle is jacked up. be sure to support

it on stands. It is extremely dangerous to do any
work on a vehicle raised on a jack alone. even for
a small job that can be finished quickly.
12. Observe the following precautions to avoid damage to
the parts:
(a) Do not open the cover or case of the EeU unless
absolutely necessary. (If the Ie terminals are touched. the Ie may be destroyed by static electricity.)
(bl To disconnect vacuum hoses. pull on the end. not
the middle of the hose.
Ie) To pull apart electrical connectors. pull on the
CORRECT
connector itself. not the wires.

(d)
""'"
(e)
(f)
WRONG
CORRECT
(g)
(h)
IH025'
Example
Be careful not to drop electrical components.

such as sensors or relays. If they are dropped on
a hard floor. they should be replaced and not
reused.
When steam cleaning an engine. protect the dis
tributor. air filter. and VCV from water.
Never use an impact wrench to remove or install
temperature switches or temperature sensors.
When checking continuity at the wire connector.
insert the tester probe carefully to prevent termi
nals from bending.
When using a vacuum gauge. never force the
hose onto a connector that is too large. Use a
step-down adapter instead. Once the hose has
been stretched. it may leak.
13. Tag hoses before disconnecting them:

(a) When disconnecting vacuum hoses. use tags to
identify how they should be reconnected.
(b) After completing a job. double check that the
vacuum hoses are properly connected. A label
under the hood shows the proper layout.
14. Unless otherwise stated. all resistance is measured at
an ambient temperature of 20C (68F). Because the
resistance may be outside specifications if measured
at high temperatures immediately after the vehicle
has been running. measurements should be made
when the engine has cooled down.
IN-8
INTROOUCTION - A88REVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
, IN
_ _M
A/C
ACV
Air Control V,lve
ACSO
Automatic Cold Stnt Device
Air Conditioner
Approx.
Approximately
AfT
BACS
BOC
ECU
EGR
Automatic T'.n111niaaion
Boo.t and "'tiudl Coml*'Ntion Stopper

Bottom Deed C.nter
Engine Control Unit
Exhlu.t Gil Rlcireul.tion
FIPG
Formed in Pl.e. Gllket
LHO
LST
MP
Left
MfT
OHC
O/S
PCS
PCV
PS
RHO
Hand Driv.
Laid Sensing Tim.r

Multipurpou
Menu.l Tran'minion
Ova, He.d Camahaft
Oversized
POWI' Control SY5tlm
po,itiva Cr.nke Ventil.tion

POWI, St ring
Right-Hand Drive
SICS
Starting Injection Control Syttem
SSM
SST
STO
SW
TOC
Special Service Mllerials
TEMP.
Tlmperalur.
U/S
VSV
Under,ill
w/
wi.
With
Special Sel"t/iCi Tool.

Stand.rd
Switch
Top o.,d Clntlr
Vacuum SwitChing V.IIII
Without
IN-9
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
--.
HOW TO DETERMINE BOLT STRENGTH

Mark
---------------
Hexagon
head bolt
Bolt
Class
456-
rOr'head No. 7BB-
'011-
Hexagon
flange bolt
wI washer
hexagon bolt
4T
Mark
---------
Class
Stud bolt
5T
6T
7T
~ No mark
BT
4T
9T
lOT
,n
No mark
4T
Nom,,'
4T
~ Grooved
6T
Hexagon
head bolt
Hexagon
flange bolt
wI washer
hexagon bolt
Hexagon
head bolt
Hexagon
head bolt
OJ
0
0
0
2
protruding
lines
5T
2
protruding
lines
6T
3
protruding
7T
lines
4
protruding
lines
BT
Welded bolt
4T
IN-IO
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Class
Diamete'
mm
Pitch
mm
N'm
IN
4T
6
8
10
12
14
16
1
, .25
1.25
1.25
1.5
1.5
5
12.5
26
47
74
115
6
8
10
12
'4
16
1
1.25
6
8
10
12
14
16
1
1.25
1.5
1.5
6
8
10
12
14
16
1
, .25
1.25
1.25
1.5
1.5
52
95
145
230
8
10
12
1.25
1.25
1.25
29
61
110
9T
8
10
12
1.25
1.25
, .25
,OT
8
10
12
8
10
12
1.25
5T
6T
7T
8T
11T
1.25
1.25
1.5
1.5
6.5
15.5
32
59
91
140
Hexagon h.ad bot!

kif-em
ftlbf
55
130
260
480
760
1,150
65
160
330
600
930
48 in.lbf
9
19
35
55
83
56 in.-lbf
12
24
43
67
101
Hexagon flange
N'm
kgl'em
6
14
29
53
84
60
145
290
540
850
7.5
17.5
36
65
100
75
175
360
670
1.050
bolt
ftlbf
52 in.lbf
10
21
39
61
65 in.lbf
13
26
48
76
9
21
44
80
125
90
210
440
810
1.250
8
19
38
70
108
166
12
28
58
105
'65
120
290
590
1.050
1,700
9
21
43
76
123
33
68
120
330
690
1.100
22
45
80
1,250
24
50
90
34
70
125
340
710
1.300
25
51
94
37
78
'40
380
790
1.450
27
57
105
1.25
1.25
1.25
38
78
140
390
600
28
58
105
42
88
155
430
890
1.600
31
64
116
1.25
42
67
155
31
64
116
47
97
175
480
990
35
1,800
130
, .25
1.25
1.25
8
19
39
71
110
170
10.5
25
1,400
80
195
400
730
1,100
1,750
110
260
530
970
1,500
2,300
300
620
1,450
430
890
1,600
69 in.lbf
14
29
53
80
127
78 in..lbf
'5
32
59
90
72
EG'
ENGINE
ENGINE MECHANICAL
EG- 1
LUBRICATION SYSTEM
EG-191
PREPARATION
EG- 2
PREPARATION
EG-l92
TROUBLESHOOTING
EG- 6
OIL PRESSURE CHECK
EG-193
OIL AND FILTER REPLACEMENT
EG-l93
EG - 11
OIL PUMP
EG-195
EG-12
OIL COOLER
EG- 203
OIL NOZZLE
EG- 208
AIR FILTER INSPECTION AND
CLEANING
COMPRESSION CHECK
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT EG-14
INJECTION TIMING INSPECTION AND
ADJUSTMENT EG- 15
tOLE SPEED AND MAXIMUM SPEED
INSPECTION AND ADJUSTMENT
EG- 17
PS IDLE-UP SPEED INSPECTION AND

ADJUSTMENT (M/T) EG- 19
Ale
IDLE - UP SPEED INSPECTION AND

ADJUSTMENT .. .. ..
.. EG- 20
TIMING BELT
EG- 21
TIMING GEAR
EG- 28
CYLINDER HEAD
EG- 38
CYLINDER BLOCK
EG- 64
SERVICE SPECiFiCATIONS .. .. EG- 89
TURBOCHARGER SYSTEM
EG- 93
PREPARATION
EG- 93
PRECAUTION
EG- 94
TROUBLESHOOTING
EG- 95
TURBOCHARGER
EG- 97
SERVICE SPECiFiCATIONS .. EG-103
FUEL SySTEM EG-I04

PREPARATION
EG-l04
FUEL FILTER
EG-l07
FUEL HEATER SYSTEM
EG-l08
INJECTION NOZZLE
EG-ll0
INJECTION PUMP
EG-122
STARTING INJECTION CONTROL

SYSTEM (SICS)
SERVICE SPECiFiCATIONS
EG-172
.. ..
EG-174
COOLING SYSTEM
EG-117
PREPARATION
EG-l77
COOLANT CHECK
EG-178
COOLANT REPLACEMENT
WATER PUMP
EG-178
EG-laO
THERMOSTAT
EG-l84
RADIATOR
EG-l86
SERVICE SPECIFICATIONS
EG-l9l
SERVICE SPECiFICATIONS .. .. EG- 209
:EG
EG-2
ENGINE - ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
_....
SST (SPECIAL SERVICE TOOLS)
~
,
.....
~~
~
{i) -',
09201
'0000
.
(09201-01070)
V,Iv, Guidi Bu.hinQ R.mover "

Repllcer Set
..............
.-..........
v,tv, Guid, Buahing RIlTICIYer I:
........... -
...........
Rlpllcer 7
09201-41020
V,tv, Stem Oil Seal Repl.e.,.
09202-70020
V,Iv, Sprine Compressor
. .
(09202-00010) Attlchmll'll
09213-58012
-----.--
................
...
--- .............................. ,._-
Crlnkah,ft PuM.., Holding Tool
.....
(90201-08131) Wlth'r
...
..-.......
.........
... _... .--..............
."
.......
........ ......... .............
............................. _................
(91111-50845) Bolt
=1
~
e:3EJ El
09214-60010
C'lnhh,ft Puu,., &. G..,

R.plle...
Cranktt\.ft pulley
09214 76011
erlnkshaft Pull., Repllcer
In)ection pump driv. S1..r baaring

Illjeetion pump drive gur oil
g.'
09222-11010
Connecting Rod Bu.hing Remoyer

& Repl,eef
.....
(09222-05020)
RemO~f
-- -----.-
.....
........ - -......... ......_----_._.- . .-
& Repl.e.,
...
.....
.................._..
........... ......... ...
EG-3

..
......
fJ
.................
(O9222-05040) Bm
09223 00010
0
~
~
~
........ .......... .. .................... .................. .........
.. ....... ..........
(09222-05030) Guide
09223-46011
-----------------------. ,-.,-
.. .......................
Cover &: Seel Repl,ee.
C'anklh,ft timing gear

Oil pump drive shaft ge8'
Cranklhaft Front Oil Seal
Cernlhafl oil ..,I
Replacer
09223-56010
Cr.nk.hlft Re,r Oil Se.l

Replacer
09223-78010
Crankshaft Oil Seal Replacer
09275-54011
Plunger Stroke Menu.ing Tool
09308-10010
O~
09330 00021
Comp.nion FI.nge Holding Tool
09950-40010
Puller B Set
C"nk$hef1 front oil sui
(2a
Seal Puller
C,anklh,ft front oil $811
...
~-&~f~
~: ~~~
.... ....
Crenk,heft pulley
, ........ ........... .............

(09951-04010) Hang.r 150
'
..... .............. , , .........
~~<liil
.................
(09952 -0401 0) Slide Aim
No.1 camshaft timing pulley
Oil pump drive sheft gear

Crankshaft timing gear
Injection pump drive g98r bearing
................................. ,
.............. .............
No.1 camshaft liming pulley
pump driv. shalt gear

Crankshaft timing gear
Injection pump drive gear bearing
O~
de
...
(09953-04010) Center Bolt 100
Oil pump drive shaft gear

Crankshaft timing g98r
~
....... ................... ..............................
....... ............. ................. ..... ........................... ........ ................. ......................

No.1 camshaft timing pulla.,.
(09953-04020) Center Bolt 150
... .....
,
Oil pump drive shalt g98r

Crankshaft timing gaar
Injection pump drive gear bear,ng
........ . ..... ...... .............. ...... .....
"
...
'EG
EG-4

(09954-04010) Arm 25
<Po!O'
No.1 cllmahalt timing pulley

Oil pump drive Ih.ft gear
Crankshalt timing gear

Injection pump drivll gear bearing
@-r~
...~
.--...ir;fii'
~ IJrn
'"".0
(09955-04060) Claw No.6
09950-50010
Puller C Se1
(09951-05010)
Hanger 150
No.' umshaft timing pulley

Oil pump drive Illaflg'a,
Cranksh.ft timing ge,r
Injection pump drive gur be,ring
""""""..,, -::::--
~
0000
(09952-05010) Slide Atm
Cr,nksh,ft pulley
Injection pump drive geer
(09953-05010)
Crtnkshaft pulley
Injection pump drive gear
Center
Boll 100
(09953-05020) Cenler 8011150
(09954-05020)
Claw No.2
09950-70010
Handle Set
(09951-07100)
Handle 100
09960-10010
V'riebl, Pin Wrench Set
(09962-01000)
Variable Pin Wrench Arm Assy
~.."P'
a~
~
~
~
C nklhaft pulley
Injection pump drive gell'
(09963-00700) Pin 7
09992 00024
Cylinder Compression Check Ga ...ge

So<
Crankstlllft pulley
Crankstlaft pulley
Injection pump drive gear
Velve guide bustling
lrljection pump drive ge.,
Injectiorl pump drive gear
EG-5

, .............
.. ......
(09992-0021l) G.UiI' Any
..
........
...........
.....
~
09992-00400
Atuc:hment No.7
Cylinder c:ompression c:tlec:lt
--..
RECOMMENDED TOOLS
~~
09040-00010
Heugon Wrenc:h Set.
09200 00010
Engine Adj... tt Kit.
09904-00010
E..pender Set.
=~
..
"A
--
~~
.
EOUIPMENT
Caliper gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dve penelrant
Engine tune
up tester
Heater
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring tester
Vel", .pring
Steel square
V,I", .pring
EG-6
Thermometer
Torque wrench
Valve seat cutter
V-block
Vernier calipers
SSM (SERVICE SPECIAL MATERIALS)

08826-00080
Seal Paeking Black or equivalent
(FIPG)
08826 00080
Seal Packing Black or equivel'nt

(FIPGj
08826-00100
Seal Packing 12828.

THREE BONO 12828
Timing belt cover

Timing gear cove.
Camshaft oil sell reUlinar
Cylinder he.d lemi-circyla. plug
Cylinder hflld cover
Main bearing cover
R... oil leal retainer
Water temperature sender gauge
or equivalerlt
(FIPGI
TROUBLESHOOTING
Diesel Engine Diagnosis
_-0'
GENERAL
1.
2.
Diesel engine problems are usually caused by the engine or fuel system. The injection pump is
very rarely the cause of fuel system problems.
Before beginning fuel system tests, first check that the engine compression. valve timing and
other major systems are within specifications.
PRELIMINARY CHECKS
1. Before performing fuel system checks, ensure that the engine is in good running condition. If
necessary, first check the compression. timing and major components or systems.
2. Check the air filter, and clean or replace it if necessary.
3. Check that there is sufficient fuel in the tank.
4. Check if the fuel is contaminated with gasoline or other foreign elements. Only good-quality
diesel fuel should be used.
5.
Bleed air from the system by pumping the priming.
6. Check for water in the fuel filter and fuel tank. and drain as necessary.
7.
If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system.
EG-7
PRECAUTION,
1. The basic troubleshooting procedures for the diesel engine (velve clearance. compression.
bearings, vatves. pistons. etc.) are the same checks you would make for gasoline engine.
2.
Repair of the injection pump requires considerable skill and use of
special test bench.
'"
+'~"_.+~,'+,~'-t,~'-t-'~"'+~".+;"'-t,~'-t-,~,'+~".+-'+"~'-t-'-+-' +-'+-'+-,~,'+,~e'+-'+"~'-t-'-+
\\'-__s_e_e_p_._9_.
Suspect area
Symptom
.~
~
~
a;;
,
'"
oc
;;
,
~
;;
,
~
Engine does not crank

5
2 1 3 6 4
~rf__---------t___+-+-f__+-+_--t-+-t___+-+___t-+-t___+-+-t__+-t___+-+_j
00
5
2
1
6
4
Engine cranks normally
,,"
~r
Bo
Engine cranks slowly
".
:E ;;;I--------+-il-+--+-I-+-I-t-+_j-+-+-I-+--+-t-+-I-t-+-I--I
'0
r
~
High engine idle speed

Rough idle with warm
engine
lack of power
6
9
12
Engine suddenly SlOPS
"
Engine does not shut

off with key
Excessive exhaust
smoke
Excessi....e fuel
consumption
Engine overheat
10
7
7
Low oil pressure

High oil pressure
Engine noise when
warm
HINT: When inspecting a wire harness or circuit the Electrical Wiring Diagram repair manual should be
referred to and the circuits of related systems also should be checked.
EG-S
'""'w
See page
EG
Suspect area
- - '"- '"'""' '"- '"'"- "''"'"'" -'"'" '"'"~
E'"
'"E,
E
'" .;; ":<
>
c
\"
~
Engine does not crank
o~
~t
Engine cranks slowly
"'"
0w 0w
u
u
<;
0w 0w 0w 0w
Symptom
.2
"
"" ~0
~
E E
0
'"
.u
," E, "gi
-"
u
'"c
>-
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w w
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00
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uu
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0
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in
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0'" u
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c';:
c.
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u",
>. >.
U
~t
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.- 0
0_
0>
c
~
High engine speed
Rough idle with warm

engine
lack of power
"
'0
Engine suddenly stops
Engine does not shut

off with key
Excessive exhaust
smoke
Excessive fuel
consumption
Engine overheat
low oil pressure

High oil pressure
Engine noise when
warm
".
-"
."
"
"
..
~
" ~ "" " 6 " ~ '"
u:
.~
;;
0w 0w
2
1
8
4
EG-9
Diesel Electrical System Diagnosis (Engine does not start cold)

HINT:
Battery voltage at 12 V
Engine cranks normally.
Fusible link okay.
Ignition switch OFF.
EG
PRE-HEATING SYSTEM
,. Inspect power supply seetion
Is there continuity in the intake heater?
No
Replace the intake heater.
(See pre-heating system)
Ves
I Replace the fusible link.
Disconnect the waler temperature sensor
connector.
Fusible Link Blown
j
When the ignition switch is turned ON,
does pre-heat side of Ihe intake heater
have battery vollage for 81 seconds?
No
Fusible Link OK
Ves
II Inspect control section.
Connect the water temperature sensor connector.
Check the fusible link for intake heater.
II
OK
2. Inspect control section
HINT:
Perform this inspection with the intake heater lead wire properly connected.
Disconnect tne water temperature

sensor connector.
When tne ignition switcn is turned

ON. does the indicator light?
(Measure the time lighted)
y"
Is tne GAUGE fuse Okay?
<D
Replace tne fuse.
Replace the bulb.
y"
Is the indicator light bulb
Ok8Y?
Ye.
CONTINUED ON PAGE EG-xx
No
No
EG-l0
ENGINE
ENGINE MECHANICAL
CONTINUED FROM PAGE EG-9
CD
Emission EeU lw I EGR System)
GirD
GRIEL
0::'._.."::
~D
EG
--
00_
;~
E7,
'.l__ ~
.000"-_
~O2
Is Iheregrounding of terminal El,

EOl or E02 of emission EeU or
terminal EG of the pre-heating
No
Open circuit or
ground faulty in wire
harness between
terminal El, EO' or

E02 of the EeU or
timer?
terminal EG of the
V"
timer and body
P23602
ground.
Pre-Heating Timer (w/o EGR Systeml
Is there battery vollage to

terminal GINO of the ECU or
limer (on wire harness side17
GAEL
L~
), =]
GINO
Ves
No
Open circuit in wire harness
between terminal GINO of the
EeU or timer and indicator light.
EG
Replace the ECU or

timer.
P22973
No
Is the lighting lime correct?

6.5 seconds
Replace tile EeU or timer.
Ves
Is there battery voltage between
terminal G of the intake heater relay
and body ground for 81 seconds
with the ignition switch ON?
No
y"
Intake
Is intake heater relay Okay?

(See pre-healing system in
Starting System)
No
Replace the intake

heater relay.
No
Replace the ECU or

timer.
y"
Hea~ Relay
1@1'~b
G
---r
B
pnS8B
,
9
Connect the water temperature

sensor connector.
When the ignition switch is turned ON, does

terminal GREL of the ECU or timer have
battery voltage fOf 81 seconds?
V"
e
0
Inspect power supply

section.
Open circuit in wire harness

between terminal GREL of the ECU
or timer and terminal g of the intake
heater relay.
Open circuil or ground faulty in
wire harness between terminal e of
the intake heater relay and body
ground.
EG-"

FUEL CUT SOLENOID VALVE
With ignition switch lurned ON, check 101'

fuel cut solenoid valve operation noise
Fuel cut solenoid valve okay.
Check for short circuit, and repair as necessary.
Noise
(clicking sound) while repeatedlv
connecting and disconnecling luel CUi

solenoid valve.
No Noise
Check luse.
Fuse OK
Fuse
Blown
Apply baltery voltage directly to solenoid,

and check for noise.
Check wire harness from luse
to luel CUI solenoid.
Noise
No Noise
I Replace luel CUI solenoid valve.
AIR FILTER INSPECTION AND

CLEANING
--.
Paper Filter Type:

1.
2.
REMOVE AIR FILTER

INSPECT AIR FILTER
Visually check that the filter element is not
ex~
cessively dirty. damaged or oily.

3.
4.
CLEAN AIR FILTER

Clean the filter element with compressed air.
First blow from the inside thoroughly. Then blow off
the outside of the filter element.
REINSTALL AIR FILTER
Washable Type:
1.
2.
REMOVE AIR FILTER

INSPECT AIR FILTER
Visually check that the filter element

cessively dirty, damaged or oily.
3.
(a)
IS
not ex-
CLEAN AIR FILTER

Blow dirt off in the filter element with compressed air.
EG-12
dIJ
,if
0.'<
"
..
~.:.;..;
Ib)
Ie)
Submerge the filter element in the water and agitate it

up and down more than 10 times.
Repeat rinsing in clean water until rinsing water is
clear.
"m~
>~
EG
..",
(d)
(e)
4.
Remove excess water by shaking the filter element or

blowing with compressed air.
NOTICE: 00 not be.t or drop filter element.
Wipe off dust on the air cleaner case interior.
REINSTALL AIR FILTER
COMPRESSION CHECK
'GIIJ_1l
HINT; If there is lack of power, excessive oil consumption or poor fuel economy. measure the compression
pressure.
1.
WARM UP AND STOP ENGINE

Allow the engine to warm up to normal operating
temperature.
2.
3.
4.
5.
6.
(a)
(b)
REMOVE CYLINDER HEAD COVER

(See steps 2 or 3 end 11 in cylinder head removal)
REMOVE INJECTION PIPES
(See .teps 3 and 5 in injection nozzles removal in
Fuel System)
REMOVE NO.1 NOZZLE LEAKAGE PIPE
(See step 4 in injection nozzles removal in
Fuel System)
DISCONNECT INJECTION PUMP (FUEL CUT
SOLENOID) CONNECTOR
CHECK CYLINDER COMPRESSION PRESSURE
NOTICE: When me.suring the compr.ssion pr.ssur. of
e.ch, the oth.r 5 injection noules must be installed in the
cylinder head.
Remove the injection nozzle.
(See steps 6 and 7 in injection nozzles removal in
Fuel System)
Install the gasket and SST (attachment) to the injec
tion nozzle hole with the nozzle holder clamp and bolt.
SST 09992 - 00400
Torque: 25 Nm (256 kgfcm. 18 ftlbf)
(e)
EG-13
Connect SST (compression gauge) to the SST (attachment).
SST 09992-00024 (09992-00160)

(d)
While cranking the engine. measure the compression

pressure.
HINT: Always use a fully charged battery to obtain

engine revolution of 250 rpm or more.
(e)
Repeat steps (b) through (d) for each cylinder.

NOTICE: This me..ur.ment mUlt b. done in .1 .hort 8
tim pouible.
Compreion preure:
(fl
(g)
(h)
7.
8.
9.
10.
11.
3.432 kP. (35.0 kgf/cm l 498 psi) or more

Minimum pr...ure:
2.452 kP. (25.0 kgf/cm'. 358 psi)
Diff.rence between ch cylinder:
490 kP. (S.O kgf/cm 1 71 psi) or I
If the cylinder compression in one or more cylinders is
low. pour a small amount of engine oil into the cylinder through the injection nozzle hole and repeat steps
(b) through (d) for the cylinder with low compression.
If adding oil helps the compression, chances are

that the piston rings and/or cylinder bore are
worn or damaged.
If pressure stays low, a valve may be sticking or

seating improperly, or there may be leakage past
the gasket.
Remove the SST.
SST 09992-00400. 09992-00024(09992-00160)
Reinstall the injection nozzle.
(See steps 1 and 2 in injection nozzles installation in
Fuel System)
RECONNECT INJECTION PUMP (FUEL CUT
SOLENOID) CONNECTOR
REINSTALL NO.1 NOZZLE LEAKAGE PIPE
(See .tep 4 in injection nozzle installation in
Fuel Sy.tem)
REINSTALL INJECTION PIPES
(See .tep. 3 and 5 in injection nozzle. installation
in Fuel Sy.tem)
REINSTALL CYLINDER HEAD COVER
(See .tep. 10 and 18 or 19 in cylinder head
in.tallation)
START ENGINE AND CHECK FOR LEAKS
EG
EG-14
VALVE CLEARANCE INSPECTION

AND ADJUSTMENT
"'_-101
1.
HINT: Inspect and adjust the valve clearance when

the engine is cold.
(See stepi 2 or 3 and 11 in cylinder head removal)
EG
2.
(a)
(b)
3_
(a)
SET NO.1 CYLINDER TO TDC/COMPRESSION

Turn the crankshaft pulley clockwise. and align its
groove with the groove of the timing gear cover.
Check that the valve rocker arm on the No.1 cylinder
are loose and valve rocker arm on the No.6 cylinder
are tight.
If not. turn the crankshaft 1 revolution (360) and
align the mark as above.
INSPECT VALVE CLEARANCE
Check only the valves indicated in the illustration.
Using a feeler gauge, measure the clearance be

tween the adjusting screw on the valve rocker
arm and the valve bridge.

Record the out - of - specification valve clearance measurements.
Velve cleerence (Cold):

Inteke
0.17 - 0.23 mm (0.007 - 0.009 in.)
Exheu.t
0.47 - 0.53 mm (0.019 - 0.021 in.)
(b)
(c)
4.
{aj
I'
Valve
Bridge
b7loosen
:ID~
Adjusting
Screw
Turn the crankshaft pulley 1 revolution (360) and

align the mark as above. (See procedure step 2)
Check only the valves indicated as shown. Measure
the valve clearance. (See procedure in step (a))
ADJUST VALVE CLEARANCE

Loosen the lock nut on the valve bridge. and loosen
the adjusting screw until the adjusting screw and
valve stem are completely separated.
NOTICE: Hold the velve bridge with e wrench. end 100.en
the lock nut. Do not epply torque to the velve bridge.
~~TU,"
(b)
Adjusting
Screw
~~kf~~
~~~)~~~-~~I;:er
020 or
O:SOmm
Slide
--
Arm
(e)
EG-15
Loosen the lock nut on the valve rocker arm. and

loosen the adjusting screw.
Insert a 0.20 mm (0.008 in.) feeler gage for intake or
0.50 mm (0.020 in.) feeler gage for exhaust between
the adjusting screw on the valve rocker arm and the

valve bridge.
(d)
Feeler
Turn the adjusting screw on the valve rocker arm until
the feeler gauge slides with a very slight drag, and

lock the adjusting screw with the lock nut.
Gauge
(e)
With the feeler gauge inserted. check that the resistance of the feeler gauge remains the same when the
adjusting scre~ on the valve bridge is loosened.

If the resistance of the feeler gauge changes. repeat
from step (b).
Adjusting
Screw
oi!-l>,__ Valve
Bridge
(f)
Tighten the adjusting screw on the valve bridge, and

lock the adjusting screw with the lock nut when the
resistance of the feeler gauge begins to get stronger.
NOTICE: Hold the valve bridge with a wranch. and lock
the adjusting .crew with the lock nut. Do not apply
torque to the valve bridge.
(g)
(h)
Adjusting
Screw
"'t~::.-_valve
T<
Rocker
Mm
5.
Loosen the lock nut on the valve rocker arm.

Turn the adjusting screw on the valve rocker arm until
the feeler gauge slides with a very slight drag, and
lock the adjusting screw with the lock nut.
REINSTALL CYLINDER HEAD COVER
(See steps 10 and 18 or 19 in cylinder head
installation)
P2J211
INJECTION TIMING INSPECTION

AND ADJUSTMENT
1.
_ _t'
SET NO.1 OR NO.6 CYLINDER TO

TDC/COMPRESSION
Turn the crankshaft pulley clockwise, and align its
groove with the groove of the timing gear cover.
EG-16

Gasket
Plug Boll
~~Q({)
2.
(a)
INSTALL SST AND DIAL INDICATOR

Remove the plug bolt and gasket from the distributive
head plug of the injection pump.
(b)
Loosen the 2 union nuts holding the injection pump to
the No.1 and No.5 injection pipes. and slide the 2

union nuts rearward.
No.1
(e)
Install SST (plunger stroke measuring tool) and a dial
indicator to the plug bolt hole of distributive head

plug.
SST 09275-54011
3.
RELEASE ACSD ADVANCE
(a)
Using a screwdriver. turn the cold starting lever coun-
(b)
terclockwise approx. 20.

Put a metal plate (thickness of 9.0 - 10.0 mm (0.354
- 0.394 in.)) between the cold starting lever and
thermo wax plunger.
4.
INSPECT AND ADJUST INJECTION TIMING
(a)
Slowly rotate the crankshaft pulley counterclockwise
(b)
and set the dial indicator at 0 mm (0 in.) when the dial

indicator reaches the minimum value.
Turn the crankshaft to the left and right and check
that the dial indicator shows the minimum value.
NOTICE: Check that the minimum value i. . .1 at 0 mm
(O in.)
(c)
(d)
Slowly rotate the crankshaft pulley clockwise until its

groove is aligned with the groove of the timing gear
cover.
Measure the plunger stroke.
Plunger .trake:
Europe
1.52 - 1.58 mm (0.0598 - 0.0622 in.)

Australia
1.37 - 1.43 mm 10.0539 - 0.0563 in.)

(8)
EG-17
Loosen these nuts and bolts:

(1) 4 remaining union nuts holding injection pipes to
injection pump
(2) 2 bolts holding injection pump to injection pump
stay
(3)
2 nuts holding injection pump to timing gear case

NOTICE: Do not turn the nut. more than 90.
(1)
Brass Bar
Adjust plunger stroke by slightly tilting the injection

pump body.
If the stroke is less than specification. tilt the pump
toward the engine.

If the stroke is greater than specification. tilt the pump
away from the engine.
HINT:
If the stroke is less than specification. move the

injection pump toward the engine.
Using a brass bar and plastic-faced hammer.

gradually tap the pump flange away from the
engine.
(g)
Tighten these nuts and bolts:

e
2 nuts holding injection pump to timing gear case
Torque: 18 Nm (185 kgfcm. 13 ft.lbf)
e
(h)
5.
6.
(a)
(b)
7.
8.
2 bolts holding injection pump to injection pump

stay
Torque: 69 Nm {JOO kgfcm. 51 ft.lbfl
Recheck the plunger stroke.
REMOVE METAL PLATE
REMOVE SST AND DIAL INDICATOR
Remove the SST and dial indicator.
SST 09275-54011
Install a new gasket and the plug bolt of the distributive head plug.
Torque: 25.6 Nm (260 k"fcm. 19 ftlbfl
TIGHTEN INJECTION PIPE UNION NUTS
Torque: 24.6 Nm {250 kgfcm. 18 ftlbfl
START ENGINE AND CHECK FOR FUEL LEAKS
_.
IDLE SPEED AND MAXIMUM SPEED

INSPECTION AND ADJUSTMENT
1.
(a)
(b)
(c)
(d)
(e)
INITIAL CONDITIONS
Engine at normal operating temperature
Air cleaner installed
All accessories switched OFF
All vacuum lines properly connected
Valve clearance set correctly
EG-18

(f)
(9)
Injection timing set correctly
AIT;
Transmission in neutral position
(hi
2.
3.
(a)
EG
(b)
(e)
MIT;
Steering wheel at straight-ahead position
CONNECT TACHOMETER
CHECK AND ADJUST IDLE SPEED
Check that the adjusting lever touches the idle speed
adjusting screw when the accelerator pedal is rel8a
sed.
If not, adjust the accelerator linkage.
Start the engine.
Check the idle speed.
Idle ,peed:
(d)
MIT
700 50 rpm
AIT
800 50 rpm
Adjust the idle speed.
Disconnect the accelerator linkage.
Loosen the lock nut of the idle speed adjusting

screw.
Adjust the idle speed by turning the idle speed
adjusting screw.
Securely tighten the lock nut, and recheck the
idle speed.
Reconnect the accelerator linkage.
After adjustment, adjust the accelerator linkage.
4.
(a)
Adjusting
Lever ~
(b)
,\
Not ~ove{
w J 0 Throttle Position Sensor
Maimum Speed
A~s".eW",;:Q>
~U,{6:>:-~ ~!":4--~
puno
PU314
(c)
(d)
(e)
CHECK AND ADJUST MAXIMUM SPEED

wI Throttle Position Sensor:
Depress the accelerator pedal all the way. Then check
that the adjusting lever does not move when you try
to push it to the maximum speed side.
wlo Throttle Position Sensor:
Ckeck that the adjusting lever touches the maximum
speed adjusting screw when the accelerator pedal is
depressed all the way.
Start the engine.
Depress the accelerator pedal all the way.
Check the maximum speed.
Maximum speed:
4.400 tOO rpm

If the maximum speed is not as specified. remove the
injection pump and adjust the maximum speed.
(See injection pump adjustment in Fuel System)
EG19
PS IDLE-UP SPEED INSPECTION

AND ADJUSTMENT
(MIT)
I.
(al
(b)
(e)
(d)
(e)
(f)
(g)
INITIAL CONDITIONS
AfT:
(h)
2.
Idle speed set correctly

CONNECT TACHOMETER
3.
ADJUST PS IDLE - UP SPEED
(a) Start the engine.

(b) Turn the steering wheel from the straight-ahead position to full left or full right position.
(e)
Check the idle-up speed.

P$ idle-up speed:
650 - 750 rpm
(d)
(e)
(f)
(g)
Loosen the 2 nuts, and adjust the idle - up setting
speed by sliding the idle-up actuator body. Lock the

idle - up actuator with the 2 nuts.
Return the steering wheel to the straight- ahead position. Then turn the steering wheel from the straightahead position to full left or full right position. and
recheck the idle-up speed.
Return the steering wheel to the straight-ahead posi

tion. and check that the rod end of the idle - up actuator is not touching the idle - up lever.
Check and adjust the AIC idle - up speed.
(See step 3 in AIC idle-up speed inspection and
adjustment)
NOTICE: After edjusting the PS Idle-up speed. always
check the Ale idle-up speed.
EG
EG-20
AIC IDLE-UP SPEED INSPECTION

AND ADJUSTMENT
1.
(a)
(b)
(c)
(d)
(8)
(f)
(gl
EG
(hi
(i)
til
2.
Idle-Up Adjusting Screw
3.
(a)
(b)
Singl.
Diephngm
Type (A/T)
(c)
INITIAL CONDITIONS
_.-.
AfT:
MfT:
Steering wheel at straight-ahead position
Idle speed set correctly
MfT:
PS idle-up speed correctly
CONNECT TACHOMETER
ADJUST AIC IDLE-UP SPEED

Start the engine.
Turn the Ale switch ON. and set these position:
Blower switch to HI
Air intake control lever to RECIRCULATED AIR
Air flow control lever to FACE
Temperature control lever to COOL

Check the idle-up speed.
Ale idle-up speed:

(d)
(e)
(f)
175 - 850 rpm

Loosen the lock nut. and adjust the idle - up setting
speed by turning the idle-up speed adjusting screw.
Lock the adjusting screw with the lock nut.
Turn the A/C switch OFF. then ON again. and recheck
the idle - up speed.
Turn the A/C switch OFF. and check that the rod end
of the idle-up actuator is not touching the idle-up
lever.
ENGINE -
EG-21
ENGINE MECHANICAL
..
TIMING BELT
.,,,.-
COMPONENTS FOR REMOVAL AND

INSTALLATION
wI EGR System
w/o EGR System
Intake Pipe Assembly
~_-,-EGR Valve Bracket

>
(1 (f
C!i' C!i'
,
~
Intake Pipe
~. -_-_--~,
,
,
Hose.~:t~""':-:--t2~~~
Vacuum
+ Gasket
Intake Heater
....... ~
',----'
I
.........,
Gasket
.........
'-
--:>~--'~Intake Pipe
: ~.
'
'.'~
,
" Gasket
,,,
,
,,,
,,,
,,
,,
Gasket
.:",
Insulator
.-_.
, ;.
, .'
,..~
,~---
.--
Vac~um
Hose (wi EGA System)
No 1 Camshaft Ttming~_------Pulley
~-~
Plate Washer
Idler Pulley
-----~~-/
----------- ,-- .-
~~
Timing Belt Tens,oner ~_.---
NO.2 Camshaft Timing <-'lP"
~:
Pulley
- .---
.'"
_.~__1. __ ~_~-~-,-~-~~~==:::::::::=~~,-..\~No.~Flange
___
~~-No.2 Flange
Timing Belt Cover-----'\
Seal Washer - - - " ' . ,

Clamp -------'<'dl
Vacuum Hose
~~
Clamp-----"
Nonreusable part
\---Timing Belt
~"..---Gasket
EG-22
"'--.,
HINT: If replacing the timing belt before the timing

belt warning light comes on, (light comes on after
100,000 km (60,000 miles) of driving). be sure to
reset the timing belt counter of the speedometer to

zero.
EG
TIMING BELT REMOVAL
1.
(a)
(b)
(e)
2.
REMOVE TIMING BELT COVER

Disconnect the vacuum hose from the 2 clamps on
the timing belt cover.
Remove the 3 clips.
Remove the 3 bolts. 3 seal washers and timing belt
cover. gasket and insulator.
SET NO.1 CYLINDER TO BOC/COMPRESSION

Turn the crankshaft pulley clockwise. align the timing
marks of the No.1 and No.2 camshaft timing pulleys
with the BOC marks.
NOTICE: If the timing belt i. disengaged. h8Ylng the
erank,h.ft pulley at the wrong angle can cau the
pilton h d and valve head 10 coma Into contact with
each other when you remove the camshaft timing pulley
(,tep 8), causing damage. $0 alway, ,et the crankshaft
pulley at the correct angle.
3.
REMOVE TIMING BELT

HINT:
When reusing timing belt:

Draw a direction arrow on the timing belt (in the
direction of engine revolution), and place match
marks on the timing pulleys and timing belt.
When replacing timing belt tensioner only:
To avoid meshing of the timing pulley and timing

belt. secure one of them with string.
(a)
Alternately loosen the 2 bolts, and remove them and

the timing belt tensioner.
Remove the timing belt.
(b)

4.
EG-23
REMOVE IDLER PULLEY

Using an 8 mm hexagon wrench. remove the pivot
bolt. idler pulley and plate washer.
EG
5.
REMOVE NO.2 CAMSHAFT TIMING PULLEY

Remove the 4 bolts. No.2 flange. timing pulley and
No.1 flange.
8.

(See steps 2 or 3 and 11 in cylinder head removal)
7.
(a)

Slightly turn the camshaft timing pulley counterclock
wise and hold the hexagon wrench head portion of the
camshaft with a wrench. and remove the bolt and
timing pulley.
(b)
Using SST. remove the timing pulley.

SST 09950-40010 (09951-04010.09952-04010.
09953-04020.09954-04010.09955-040601
(c)
Remove the set key.
--.
TIMING BELT COMPONENTS INSPECTION

1.
INSPECT TIMING BELT

NOTICE:
Do not bend. twi.t or turn the timing belt inside out.
Do not ellow the timing belt to come into contect

with oil. weter or st.em.
EG-24
Do not utilize timing belt tension when installing or

ramoving the mount bolt of the camshaft timing
pulley.
If there are any defects. as shown in the illustrations.

check these points:
(a)
Premature parting
(b)
(0)
(d)
(e)
2.
(a)
Check for proper installation.

Check the timing cover gasket for damage and
proper installation.
If the belt teeth are cracked or damaged. check to see
if either camshaft is locked.
If there is noticeable wear or cracks on the belt face.
check to see if there are nicks on the side of the idler
pulley lock.
If there is wear or damage on only one side of the belt.
check the belt guide and the alignment of each pulley.
If there is noticeable wear on the belt teeth. check
timing cover for damage and check gasket has been
installed correctly and for foreign material on the
pulley teeth.
If necessary. replace the timing belt.
INSPECT IDLER PULLEY
Visually check the seal portion of the idler pulley for
oil leakage.
If leakage is found. replace the idler pulley.
(b)
Check that the idler pulley turns smoothly.

If necessary. replace the idler pulley.
3.
{al
INSPECT TIMING BELT TENSIONER

Visually check the seal portion of the tensioner for oil
leakage.
HINT: If there is only the faintest trace of oil on the
seal on the push rod side. the tensioner is all right.
If leakage is found. replace the tensioner.
(b)
EG-25
Hold the tensionsr with both hands and push the push
rod strongly as shown to check that it doesn't move.
If the push rod moves, replace the tensioner.
NOTICE: Never hold the t"nsione' push rod facing downwe rd.
EG j
(c)
Protrusion
---..;
Measure the protrusion of the push rod from the

housing end.
Protrusion:
9.0 - 9.8 mm (0.354 - 0.386 in.)
If the protrusion is not as specified. replace the tensi-
oner.
"''''
TIMING BELT INSTALLATION
1.
lal
Ibl
lei
Idl
2.
3.
lal
Ibl
4.
lal
Bmm
Hexagon
Wrench
Ib)
\
f
"""
---.,
INSTALL NO.1 CAMSHAFT TIMING PULLEY

Install the set key to the key groove of the camshaft.
Align the pulley set key with the key groove of the
timing pulley, and slide the timing pulley.
Temporarily install the pulley bolt.
Hold the hexagon wrench head portion of the camshaft with a wrench. and tighten the pulley bolt.
Torque: 98 Nm (1.000 kgfcm. 72 ftlbf)
INSTALL CYLINDER HEAD COVER
(See steps 10 and 18 or 19 in cylinder head
installation)
Align the knock pin on the injection pump drive gear
with the knock pin hole of the No.1 flange and the
knock pin groove of the timing pulley.
Install the No.1 flange. timing pulley and No.2 flange
with the 4 bolts.
Torque: 31 Nm (315 kgfcm. 23 f1.lbfl
INSTALL IDLER PULLEY
Using an 8 mm hexagon wrench. install the plate
washer and idler pulley with the pivot bolt.
Torque: 34.5 Nm (350 kgfcm. 25 ftlbf)
Check that the pulley bracket moves smoothly.
EG-26

5.
(a)
SET NO.1 CYLINDER TO BOC/COMPRESSION

Check that the timing mark of the No.2 camshaft
timing pulley is aligned with the BOC mark.
NOTICE: Do not turn the crankshaft pulley. The valve
heads will hit against the piston top.
(b)
Align the timing mark of the No.1 camshaft timing

pulley with the BOC mark.
6.
INSTALL TIMING BELT

NOTICE: The engine should b. cold.
HINT (When re-using timing belt): Align the points
marked during removal, and install the belt with the
arrow pointing in the direction of engine revolution.
(a)
Remove any oil or water on the pulleys. and keep them
clean.
NOTICE: Only wipe the pulleys; do not us. any cleansing
agent.
(b)
7.
(a)
(b)
1.5mm
Hexagon
Wrench
~,.
(c)
8.
(a)
1.5 mm
Hexagon
Wrench
\/~.
(b)
(c)
9.
Install the timing belt under tension between the No.1

and No.2 camshaft timing pulleys.
SET TIMING BELT TENSIONER
Using a press, slowly press in the push rod using 981
- 9.807 N (100 - 1.000 k9t. 220 - 2.205 Ibtl ot
force.
Align the holes of the push rod and housing, pass a
1.5 mm hexagon wrench through the holes to keep
the setting position of the push rod.
Release the press.
INSTALL TIMING BELT TENSIONER
Temporarily install the timing belt tensioner with the 2
bolts while pushing the idler pulley toward the timing
belt.
Alternately tighten the 2 bolts.
Torque: 13 Nm (130 kgfcm.10 ftlbfj
Remove the 1.5 mm hexagon wrench from the tensioner.
CHECK VALVE TIMING

Turn the crankshaft pulley clockwise and check that
each pulley timing mark aligns with the TOe marks.
If the marks do not align. remove the timing belt and
reinstall it.
EG-27
10. INSTALL TIMING BELT COVER

(a) Remove any old packing (FIPG) material.
(b) Apply s8al packing to the camshaft oil seal retainer
and timing gear cover as shown in the illustration.
S. .I JNIcking:
Pert No. 08826-00080 or equivelent
(0)
(d)
Install the insulator to the timing gear cover.

Install the gasket to the timing belt cover.
(el
Install the timing belt cover with the 3 seal washers.
(f)
3 bolts and 3 clips.

Install the vacuum hose to the 2 clamps on the timing
belt cover.
EG-28
TIMING GEAR
INSTALLA TION
--.
wI EGR System
w/o EGR System
~ ~
Vacuum
n.
~1.
Intake Pipe
'
Hose'~~?-~;;1
~~~~
~
-,
Gasket
Intake Heater
......"
+Gasket' . .
~EGAValveBracket
""0~>
. . --__,...W>--'.:s.-,--. Gasket
......""'-
_--~;-i:'= - - - - - '
~-:~:.~
"'_-_ Intake Pipe
Insulalor
",
,
,
,~
a~:
,
,,,
,
;,.",- '
Gasket
'.0----1
.........\
_"",,:.::.,.<::-:t::7\~cuum Hose
Drive Belt
(wI EGA System)
Pulley Set Key."
No.1 Camshaft 1iming _ _-,~
---
f$?'\;:f,J
Pulley
Clamp lwl EGR System)
Idler Pulley - - - - - -
,\---Timing Belt
Clamp
-"'''\\
~IP-----Gasket
Vacuum HO$e-----'~
Clamp
.,
-"
Seal Washer
Non-reusable part
EG-29
(
.'
No.2 Cylinder Block Insulator

Injection Pump Drive
Gear
Gear Bearing
.0.R;nJ~'
.~
,,
,
,,,
.-
~-
Crankshaft Timing Gear
~-
p"m~OdV'~""'W"
~:,::::;: ; .. ~.
,,
-~-
:,~~J-::::~--',,---:,~-,-~
i
0"
Q)""',- q&:
:'
Thrust Plale
~.J
,
I
I
--
_-----
_--.... __
I
I
--
1-- --
.-- .'
~
...
~--iI :V-~
I
I
,
+'njection Pump Drive

Gear Oil Seal
Crankshaft Front Oil Seal
x6
Crankshaft Pulley ----,''''''~~
l,,
,,
,,
,,
,,
,
,,
,,
,,
,,
'I--:--~',
,,
Timing Gear Cover
i----'-:-Clamp
, <>::;:---+
1M
Gasket
.. ,
.'
.'
Non-reusable part
.-
_-----
_----
_------- - _--------
Idler Gear Shaft

.'
- -
:I
r:'i .
:.~
..
'
EG-30
TIMING GEARS REMOVAL

1.
-_...
REMOVE DRIVE BELTS. FAN. FLUID COUPLING

AND WATER PUMP PULLEY
(See step 2 in water pump removal in Cooling
System)
2.
3.
4.
LOOSEN CRANKSHAFT PULLEY

Using SST. loosen the pulley bolt.
SST 09213 - 58012 (90201 -08131. 91111 - 50845).
09330-00021
NOTICE: If the timing belt ia disengaged. having the
crankshaft pulley 81 the wrong angle can cause the
piston head and valve head to come Into contact with
each other when you remove the cemshaft timing pulley
(step 8 in timing belt removal), causing damage.
REMOVE TIMING BELT AND PULLEYS
(See steps 1 to 7 timing belt removal)
REMOVE CAMSHAFT OiL SEAL RETAINER
(See step 14 in cylinder head remoYal)
5.
(a)
REMOVE CRANKSHAFT PULLEY

Remove the pulley bolt and plate washer.
heed. will hit ageins. the piston top.
(b)
Using SST. remove the crankshaft pulley.
(e)
SST 09950-50010 (09951-05010. 09952-05010.

09953 - 0501 O. 09953-05020. 09954 - 05020)
Remove the a-ring from the crankshaft pulley.
6.
(a)
(b)
REMOVE OIL PIPE

Remove the 2 union bolts and 4 gaskets.
Remove the bolt and oil pipe.
7.
(a)
(bJ
REMOVE VACUUM PUMP

Remove the 2 nuts and vacuum pump.
Remove the O-ring.
EG-31
8.
(a)
REMOVE TIMING GEAR COVER

Remove the 14 bolts. clamp and bracket.
(b)
Pry out the timing gear cover.
9.
REMOVE NO.2 CYLINDER BLOCK INSULATOR
10. REMOVE OIL PUMP DRIVE SHAFT GEAR

Using SST. remove the drive shaft gear.
SST 09950-4001 0 (09951-04010.09952 -0401 O.
09953-04010.09953-04020.09954-04010.
09955-04060)
11. CHECK THRUST CLEARANCE OF IDLER GEAR

Using a feeler gauge. measure the thrust clearance.
Standard thrust clearance:
0.05 - 0.15 mm (0.0020 - 0.0059 in.)
Maximum thrust clearance:
0.30 mrn (0.0118 in.)
If the thrust clearance is greater than maximum. ra

place the thrust plate. If necessary. replace the idler
gear and/or idler gear shaft.
12. REMOVE IDLER GEAR

(a)
(b)
Remove the 2 bolts and thrust plata.

Using SST. turn the injection pump drive gear clock
wise or counterclockwise and remove the idler gear.
SST 09960-10010 (09962-01000. 09963-00700)

(c)
Remove the idler gear shaft.
13. REMOVE INJECTION PUMP DRIVE GEAR

(a) Using SST. loosen the gear nut.
SST 09960-10010 (09962-01000. 09963-00700)

(b)
Remove the gear nut and a-ring.
EG32

(c)
Using SST. remove the drive gear.

SST 09950-50010 (09951-05010.09952-05010.
09953-05010.09954-050201
~.;<-_SST
EG
14. REMOVE CRANKSHAFT TIMING GEAR
Using SST. remove the timing gear.

SST 09950-40010 (09951 -04010.09952-04010.
09953-04010.09953-04020.09954-04010.
09955-04060)
TIMING GEARS INSPECTION

1.
(a)
--
INSPECT IDLER GEAR

Using a cylinder gauge, measure the inside diameter
of the idler gear.
Idler gear inside diamet.r:
45.000 - 45.025 mm (1.7717 - 1.7726 in.)
(b)
Using a micrometer. measure the diameter of the idler
(c)
gear shaft.
Idler g8.' shaft diamat.r:
44.950 - 44.975 mm (1.7697 - 1.7707 in.)
Subtract the idler gear shaft diameter measurement
from the idler g8ar inside diameter measurement.

Standard oil cle.ranca:
0.025 - 0.075 mm (0.0010 - 0.0030 in.)
Maximum oil cle.ranca:
0.20 mm (O.DOJ9 in.)
If the clearance is greater than maximum. replace the

gear and shaft.
2.
INSPECT INJECTION PUMP DRIVE GEAR BEARING
Check that bearing is not rough or worn.

3.
A.
EG33
IF NECESSARY. REPLACE INJECTION PUMP DRIVE

GEAR BEARING
Remove bearing
Using SST. remove the bearing.
SST 09950-40010 {09951 -04010.09952-04010.
09953-04020.09954-04010.09955-040401
B.
Install bearing
Using SST and a press. press in a new bearing.
SST 09214-76011
SST
Crankshaft Timing Gear to Idler Gear
4.
CHECK BACKLASH OF TIMING GEARS
(a)
(b)
Install the gears.

Using a dial indicator. measure the backlash.
Standard g88r backlash:
0.05 - 0.15 mm (0.0020 - 0.0059 in.)
Maximum gear backlash:
0.30 mm (D.O' 18 in.)
(c)
Oil Pump Drive Shaft Gear to

Driven Shaft Gear
'v>~_
Mov,e
pn243
P23221
pn244
If the gear backlash is greater than maximum. replace

the gears as a set.
Remove the gears.
EG-34
CRANKSHAFT FRONT OIL SEAL

REPLACEMENT
--.
(a)
HINT: There are 2 methods (A and B) to replace the oil

seal as follows:
REPLACE CRANKSHAFT FRONT OIL SEAL
If timing geer cover i' removed from cylinder block:
Using a screwdriver and hammer. tap out the oil s8al.
(b)
Using SST and a hammer. tap in a new oil seal until its
A.
surface is flush with the timing gear cover edge.

SST 09223-78010
(e)
Apply MP grease to the oil seal lip.
B.
(a)
If timing ge.r cover i, in,talled to the cylinder block:

Using SST. remove the oil seal.
SST 09308-10010.09950-50010 (09953-050101
(b)
Ie)
Apply MP grease to a new oil seal lip.

Using SST and a hammer. tap in the oil seal until its
SST 09223-78010
--
INJECTION PUMP DRIVE GEAR OIL SEAL

REPLACEMENT
A.
(a)

seal as follows:
REPLACE INJECTION PUMP DRIVE GEAR OIL SEAL
If timing geer cover i. removed from cylinder block:
Using a screwdriver and hammer. tap out the oil seal.

(b)
(c)
EG35
SST 09214-76011
EG
"""
B.
(a)
(b)
(c)
(d)
If timing gear cover is installed to the cylinder block:

Using a knife. cut off the oil seal lip.
Using a screwdriver. pry out the oil seal.
NOTICE: B. careful not to damage the injection pump
drive g8.r. Tepa the screwdriver tip.

SST 09214-76011
"""
__-0'
TIMING GEARS INSTALLATION

1.
INSTALL CRANKSHAFT TIMING GEAR
(a)
Put the timing gear with the timing mark facing forward.
Align the set key on the crankshaft with the key
groove of the timing gear.
Using SST and a hammer. tap in the timing gear.
(bl
(e)
SST 09223-00010
2.
INSTALL INJECTION PUMP DRIVE GEAR
(a)
Align the set key on the drive shaft with the key
groove of the drive gear. and install the drive gear.
Install a new 0 - ring to the drive gear groove.
Install the gear nut.
Using SST. tighten the gear nut.
(b)
(e)
(d)
SST 09960-10010 (09962-01000.09963-00700)

EG-36

3.
(a)
INSTALL IDLER GEAR

Align the bolt holes of the idler gear shaft and cylinder
block. and install the idler gear shaft.
(b)
Using SST. turn the injection pump drive gear clock-
wise or counterclockwise. and align timing marks "3'"

and "4" of the idler gear with timing mark *3" of the
crankshaft timing gear and timing mark "4" of the

injection pump drive gear respectively, and mesh the
gears.
(0)
SST 09960-10010 (09962-01000.09963-00700)

Install the thrust plate with the 2 bolts.
Torque: 68 Nm (694 kgfcm. 50 ftlbfj
4.
INSTALL OIL PUMP DRIVE SHAFT GEAR
,
SST
mm
-~~
~
')
lal Align the set key on the crankshaft with the key
groove of the drive shaft gear.
Ibl Using SST and a hammer. tap in the drive shaft gear.
Front
SST 09223-00010
\'-
5. INSTALL NO.2 CYLINDER BLOCK INSULATOR

6. INSTALL TIMING GEAR COVER
(a) Remove and old packing (FIPG) material and be careful not to drop any oil on the contact surface of the
timing gear cover and cylinder block.
Using a razor blade and gasket scraper, remove

all the old packing (FIPG) material from the
gasket surfaces and sealing groove.
Thoroughly clean all components to remove all
the loose material.
Using a non-residue solvent, clean both sealing

surfaces.
mm
(b)
Apply seal packing to the timing gear cover as shown

in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 2 - 3 mm

(0.08 - 0.12 in.) opening.
Parts must be assembled within 5 minutes of
application. Otherwise the material must be reo
moved and reapplied.
Immediately remove nozzle from the tube and
reinstall cap.
(e)
EG-37
Install the timing gear cover. clamp and bracket with

the 14 bolts.
Torque: 19.6 Nm (200 kgfcm. 14 ftlbtl
HINT: Each bolt length is indicated in the illustration.

Bolt length:
A 25 mm (0.98 in.)
8 50 mm (1.97 in.)
A
EG
Bracket
Mm
7.
(a)
(b)
INSTALL CRANKSHAFT PULLEY

Install a new a-ring to the crankshaft pulley groove.
Align the set key on the crankshaft with the key
groove of the crankshaft pulley.
(c)
Using SST and a hammer. tap in the crankshaft pulley.
SST 09214-60010
(d)
Temporarily install the plate washer and pulley nut.

hd, will hit againlt the pitton top.
B.
INSTALL VACUUM PUMP
(a)
(b)
Install a new O-ring to the vacuum pump.

Install the vacuum pump with the 2 nuts.
9.
INSTALL OIL PIPE
New
O-Ring
"""
Install the oil pipe with the bolt. 2 union bolts and 4
new gaskets.
Torque:
Bolt
1S.6 Nm (200 ksfcm. 14 ft.lbf)
Union bolt
18 Nm (185 kgfcm. 13 ftlbf)
10. INSTALL CAMSHAFT OIL SEAL RETAINER

(See Itep 6 in cylinder head inltallation)
11. INSTALL TIMING PULLEYS AND TIMING BELT
(See steps 1 to 10 in timing belt installation)
12. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST. tighten the pulley nut.
SST 09213-58012 (90201 -08131. 91111- 508451.
09330-00021
Torque: 430 Nm (4.400 kgfcm. 317 ftlbfj
13. INSTALL WATER PUMP PULLEY. FAN. FLUIO

COUPLING AND ORIVE BELTS
(See Itep 7 in water pump installation in Cooling
SYltem)
EG-38
CYLINDER HEAD
INSTALLATION
w J EGR System
Heal Insulator
gis'
<il,
(0,"
~"
--,
__ -I
,,
,,,
"
--
r---EGA Valve Bracket
-, >
~ -.-.~<:@-:--'",-.
Gasket
~~.~~
.--'.'
--,,
,
Turbocharger ---1~~
and Exhaust
Manifold
Assembly
Turbocharger
Stay
Vacuum
Clamp~
""&C"'- Hose:QJ@~~~~;~~~;:.
Gasket
Vacuum--"
Hose
.,
"
Non-reusable part
,,
Throttle Position Sensor
ConnectOr
EG-39
w/o EGR System

Heat Insuletor
---
~~
__ ~~"
1.~ . . --,-,-:1;;;y~~@
,,,
~T---IntakePipe
~~~~~[=.:
Gasket
Intake Heater
~.
Vacuum Hose
rGJ'--Turbochargar and
Gasket
E~haust Manifold Assembly
~Intake Pipe Insulator
~,
~:fiiblf----'----'-'; -. Gasket
_--I!
'~'
~_
Turbocharger
Stay
~ ~
~---l
Injection Pipe
,,
,
If
,
"'~Cla~p
"""
~~~,
... ..., ... ~&
~:J~~~'~;~~i~:~:~~5~
Intake Manifold
Insulator
I ,
,,,
,
,,
,,
'~
,,
,
,,,
,
Clamp
'
't
Clamp
Accelerator
link Assembly
,,
-,
,,

Connector (AfT)
Non-reusable part
EG
EG-40
No.1 NOlzle Leakage Pipe
Cylinder Head C over
-----t:"!~:~".::::::;
",
----_:_---_:~
,j
'"
12
' _ --1l-. "'''-''
..,
--Elll~0:--~:---
~---,
eal Washer
Gasket
~::.~::~~,~~,:::.
~g~==~~~5~~~~~~~~~~~~~~~~t~."..
C,m,h," B
ocker Shaft A
C,m,h,"
, ,y Sot BK,y _
P II
ear,"
--
-,
",mbly
" ", .
Q;:J
""'9
Th,""
PI."
Seal Retainer----O'"
! ,'
,,NO""
,1,
Hold"
F r ' Injection
S"I
~. NOlzleSeat
'"1iQ:t!~:~:"'-'
;-,
" _-. . :~~_-_J
S,ml.Cr",I,
P I ' 9 ' ----""
0'
~~~~~~~~~~~~~~~~~---CYljnder
_~~;~~;~~~~~~~~~~~.~~~
.. "-
D-Rlng
Timing Belt
~.
~_'
\\'
"'\
\
Head
ypa~s
(from InJectlOnHose
Pum I
Cy rmder Head Gasket
Clip--~~
_.IJ!'--=--.
Insulator
(p~Seal Washer
Non-reusabl c part
Gasket
~~if
Camshaft Oil
Timing Belt
Cover
Seat Washer
'
>--
Gasket
Water B
EG41
ENGINE - ENGINE M ECHANICAL
Rocker Arm , Nozzle Holder CIamp and Rocker Shaft A ssembly

Camshaft Bearing Cap, Vave
I
Nozzle Holder Clamp

Camshaft
Be Bring
.
Cap
Valve Rocker Arm
r--
Cylinder Head Assembly
'<l':''b
Ii
Valve Bridge
.~ Keeper
:=-sprin g Retainer
0: ~
Valve Spring
,
Ol@)--------SP'
e
U: R
RI
Val
nng Seat
Oil Seal
'Ie GUide=f+U
Bushing
I I '
"
Turbocharger and
Exhaust Manifold A ssembly
'
Rear Exh Bust Manifold
Front Exhaust
,
* Water
-~
Tsemperature/ /
l!-v"ve
ansar
Manifold
._~\
m ,,0
,', "0
,
Collar
"'"
'r. C(' ~ti';" c RI09-O'l,j'-""'"

aRing '~:,
1~!
R;09~-~'_:'
~ . Gasket
D-Ring
~~J~~J!j---TurbOCharger
III
:~
"
'
~ ~ :
Non-reusable
* Preeo,' e d partpart
!iI !iI
P2Jl89
EG-42
CYLINDER HEAD REMOVAL

1.
2.
DRAIN ENGINE COOLANT

wi EGR System:
REMOVE INTAKE PIPE ASSEMBLY
(a)
Disconnect the 3 vacuum hoses from the vacuum
pipe on the intake manifold.

(b)
EG
Disconnect the vacuum hose from the 3 clamps on
the timing belt cover and fuel return hose.

(e)
(d)
(e)
Remove the
Remove the
the exhaust
Remove the
2 bolts and EGR valve bracket.

2 nuts holding the EGR valve adapter to
manifold.
2 bolts and 2 nuts holding the intake pipe
to the intake manifold.

(f)
Disconnect the intake pipe from the air hose. and

remove the intake pipe assembly, 2 gaskets and
intake pipe insulator.
w/o EGR
svs(t~;m~zJ~5"m~""
3.
w/o EGR System:

REMOVE INTAKE PIPE AND INTAKE HEATER
(a)
(b)
(c)
(d)
4.
5.
(a)
(bl
Disconnect the vacuum hose from the vacuum pipe
on the intake manifold.

Remove the bolt. and disconnect the ground cable
from the cylinder head.
Remove the 3 bolts and 2 nuts.
Disconnect the intake pipe from the air hose. and
remove the intake pipe. intake heater. 2 gaskets and
intake pipe insulator.
(See Itepi 3 and 5 in injection nozzles removal in
Fuel SYltem)
REMOVE INTAKE MANIFOLD
wi EGR System:
Disconnect the 3 vacuum hose from the injection
pump.
w/o EGR System:

Disconnect these vacuum hose:
2 vacuum hoses from injection pump
Vacuum hose from 2 clamps on timing belt cover

(e)
EG43
Remove the 8 nuts. 8 seal washers. intake manifold
and 2 gaskets.
6.
(a)
(b)
REMOVE WATER OUTLET

Remove the 2 nuts.
Disconnect the water bypass hose from the water
outlet. and remove the water outlet.

(c)
7.
Remove the gasket.

REMOVE TURBOCHARGER ANO EXHAUST
MANIFOLOS ASSEMBLY
(See steps 3 to 5. 7 and 8 in turbocharger removal

Water Bvpass Hose
6.
in Turbocharger System)
REMOVE EXHAUST MANIFOLDS FROM
TURBOCHARGER
(See step 10 in turbocharger removal in
Turbocharger System)
9.
(a)
(b)
SEPARATE EXHAUST MANIFOLDS

Separate the front and rear exhaust manifolds.
Remove the collar.
(e)
Using snap ring pliers. remove the 2 rings from the
(d)
rear exhaust manifold.

Remove all the O-ring materials from the rear ex
haust manifold grooves.

10. REMOVE REAR ENGINE HANGER
EG44

11. REMOVE CYLINDER HEAD COVER
Remove the 12 bolts. 12 seal washers. cylinder head
cover and gasket.
12. REMOVE SEMI-CIRCULAR PLUG
13. REMOVE TIMING BELT AND PULLEYS
(See steps 1 to 4 and 7 in timing belt removal)
EG
14. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b)
Pry out the oil seal retainer.
15. REMOVE INJECTION NOZZLES
(See steps 4. 6 and 7 in injection nozzles removal

in Fuel System)
16. REMOVE CAMSHAFT BEARING CAPS. VALVE

ROCKER ARMS. NOZZLE HOLDER CLAMPS.
ROCKER SHAFT ASSEMBLY AND CAMSHAFT
(a) Remove the 7 bolts (A).
(bl
(e)
Uniformly loosen and remove the 14 other bolts in
several passes. in the sequence shown.

Remove the 7 bearing caps, 12 rocker arms. 6 holder
clamps. rocker shaft assembly and 7 upper camshaft
bearings.
(d)
Keep the bearing caps. rocker arms and n02zle
holder clamps installed with the rocker shaft.
Keep the bearings inserted with the bearing cap.

Remove the camshaft. thrust plate and 7 lower camshaft bearings.
HINT: Arrange the bearings in correct order.
17. REMOVE CYLINDER HEAD ASSEMBLY

(a) Disconnect the water bypass hose (from the injection
pump) from the cylinder head.
(b) Uniformly loosen and remove the 26 cylinder head
bolts in several passes, in the sequence shown.
NOTICE: Head warpage or cracking could result from
removing bolts in incorrect order.
(c)
EG-45
Lift the cylinder head from the dowels on the cylinder

block. and place the cylinder head on wooden blocks
on a bench.
HINT: If the cylinder head is difficult to lift off. pry
with a screwdriver between the cylinder head and
block.
NOTICE: a. car.ful not to damage the contact surfac
of the cylinder head and cylinder block.
CYLINDER HEAD DISASSEMBLY

1.
2.
3.
(a)
REMOVE WATER TEMPERATURE SENDER GAUGE

REMOVE VALVE BRIDGE
HINT: Arrange the valve bridge in correct order.
REMOVE VALVES
Using SST. compress the valve spring and remove the
2 keepers.
SST 09202-70020 109202-00010)
(b)
Remove the spring retainer. valve spring, valve and

spring seat.
HINT: Arrange the valves. valve springs. spring seats
and spring retainers in correct order.
(c)
Using needle - nose pliers. remove the oil seal.
CYLINDER HEAD COMPONENTS

INSPECTION AND REPAIR
1.
(a)
"m"
CLEAN TOP SURFACES OF PISTONS AND

CYLINDER BLOCK
Turn the crankshaft. and bring each piston to the top
dead center (TOe). Using a gasket scraper. remove all
the carbon from the piston top surface.
EG-46
(b)
Remove all the gasket material from the top of the

cylinder block.
NOTICE: B. careful not to scratch the surfac.
(el
Using compressed air. blow carbon and oil from the
bolt holes.
CAUTION: Protect your ay when using high - compr....d air.
2.
CLEAN CYLINDER HEAD
A.
Remove gasket material

Using a gasket scraper. remove all the gasket material
from the cylinder block contact surface.
NOTICE: Ba careful not to scratch the cylinder block
contact lurface.
B.
CI n intake and exhaust ports

Using a wire brush. remove all the carbon from the
intake and exhaust ports.
NOTICE: Ba careful not to scratch the valve contact
lurt8ca.
C.
Clean valve guide bushings

Using a valve guide bushing brush and solvent. clean
all the guide bushings.
D.
Clee" cylinder heed
nr
Using a soft brush and solvent, thoroughly clean the
cylinder head.

3.
A.
Cylinder Block Side
EG47
INSPECT CYLINDER HEAD

Inspect for flatness
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder block
and the manifolds for warpage.
Maximum warpage:
0.20 mm (O.0079 in.)
If warpage is greater than maximum. replace the cylin-
der head.
. ".,-'
~'"Y'
Intake Manifold Side
:f@ "U CI~ll::Nl
IXI
Exhaust Manifold Side
m:i~
P22&96
1\':007
B.
Inspect for cracks

Using a dye penetrant. check the intake ports. exhaust
ports and surface contacting the cylinder block.
If cracked. replace the cylinder head.
C.
Inspect cylinder head bolts

Using vernier calipers. measure the minimum outer
diameter of the compressed thread at the measuring
point.
Standard outer diameter:
10.800 - 11.000 mm (0.4252 - 0.4331 in.)
Minimum outer diameter:
10.55 mm (0.4154 in.)
If the outer diameter is less than minimum. replace the
bolt.
CLEAN VALVES
Using a gasket scraper. chip off any carbon from the
valve head.
Using a wire brush. thoroughly clean the valve.
Thread
Eod
4.
(a)
(b)
EG-48

5.
(a)
INSPECT VALVE STEMS AND GUIDE 8USHINGS
Using a caliper gauge, measure the inside diameter of

the guide bushing.
Bushing inside diameter:
7.010 - 7.030 mm (0.2780 - 0.2768 in.)
nr
+
(b)
Using a micrometer. measure the diameter of the

valve stem.
Valve ,tern diameter:
Intaka
6.970 - 6.985 mm (0.2744 - 0.2750 in.)
Exh8USt
6.960 - 6.975 mm 10.2740 - 0.2746 in.)
lllol109llJlMO!l64o
(e)
Subtract the valve stem diameter measurement from

the guide bushing inside diameter measurement.
Standard oil cl rance:
Intake
0.025 - 0.060 mm (0.0010 - 0.0024 In.)

Exhaust
0.035 - 0.070 mm (0.0014. - 0.0028 in.'

Meximum oil clrance:
lntak.
0.08 mm (0.003' in.)

Exhaust
0.10 mm (0.0039 In.)

valve and cylinder head.
6.
(a)
(b)
[M01'1
INSPECT AND GRIND VALVES

Check the valve face for wear.
If the valve face is worn. replace the valve.
Check the valve head margin thickness.
Standard margin thickness:
1.00 mm (0.0394 in.)
Minimum margin thickness:
0.83 mm (0.0327 in.)
If the margin thickness is less than minimum. replace
the valve.

(e)
EG-49
Check the valve overall length.

Standard overall length:
Intake
126.85 - 127.45 mm (4.9941 - 5.0177 in.)

Exhaust
126.43 - 127.03 mm (4.9775 - 5.0012 in.)
Minimum overall length:
Intake
126.85 mm (4.9941 in.)
Exhaust
126.43 mm (4.9775 in.)
Overall Length
'-
"""
(d)
If the overall length is less than minimum. replace the

valve.
Check the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
7.
(a)
INSPECT AND CLEAN VALVE SEATS

Using a 45 carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b)
Check the valve seating position.

Apply a light coat of prussian blue (or white lead) to
the valve face. lightly press the valve against the
(e)
seat. Do not rotate valve.

Check the valve face and seat for the following:
If blue appears 360 0 around the valve face. the
valve is concentric. If not. replace the valve.

If blue appears 360 0 around the valve seat. the
guide and face are concentric. If not. resurface

the seat.
Check that the seat contact is in the middle of the

valve face with the following width:
Intake
1.4 - 1.8 mm (0.055 - 0.071 in.)
Exhaust
1.6 - 2.0 mm (0.063 - 0.079 in.)
EG-50
..
If not, correct the valve seats as follows:

(1) If the seating is too high on the valve face. use
25 and 45" cutters to correct the seat.
45
25"
~--'---"
1.4 - 1.8 mm (Inlake)

1.6 - 2.0 mm (Exhaustl
(2)
70 (Intake)
..
6S" (Exhaust)
If the seating is too Iowan the valve face. use

70" (intake) or 65 (exhaust) and 45 cutters to
correct the seat.
"""
(d)
Hand-lap the valve and valve seat with an abrasive

compound.
60~~
~()O uC;;
Deviation
(e)
After hand-lapping. clean the valve and valve seat.
8.
(a)
INSPECT VALVE SPRINGS

Using a steel square. measure the deviation of the
valve spring.
M8xlmum devl.tion:
2.0 mm (0.079 In.)
""'"
If the deviation is greater than maximum. replace the

valve spring.
(b)
Using vernier calipers. measure the free length of the

valve spring.
Fr I.ngth:
49.8 mm (1.9527 In.)
If the free length is not as specified. replace the valve
spring.
EG-51

(0)
Using a spring tester, measure the tension of the valve

spring at the specified installed length.
Installed tension:
237 - 263 N (24.2 - 26.8 kgt. 53.4 - 59.1 Ibt)
at 39.5 mm (1.555 in.)
If the installed tension is not as specified. replace the
valve spring.
EG
EM0281
9.
INSPECT VALVE ROCKER ARM AND SHAFT
(a)
Check that each rocker arm turns smoothly.

If movement is felt. disassemble and check.
(b)
Remove the bolt. and disassemble the parts.

HINT: Arrange the disassembled parts in correct
order.
{31
Camshaft Bearing Cap

No.1(l)
NO.7 121
(21
Others (3)
~~~
~ ~Mar~
Mark 1
{41
(2)
Mark 7
(51
{51
{51
(5)
Valve Rocker Arm

Nozzle Holder
~~~
Intake (4)
Exhaust (5)
. Valve Rocker Shah
{41
P2Jl92
,,,,,,
(e)
Using a caliper gauge. measure the inside diameter of
the rocker arm.

Rocker arm inside diameter:
20.012 - 20.033 mm (0.7879 - 0.7887 in.)
"""
EG-52
(d)
Using a micrometer. measure the diameter of the

rocker arm shaft.
Shaft diemeter:
19.972 - 19.993 mm (0.7863 - 0.7871 in.)
(8)
Subtract the rocker arm shaft measurement from the

rocker arm measurement.
Standard oil cla.rence:
0.019 - 0.061 mm (O.OOO7 - 0.0024 in.)
Maximum oil cI rence:
0.' 0 mm (0.0039 in.)
EG
If the clearance is greater than maximum, replace the

rocker shaft and shaft.
(f)
Assemble the parts as shown in the illustration.
(See step (b) above)
10. INSPECT CAMSHAFTS AND BEARINGS

A. Inspect cam.haft for runout
(a) Place the camshaft on V-blocks.
(b) Using a dial indicator. measure the circle runout at the
center journal.
Maximum circle runout:
0.10 mm (0.0039 in.1

If the circle runout is greater than maximum. replace
the camshaft.
B.
Inspect cam lobes

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
48.498 - 48.598 mm (1.9094 - 1.9133 in.)

Exhauat
50.734 - 50.834 mm (1.9974 - 2.0013 in.)
Minimum cam lobe height:
Intake
47.998 mm (1.8897 in.)
Exhauat
50.234 mm (1.9777 in.)
If the cam lobe height is less than minimum. replace

the camshaft.
c.
EG53
Inspect camshaft journals

Using a micrometer. measure the journal diameter.
Journal diameter:
No.1
34.969 - 34.985 mm (1.3767 - , .3774 In.)
Oth.,.
27.986 - 27.998 mm (1.1018 - 1.1023 in.)
If the journal diameter is not as specified. check the oil

clearance.
Plastigage
D.
Inspect camshaft bearings

Check the bearings for flaking and scoring.
If the bearings are damaged. replace the bearing caps
and cylinder head as a set.
E.
(a)
Inspect camshaft journal oil clearance

Clean the bearing caps and camshaft journals.
(b)
Place the camshaft on the cylinder head.
(e)
Lay a strip of Plastigage across each of the camshaft

journals.
(d)
Remove the 7 bearing caps from the valve rocker

shaft. (See item E above)
t.
10 9 '4t 13
t5
t
t
'11
(e)
Install the 7 bearing caps with the 14 bolts. Uniformly

tighten the bolts in several passes, in the sequence
shown.
Torque: 25 Nm (250 kgfcm, 18 ft.lbfj
NOTICE: Do not turn the camshaft.
(f)
Uniformly loosen and remove the 14 bolts in several

passes, in the sequence shown.
Remove the 7 bearing caps.
's
(g)
EG-54
(h)
Measure the Plastigage at its widest point.

Standard oil deer. nee:
No.1
0.022 - 0.074 mm (0.0009 - 0.0029 in.)

Oth.r.
0.023 - 0.075 mm (o.oooe - 0.0030 in.)
Maximum oil cla.r.nc.:
0.10 mm (0.0039 In.)
EG
(i)
If the oil clearance is greater than maximum. replace

the camshaft. If necessary. replace the bearing caps
and cylinder head as a set.
Completely ,emove the Ptastigage.
Install the 7 bearing caps to the valve rocker shah.
(See item E above)
F.
(a)
Inspect c.mlh.ft thrust cleer.nce

Install the camshaft.
(Se8 procedure in item E above)
(b)
Using a dial indicator. measure the thrust clearance

while moving the camshaft back and forth.
Standard thrust cl renc.:
(c)
Intake Manifold
0.100 - 0.200 mm (0.0039 - 0.0079 in.)

Mnimum thru.t cle.rance:
0.30 mm (0.01'8 In.)
If the thrust clearance is greater than maximum. replace the camshaft. If necessary. replace the bearing
caps and cylinder head as a set.
Remove the camshaft.
11. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge. measure the surface contacting the cylinder head for war
page.
M.ximum w.rp.g.:
0.40 mm (0.0157 in.)
If warpage is greater than maximum. replace the manifold.

Exhaust Manifold
EG-55
12. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and feeler gauge, mea

sure the surface contacting the cylinder head for warpage.
Maximum warp.g.:
0.40 mm (0.0157 in.)
If warpage is greater than maximum. replace the manifold.
CAMSHAFT OIL SEAL REPLACEMENT
--

seal which are as follows:
A.
(a)
(b)
Ie)
REPLACE CAMSHAFT OIL SEAL

If camshaft oil .8al retainer is removed from
cylinder head:
Using a screwdriver. tap out the oil seal.
surface is flush with the oil seal retainer edge.
SST 09223-46011
B.
If camshaft oil s881 retainer is installed to cylinder

heed:
(a)
(b)

Using 2 screwdrivers. pry out the oil seal.
NOTICE: Be careful not to damage the cemshaft. Tape
the screwdriver tip.
Cut Position
EG
EG56
(e) , Apply MP grease to a new oil seal lip.

(d) Using SST and a hammer. tap in the oil seal until its
surface ;s flush with the oil seal retainer edge.
SST 09223-46011
CYLINDER HEAD ASSEMBLY
--
HINT:
Thoroughly clean all parts to be assembled.

Before installing the parts. apply new engine oil
to all sliding and rotating surfaces.
1.
(a)
(b)
(e)
Replace all gaskets and oil seals with new ones.
INSTALL VALVES
Using SST. push in a new oil seal.
SST 09201-41020
Install these parts:

(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
Using SST. compress the valve spring and place the 2

keepers around the valve stem.
SST 09202-70020 109202-00010)
SST
.,,,,,
(d)
EG-57
Using a plastic-faced hammer. lightly tap the valve

stem tip to assure a proper fit.
EG
2.
(a)
(b)
Seal Packing
INSTALL VALVE BRIDGES

Install the valve bridge.
Check that the valve bridge rotates smoothly.
3.
INSTALL WATER TEMPERATURE SENDER GAUGE
(a)
Apply seal packing to 2 or 3 threads.

SI packing:
(b)
Part No. 08826 - 00100 or equivalent

Install the sender gauge.
EG-58
--
CYLINDER HEAD INSTALLATION

1.
A.
(a)
(b)
(e)
(d)
PU"~
PHIlO
''''''
(f)
0c:::;
0<::)
~
~
O~
0
Measuring Point
"""
HINT:
Use a dial indicator measuring tip as shown in the

illustration.
Make sure that the measuring tip is square to the

cylinder block gasket surface and piston head
when taking the measurements.
Find where the piston head protrudes most by slowly
turning the crankshaft clockwise and counterclock-
Measure each cylinder at 2 places as shown in the

illustration. making a total of 12 measurements.
For the piston protrusion value of each cylinder. use
the average of the 2 measurements of each cylinder.
Protrusion (P):
0.175 - 0.425 mm (0.0069 - 0.0167 in.)
r(@)"~
-.g...
Clean the cylinder block with solvent.

Set the piston of the cylinder to be measured to
slightly before TOe.
Place a dial indicator on the cylinder block, and set the
dial indicator at 0 mm (0 in.).
wise.
(8)
dOo0<f!.<;;,o tP~OO~~O~o'5
~O<::)
CHECK PISTON PROTRUSION AND SELECT

CYLINDER HEAD GASKET
Check piston protrusions for each cylinder
B.
When removing piston and connecting rod assembly:

If the protrusion is not as specified. remove the piston
and connecting rod assembly and reinstall it.
(See cylinder block disassembly and assembly)
Select new cylinder head gasket
HINT: There are 5 types of gasket (cutout number 1 to
5) installed at factory. but only 3 types for supply
parts (cutout number 1. 3 and 5). so when replacing
the gasket select from one of 3 types above.
New Installed cylinder h..d gasket thickne..:
Cutout number 1
0.85 - 0.95 mm (0.0335 - 0.0374 in.)
Cutout number 3
0.95 - 1.05 mm (0.0374 - 0.0414 in.)
Cutout number 5
1.05 - 1.15 mm (0.0414 - 0.0453 in.)
Select the largest piston protrusion value from the

measurements made. then select a new appropriate
gasket according to the table below.
Piston protrusion
Gasket sizi
0.225 mm (0.0089 in.) or leu
Us, 1
0.226 - 0.325 mm 10.0089 - 0.0128 in.)
Uroe 3
0.326 mm (0.0128 in.) or more
Un 5
Turn
EG-59
2.
SET NO.1 CYLINDER TO BDC/COMPRESSION

Turn the crankshaft pulley, and align the timing mark
of the No.2 camshaft timing pulley, with the BOC
mark of the timing gear cover.
3.
A.
la}
INSTALL CYLINDER HEAD
,,,,,,
Place cylinder head on cylinder block
Place a new cylinder head gasket in position on the
cylinder block.
NOTICE: B. car.ful of the install.tion diraction.
(b)
Place the cylinder head in position on the cylinder

head gasket.
B.
Inltall cylinder head bolts
(al
HINT:
The cylinder head bolts are tightened in 3 pro

gressiv8 steps (steps (b). (d) and (e)).
a
If any bolts is broken or deformed. replace it.
Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(bl
Install and uniformly tighten the 26 cylinder head

bolts in several passes. in the sequence shown.
Bolt length;
A 121.5 mm (4.783 in.)
B 133.5 mm (5.256 in.)
If anyone of the cylinder head bolts does not meet the
torque specification. replace the cylinder head bolt.
(c)
(d)
Mark the front of the cylinder head bolt with paint.

Retighten the cylinder head bolts 90 in the numerical
order shown.
Retighten cylinder head bolts by an additional 90 .
Check that the painted mark is now facing rearward.
Connect the water bypass hose (from the injection
pump) to the cylinder head.
(e)
(f)
(g)
EG60

4.
Others
No.1
EG
29mm
INSTALL CAMSHAFT. CAMSHAFT BEARING CAPS

VALVE ROCKER ARMS NOZZLE HOLDER CLAMPS
AND ROCKER SHAFT ASSEMBLY
HINT: Camshaft bearings come in widths of 20 mm
(0.79 in.) and 29 mm (1.14 in.). Install the 29 mm
(0.886 in.) bearings in the No.1 cylinder head journal
positions with the camshaft bearing cap. Install the 20
mm (0.79 in.) bearings in the other positions.
(al
Install the 710wer camshaft bearings and thrust plate.
(b)
Place the camshaft on the cylinder head. facing the

key groove upward.
(e)
Install the 7 upper camshaft bearings to the bearing
caps.
(d)
(e)
Install the 7 bearing caps, 12 rocker arms, 6 holder

clamps and rocker shaft assembly.
Install and uniformly tighten the 14 bearing cap bolts
in several passes, in the sequence shown.

(f)
5.
6.
(a)

Install the 7 others bolts.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
INSTALL INJECTiON NOZZLES
(See steps 1, 2 end 4 in injection nozzles install.tion
in Fuel System)
INSTALL CAMSHAFT OIL SEAL RETAINER
Remove any old packing (FIPG) matarial and be care
ful not to drop any oil on the contact surfaces of the
oil seal retainer and cylinder head.
e
all the oil packing (FIPG) material from the gasket
surfaces and seating groove.
e
the loose material.
(b)
Seal Width
2-3mm
EG-61
Using a non-residue solvent. clean both sealing
surfaces.
Apply seal packing to the oil seal retainer as shown in
the illustration.
S' packing:
Pert No. 08826-00080 or .qulnlan'

application. Otherwise the material must be reo
(0.08 - 0.12 in.) opening.
(e)
reinstall cap.
Install the oil seal retainer with the 4 bolts. Uniformly
tighten the bolts in several passes.
Torque: 19.6 Nm (200 kgfcm. 14 ft.lbf)
7.
B.
9.
(a)
(b)
Ie)
INSTALL PULLEYS AND TIMING BELT

(See .tep. 1 end 4 to lOin timing belt installation)
CHECK AND ADJUST VALVE CLEARANCE
(See steps 2 to 4 in valve cleafence inspection
and adjustment)
INSTALL SEMI- CIRCULAR PLUG
Remove any old packing (FIPG) material.
Apply seal packing to the semi - circular plug as
shown in the illustration.
SI puking:
Part No. 08826-00080 or .quinlent
Install the semi-circular plug to the cylinder head.
10. INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in
the illustration.
S..I pecking:
Part No. 08826-00080 or .qulvalent
(c)
(d)
New D-Ring
Install the gasket to the cylinder head cover.

Install the cylinder head cover with 12 new seal washers and 12 bolts. Uniformly tighten the bolts in several
passes.
Torque: 6.4 Nm (65 kgfcm. 57 in..lbf)
11. INSTALL REAR ENGINE HANGER

-Ring End
12. ASSEMBLE EXHAUST MANIFOLDS

(a) Install 2 new 0 - rings to the rear exhaust manifold.
(b) Using snap ring pliers. install the 2 rings to the rear
exhaust manifold.
(c) Position the rings so that the ring ends are as shown.
NOTICE: Do not align the ring end.
EG-62
(d)
(e)
Install the collar to the rear exhaust manifold.

Assemble the front and rear exhaust manifolds.
13. INSTALL EXHAUST MANIFOLD TO

TURBOCHARGER
(5 step 2 in turbocharger installation in
Turbocherger Sy.tem)
EG
14. INSTALL TURBOCHARGER AND EXHAUST

MANIFOLDS ASSEMBLY
(S step. 4. 5 and 8 to 9 in turbocharger

installation in Turbocherger System)
15. INSTALL WATER OUTLET
(a) Install a new gasket to the intake manifold.
(b)
(e)
Connect the wate, bypass hose to the water outlet.

Install the water outlet with the 2 nuts.
Torque: 19.8 Nm (200 kgt.em. , . ftlbf)
16. INSTALL INTAKE MANIFOLD

(a) Install 2 new gaskets and the intake manifold with the
8 seal washers and 8 nuts. Uniformly tighten the nuts
in several passes.
Torque: 19.8 Nm {200 kgfem, 14 ftlbt)
(b)
wi
EGR System:
Connect the 3 vacuum hoses to the injection pump.
(e)
w/o EGR System:

Connect these vacuum hoses:
2 vacuum hoses to injection pump
Vacuum hose to 2 clamps on timing belt cover
17. INSTALL INJECTION PIPES
(See stepi 3 end 5 in injection nozzles installation in

Fuel SYltem)

18.
(a)
(b)
wi
EG-63
EGR Sy.tem:
INSTALL INTAKE PIPE ASSEMBLY

Place the intake pipe insulator on the cylinder head.
Install a new gasket to the intake manifold.

NOTICE: B. c.r.ful of the in.tell.tion direction.
(e)
(d)
Install a new gasket to the exhaust manifold.

Connect the intake pipe to the air hose.
(e)
Place the intake pipe assembly on the intake manifold

and exhaust manifold.
(f)
Install the 2 bolts and 2 nuts holding the intake pipe to

the intake manifold.
(g)
Install the 2 nuts holding the EGA valve adapter to the
exhaust manifold.
Torque: 40 Nm (400 kgfcm, 26 ftlbf)
(h)
Install the EGR valve bracket with the 2 bolts. Alter

"ately tighten the bolts in several passes.
(i)
Install the vacuum hose to the 3 clamps on the timing

belt cover and fuel return hose.
Ul Connect the 3 vacuum hoses to the vacuum pipe on
the intake manifold.
19. w/o EGR Sy.tem:
INSTALL INTAKE PIPE AND INTAKE HEATER
(a) Place the intake pipe insulator on the cylinder head.
(b) Install a new gasket. the intake heater and a new
gasket to the intake manifold.
NOTICE: B. careful of the Inlt.lI.tion direction.
(c) Connect the intake pipe to the air hose.
(d) Install the intake pipe to the intake manifold with the
3 bolts and 2 nuts.
Torque:
10 mm hd
1.5 Nm (75 kgfcm. 66 in..lbf)
12 mm h..d
19.8 Nm 1200 k"fcm. 14 ft.lbf)
(e)
Install1he ground cable to the cylinder head with the

bolt.
(f) Connect the vacuum hose to the vacuum pipe on the
intake manifold.
20. FILL WITH ENGINE COOLANT
21. START ENGINE AND CHECK FOR LEAKS
22. RECHECK ENGINE COOLANT LEVEL AND OIL
LEVEL
EG64
--
CYLINDER BLOCK
COMPONENTS FOR PREPARATION AND

AFTER ASSEMBLY
Water Inlet
" "," G)'.?'Ii
V'
Q..........
G"kat
Thermostat
~NO.1CYlinderBrOCk
~
Insulator
"
... .........
Alternator and Bracket

Assembly
------
Alternator
........
, I
:::::at~---,,-.Jrlll~'~~i~
Oil Cooler
---
l~
......
Assembly
+__
.1>._";;~
"-",-+-_W8ter Bypass
r
Hose
,,'
, "
~fl--Oil
",
Dipstick and Guide
Rear End Plate
.,'
,,,,00
"
Flywheel
(MIT)
_~x8
Taper Screw
Plug
J.., '
~
,,
,
1-<[\1/,,---1
~~
x7~
Q.
z..---ti,'1'1
t I
..
::" . ~
: :
,
......
"':":-',
..
..
:<
..... ......
"< ..
.. <
---+l-~~,-~
,
Gl!ISket~
Drain Plug
Non-reusable part
* Preeeated part
~i
O;IP.n_",,(~~,~~'~i~
.
... "
u
InjeclionPumpStay
lH Engine
~~
_____
i-x 27
""
, .... ..:~~
')J
Q-Ring
Oil Pressure Sender

"'~'-----'G. go
~~;;- ..
..
I!
r~--I
Oil Pump
Injection Pump
,
,
-~'~. . , ( :"
,~'-~~~'
.- ~
..
AfT
Flywheel
Mounting Bracket
PREPARATION FOR DISASSEMBLY

1.
2.
3.
4.
5.
6.
7.
B.
9.
10.
,1.
12.
13.
14.
15.
16.
17.
18.
EG-65
--.
MIT:
REMOVE FLYWHEEL
A/T:
REMOVE REAR PLATE. DRIVE PLATE AND
FLYWHEEL
REMOVE REAR END PLATE
INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
REMOVE TIMING BELT AND PULLEYS
(See timing belt removal)
REMOVE CYLINDER HEAD
(See cylinder head removal)
REMOVE TIMING GEARS
(See timing gears removel)
REMOVE ALTERNATOR ADJUSTING BAR. TURBO
WATER PIPE AND WATER PUMP
(See water pump removal in Cooling System)
REMOVE WATER INLET AND THERMOSTAT
(See thermo.tat removal in Cooling System)
REMOVE ALTERNATOR AND BRACKET
ASSEMBLY
REMOVE INJECTION PUMP
(See injection pump removal in Fuel System)
REMOVE NO.1 CYLINDER BLOCK INSULATOR
REMOVE INJECTION PUMP STAY
REMOVE OIL PAN. OIL PUMP (TIMING GEAR CASE)
AND OIL STRAINER
(See oil pump removal in Lubrication System)
REMOVE OIL DIPSTICK. GUIDE AND OIL COOLER
ASSEMBLY
(See oil cooler removal in lubrication System)
REMOVE OIL PRESSURE SENDER GAUGE
REMOVE TURBO OIL HOSE
REMOVE ENGINE MOUNTING BRACKETS
EG-66
_.".
COMPONENTS FOR DISASSEMBLY AND

ASSEMBLY
No.1 Piston Ain

No.2 Piston Ring
======1Gi.
~,
Oil Ring
...
..,;;;;...o:l'------Coil
t3
Pislon-----=-"1
Snap Ring
Connecting
----!1
()>----+ Snap Ring
{[l------+ Connecting Rod Bushing
Rod------i
Connecting Rod Bearin9l'---_ _-'

Connecting Rod C a p - - - - - -
Rear Oil Seal Retainer
Oil N O l z \ e - - - - - -
Check Valve
Crankshaft ------::~
M.;n Be,,;n. C.p-O);;~'H~o;,~e;G;e~'k;e~t;~~~Ij>~;'~~I~j~

'
~:;P",
Cylinder Block
!
Non-reusable part
.
0-
Crankshaft
Rear Oil
Seal
EG-67
_ _M
CYLINDER BLOCK DISASSEMBLY

,.
(a)
(b)
2.
REMOVE REAR OIL SEAL RETAINER

Remove the 6 bolts.
Using a screwdriver. remove the oil seal retainer by
prying the portions between the oil seal retainer and
main bearing cap.
CHECK CONNECTING ROD THRUST CLEARANCE

while moving the connecting rod back and forth.
Standard thrust cle.rance:
0.100 - 0.200 mm (0.0039 - 0.0079 in.)
3.
(a)
(b)
....
0.30 mm (0.0118 in.)

If the thrust clearance is greater than maximum. re
place the connecting rod assembly. If necessary. replace the crankshaft.
REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE
Check the match marks on the connecting rod and cap
to ensure correct reassembly.
Remove the 2 connecting rod cap bolts.
(e)
Using the 2 removed connecting rod cap bolts. and

remove the connecting cap by wigging the connecting
rod cap right and left.
HINT: Keep the lower bearing inserted with the connecting rod cap.
(d)
(el
Clean the crank pin and bearing.

Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged. replace the
bearings. If necessary. grind or replace the crankshaft.
EG-68
ENGINE -
ENGINE MECHANICAL
(1)
Lay a strip of Plastigage across the crank pin.
(9)
Install the connecting rod cap with the 2 bolts.

(See step 8 in cylinder block assembly)
Torque:
lot
37 Nm (375 kgfcm. 27 ftlbf)
2nd
Turn 90 0
NOTICE: 00 not turn the crank.haft.
(h)
Remove the 2 bolts. connecting rod cap and lower

bearing. (See procedure (b) and (e) above)
(i)

Standard oil c.J rence:
$TD
0.036 - 0.054 mm (0.0014 - 0.0021 in.)

U/S 0.25 and U/S 0.50
0.037 - 0.077 mm (0.0015 - 0.0030 in.)
Maximum oil cl ranc8:
0.10 mm (0.0039 in.)

the bearings. If necessary. grind or replace the crankshaft.
Mark
l,2or3
Mark
1,2 or 3
HINT: If using a standard bearing, replace it with one

having the same number. If the number of the bearing
cannot be determined, select the correct bearing by
adding together the numbers imprinted on the crank
shaft and connecting rod, then selecting the bearing
with the same number as the total. There are 5 sizes
of standard bearings, marked '"r, '"3'", '"4, '"5, and '"6
accordingly.
Connecting rod
Crankshaft
Bearing
EXAMPLE:
Number marked
2
2
H
Connecting rod '"2 + Crankshaft H, H
:: Total number (Use bearing '"3
H
P211!103
1'227M
P23lJO
''''''
EG-69

Reference
Connecting rod big end inside diameter:

Mark""
82.014 - 62.020 mm (2.4415
2.4417 in.)
Merit "z"
82.020
82.026 mm (2.4417
2.4420 in.)
62.026
82.032 mm (2.4420 - 2.4422 in.)
Mark "3"
Crankshaft crank pin diameter:

Mark""
58.994 - 59.000 mm (2.3226
2.3228 in.)
Mark "2"
58.988
58.994 mm (2.3224
2.3226 in.)
Mark '3"
58.982
58.988 mm (2.322'
2.3224 in.)
Standard sized be.ring center wall thickne.s:
(j)
4.
Mark '2"
1.486
1.489 mm (0.0585
0.0586 in.)
Mark '3"
1.489
1.492 mm (0.0586
0.0587 in.)
Mark "4"
1.492
1.495 mm (0.0587
0.0589 in.)
Mark "5"
1.495
1.498 mm (0.0589
0.0590 in.)
Mark "6"
1.498 - 1.501 mm (0.0590
0.0591 in.)
Completely remove the Plastigage.
REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Using a ridge reamer. remove all the carbon from the
top of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings. connecting rod and cap together.
Arrange the piston and connecting rod assemblies in correct order.

5. CHECK CRANKSHAFT THRUST CLEARANCE
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.040 - 0.240 mm (0.0016 - 0.0094 in.)
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum. reo
place the thrust washers as a set.
Thrust washer thickneas:
2.930 - 2.980 mm (0.1154 - 0.1173 in.)
6. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Remove the 15 main bearing cap bolts (6 pointed
head).
Ell
EG-70

(b)
Uniformly 100s8n and remove the 14 main bering cap

bolts (12 pointed head) in several passes, in the sa
quence shown.
(c)
Using a screwdriver. remove the main bearing cap by
prying the portions between the main bearing cap and

cylinder block.
NOTICE: S. careful not to scratch the surfac contacting the main bring cap and cylinder block.
(d)
HINT: Keep the lower bearings inserted with the main

bearing cap.
lift out the crankshaft.
HINT:
Keep the upper bearings inserted with the cylinder block.
(e)
(t)
Arrange the thrust washers in correct order.
Clean each main journal and bearing.

Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged. replace the bear
ings. If necessary, grind or replace the crankshaft.
Plastigage
(g)
(h)
Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.
(i)
Install the main bearing cap with the 14 bolts (12

pointed head).
(See step 5 in cylinder block assembly)
Torque:
1st
103 Nm (1,050 kgtem, 76 ftlbf)
2nd
Turn 90
NOTICE: Do not turn the er.nksh.ft.
Remove the 14 bolts (12 pointed head) and main

bearing cap. (See procedure (b) and (c) above)
EG-71
(k)

Standard cl ranc.:
STD
0.038 - 0.054 mm (0.0014 - 0.0021 in.)
U/S 0.25 and U/S 0.50
0.037 - 0.077 mm (0.0015 - 0.0030 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
the bearings. If necessary, grind or replace the crank

shaft.
HINT: If using a standard bearing. replace it with one
having the same number. If the number of the bearing
cannot be determined. select the correct bearing by
adding together the numbers imprinted on the main
bearing cap and crankshaft. then selecting the bearing
with the same number as the total. There are 5 sizes
of standard bearings. marked .2". 3, 4-, -5 and 6"'
Mark
..., l,2,3,40r5
accordingly.
Crankshaft
Bearing
Main bearing cap
EXAMPLE:
Mark
1,2 or 3
,
2
3
Number marked
2
2
Main bearing cap "'2" + Crankshaft -, ..

= Total number (Use bearing -3"')
1'12170
f>1111l
PJ2772
Reference
Cylinder block main journal bore diameter:
71.006 mm (2.7953
Mlrk'l"
71.000
2.7955 in.)
Mark '2"
71.006 - 71.012 mm (2.7955 - 2.7957 in.)
Mark "3"
71.012 - 71.018 mm (2.7957 - 2.7960 in.)
Crankshaft main journal diameter:

Marlt"l"
66.994 - 67.000 mm (2.6376 - 2.6378 n.)
Mlrk "2"
66.988 - 66.994 mm (2"6373 - 2.6376 in.)
Mark "3"
66.982
66.988 mm (2.6371
2.6373 in.)
Standard sized bearing center wall thickne..:
(I)
Mark "2'
1.979 - 1.982 mm (0.0779 - 0.0780 in.)
Mlrk "3"
1.982 - 1.985 mm (0.0780 - 0.0781 in.)
Mlrk "4"
1.985 - 1.988 mm (0.0781 - 0.0783 in.)
MlrIt "5'
1.988 - 1.991 mm (0.0783 - 0.0784 in.)
Mlrk "6"
1.991 - 1.994 mm (0.0784 - 0.0785 in.)
Completely remove the Plastigage.
EG72

7.
(a)
(b)
REMOVE CRANKSHAFT
Lift out the crankshaft.
Remove the upper bearings and thrust washers from
the cylinder block.

HINT: Arrange the main bearings and thrust washers
in correct order.
8.
REMOVE CHECK VALVES AND OIL NOZZLES
(58e step 2 in oil nozzles removal in Lubric8tion

System)
CYLINDER BLOCK INSPECTION

1.
CLEAN CYLINDER 8LOCK
A.
Remove guket materi.1

Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
B.
Clean cylinder block

Using a soft brush and solvent. thoroughly clean the
cylinder block.
2.
INSPECT TOP SURFACE OF CYLINDER BLOCK FOR

FLATNESS
Using a precision straight edge and feeler gauge. mea

sure the surfaces contacting the cylinder head gasket
for warpage.
Maximum warpage:
0.20 mm (0.0079 In.)

If warpage is greater than maximum. replace the cylinder block.
11">312
3.
""'"
INSPECT CYLINDER FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present. rebore all the 6 cylinders. If necessary. replace the cylinder block.
4.
EG-73
INSPECT CYLINDER BORE DIAMETER

HINT: There are 3 sizes of the standard cylinder bore
diameter. marked "'1, "2" and "'3" accordingly. The

mark is stamped on the top of the cylinder block.
.. GD
EG
~.
Using a cylinder gauge, measure the cylinder bore
CD Th,""
ED
I~
2 SV
Front
o.
NO.6
4 NO.5
diameter at positions A. Band C in the thrust and axial
1 Direction
Axial
-A-
directions.
Standard diamet.r:
STO
Mark .,.
Direction
'0mm
(0.39 in.)
- B
_.
-C~
l 10mm
94.000 - 94.010 mm (3.7001 - 3.7012 in.)

Mark -2-
94.010 - 94.020 mm (3.7012 - 3.7016 in.)
10.39 in.!
Mark -3-
94.020 - 94.030 mm (3.7016 - 3.7020 in.)

Maximum diamet.r:
STD
94.23 mm (3.7098 in.)
O/S 0.50
94.73 mm (3.7295 in.)
If the diameter is greater than maximum. rebore all the
6 cylinders. If necessary. replace the cylinder block.
11~1
(
Thre1'ld
End
5.
REMOVE CYLINDER RIDGE

If the wear is less than 0.2 mm (0.008 in.). using a
ridge reamer, grind the top of the cylinder.
6.
INSPECT MAIN BEARING CAP BOLTS

Using vernier calipers. measure the thread outside
diameter at the measuring point.
St.nd.rd di.meter:
11.800 - 12.000 mm (0.4646 - 0.4724 in.)
Minimum di.meter:
11.50 mm (0.4528 in.)
If the diameter is less than minimum. replace the bolt.
EG-74
PISTON AND CONNECTING ROD

DISASSEMBLY
1.
--.
CHECK FIT BETWEEN PISTON AND PISTON PIN

Try to move the piston back and forth on the piston
pin.
If any movement is felt. replace the piston and pin as
a set.
""'''
2_
(a)
(b)
REMOVE PISTON RINGS

Using a piston ring expander. remove the No.1. No.2
and oil rings.
Remove the coil by hand.
HINT: Arrange the rings in correct order only.
3.
(a)
DISCONNECT CONNECTING ROD FROM PISTON

Using a small screwdriver. pry off the snap ring from
the piston.
(b)
Gradually heat the piston to approx. SDoe (176F).
(c)
Using a plastic-faced hammer and brass bar. lightly
tap out the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.

Arrange the pistons. pins. rings. connecting rods
and bearings in corract order.

INSPECTION
EG-75
--
1.
la}
CLEAN PISTON
Using a gasket scraper. remove the carbon from the
piston top.
(b)
Using a groove cleaning tool or broken ring, clean the

piston ring grooves.
Sized Mark
Front Mark
Ie)
Using solvent and a brush. thoroughly clean the

piston.
NOTICE: Do not u wi,. brush.
2.
A.
INSPECT PISTON AND PISTON RING

In.pect pilton diameter and oil clearance
HINT: There are 3 sizes of the standard piston diams
ter. marked "1'", '"2"' and "3'" accordingly. The mark is
stamped on the piston top.
(a)
Using a micrometer. measure the piston diameter at

right angles to the piston pin center line. 39.06 mm
(1.5378 in.) from the piston head.
(Arrow)
39.06mm
Piston diameter:
STD
Mark
.,O'
93.845 - 93.855 mm (3.6947 - 3.6951 In.)

Mark '"2
93.855 - 93.865 mm (3.6951 - 3.6955 in.)
M.rk "3-
93.865 - 93.875 mm (3.6955 - 3.6959 in.)
O/S 0.50
94.345 - 94.375 mm (3.7144 - 3.7155 in.)
EG-76
(b)
Cylinder Block
(c)
Measure the cylinder bore diameter in the thrust directions. (See step 4 in cylinder block inspection)
Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil cla.rance:
0.145 - 0.185 mm (0.0057 - 0.0065 in.)
Maximum oil cle.rance:
0.215 mm (0.0085 in.)

all the 6 pistons and rebore all the 6 cylinders. If
necessary. replace the cylinder block.
HINT (Use new cylinder block): Use a piston with the
same number mark as the cylinder bore diameter
marked on the cylinder block.
Piston
Mark
,..---::"...----,. 2 or 3
Front
Mark
-....,.~
(Arrow)
''''''
No.1 Ring
No.2 and Oil Ring
B.
Inspect piston ring groove clearance

No.1 Ring:
Install a new piston ring to the piston. Using a feeler
gauge, measure the clearance between the piston ring
and the wall of the ring groove.
Standud groo..... clearanc.:
0.050 - 0.095 mm (0.0020 - 0.0037 in.)
Maximum groove clrance:
0.20 mm (0.0079 in.)
piston.
No.2 and Oil Rings:
Using a feeler gauge, measure the clearance between
a new piston ring and the wall of the ring groove.
Standard groo..... clearanc.:
No.2
0.060 - 0.100 mm (0.0024 - 0.0039 in.)
Oil
0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Maximum groo..... cl.aranc.:
0.020 mm (0.0079 in.)
piston.
C. Inspect piston ring end gap
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the
bottom of the ring travel. 130 mm (5.12 in.) from the
top of the cylinder block.

(c)
EG-77
Using a feeler gauge. measure the end gap.

Standard end gap:
No.1
0.270 - 0.470 mm (O.010e - 0.0185 in.)

No.2
0.400 - 0.650 mm (0.0157 - 0.0256 in.)

Oil
0.200 - 0.500 mm (0.0079 - 0.0197 in.)
Maximum end gap:
No.1
0.85 mm (0.0335 in.)
No.2
0.90 mm (O.0354 in.)

Oil
0.88 mm (0.0348 In.)

If the end gap is greater than maximum. replace the
piston ring. If the end gap is greater than maximum.
even with a new piston ring, rebore all the 6 cylinders
or replace the cylinder block.
3.
INSPECT PISTON PIN FIT

At soe 1176F). you should be able to push the
piston pin into the piston pin hole with your thumb.
4.
A.
INSPECT CONNECTING ROD

Inspect connecting rod alignment
Using a rod aligner and feeler gauge, check the con
nacting rod alignment.

e
Check for bend.
M8ximum bend:
0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
If bend is greater than maximum. replace the connecting rod assembly.
'121:10 (Mlll8l
Check for twist
M8ximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum. replace the connecting rod assembly.
'22731 (MOztO
115310
EG-78
B.
In.pect connecting rod boltl

Using vernier calipers. measure the tension portion
diameter.
Standard diameter:
8.300 - 8.400 mm (0.3268 - 0.3307 In.)
Minimum diameter:
7.95 mm (0.3130 In.)
If the diamet.r is less than minimUm, replace the

connecting rod bolt.
C.
Inspect piston pin oil clearance
(a)
Using caliper gauge. measure the inside diameter of

the connecting rod bushing.
Bushing inside diameter:
33.008 - 33.020 mm (1.2995 - 1.3000 in.)
(b)
Using micrometer. measure the piston pin diameter.

PI,ton pin diameter:
33.000 - 33.012 mm (1.2992 - 1.2997 In.)
(e)
Subtract the piston pin diameter measurement from

the bushing inside diameter measurement.
..,,,
~=
D.
(a)
BUShing"""
~2282&
fr
P228Y.>
St.nd.rd oil clr.nce:

0.004 - 0.012 mm (0.0002 - 0.0005 in.)
M.ximum oil clr.nce:
0.03 mm (0.0012 in.)
the bushing. If necessary. replace the piston and
piston pin as a set.
If necessary. raplace connecting rod bushing
Using SST and a press, press out the bushing.
SST 09222-17010 (09222-05020, 09222-05040)
L----
SST
-
Zl~
(b)
Using a round file. lightly file off any roughness from

the small end of the connecting rod.
(c)
~o;IHOle
EG-79
Attach the bushing to SST with the ball of SST inside

the oil hole of the bushing.
SST 09222-17010 (09222-05030)
~Bell
o-SST
(d)
Align the oil holes of a new bushing and the connecting rod.
-oliHOle
Oil Hole
"""
(e)
Using SST and a press. press in the bushing.
SST 09222- I 701 0 (09222-05020. 09222-05030.

09222-05040)
SST
~
B--SST
Bushing
SST
l'12M2 1'l28l5l
''''''
(f)
Using a pin hole grinder, hone the bushing to obtain
the standard specified clearance (se8 item C above)

between the bushing and piston pin.
(9)
Check the piston pin fit at normal room temperature.

Coat the piston pin with engine oil. and push it into the
connecting rod ns oil. and push it into the connecting

rod with your thumb.
EG-BO
CYLINDER BORING
--
HINT:
Bore all the 6 cylinders to the oversized piston

outside diameter.
1.
EG
Sized Mark
Front Mark
(Arrow)
2.
(a)
(b)
Replace all the piston rings with ones to match

the oversized pistons.
KEEP OVERSIZED PISTDNS

Over.ized piston diametar:
O/S 0.50
94.345 - 94.375 mm (3.7U4 - 3.7155 in.)
CALCULATE AMOUNT TO BORE CYLINDERS
Using a micrometer. measure the piston diameter at
right angles to the piston pin center line. 39.06 mm

(1.5378 in.) from the piston head.
Calculate the amount each cylinder is to be raborad as
follows:
Size to b. ,.bored = P + C - H
P = Pi.ton diemeter
C = Piston cle.rence
0.145 - 0.165 mm (0.0057 - 0.0065 in.1
H = Allowance for honing
0.02 mm (0.0008 in.) or I
39.06 mm
3.
BORE AND HONE CYLINDER TO CALCULATED

DIMENSIONS
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE: Exc honing will dtroy the fini.h.d roundn
EG-S1
--,.
CRANKSHAFT INSPECTION AND REPAIR

1.
(a)
(b)
INSPECT CRANKSHAFT FOR RUNOUT

Place the crankshaft on V- blocks.
Using a dial indicator. measure the circle runout at the
center journal.
Maximum circle runout:
0.08 mm (0.0024 in.)
If the circle runout is greater than maximum. replace
the crankshaft.
2.
(a)
INSPECT MAIN JOURNALS AND CRANK PINS

Using a micrometer. measure the diameter of each
main journal and crank pin.

Main journal diameter:
STD
68.982 - 67.000 mm (2.8371 - 2.6378 In.)
U/S 0.25
66.745 - 66.755 mm (2.6278 - 2.6281 in.)
U/S 0.50
66.495 - 66.505 mm (2.6179 - 2.6183 in.)
Crank pin diameter:
STD
58.982 - 59.000 mm 12.3221 - 2.3228 in.)
U/S 0.25
58.745 - 68.756 mm (2.3128 - 2.3132 in.)
U/S 0.50
58.495 - 58.505 mm (2.3029 - 2.3033 in.)
(b)
If the diameter is not as specified. check the oil clear

ance. (See steps 6 and 9 in cylinder block assembly) If
necessary, grind or replace the crankshaft.
Check each main journal and crank pin for taper and
out-of-round as shown.
Mexlmum teper end out-of-round:
3.
0.020 mm (0.0008 in.)

If the taper and out-of-round is greater than maxi
mum, replace the crankshaft.
IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to
the finished undersized diameter (See procedure in
step 2).
Install new main journal and/or crankshaft pin under
sized bearing.
EG-82
--.
CRANKSHAFT OIL SEAL REPLACEMENT
A.

seal which are as follows:
REPLACE CRANKSHAFT REAR OIL SEAL
If r r oil 1 reteiner i, removed from cylinder
block:
(a)
Using a screwdriver and hammer. tap out the oil seal.
(b)
(c)
Using SST and a hammer. tap in a new oil seat until its
surface is flush with the rear oil seal retainer edge.
SST 09223-56010
B.
If r r oil .eal reteiner i, in.telled to cylinder block:
(a)
(b)

Using a screwdriver. pry out the oil seal.
NOTICE: Be careful not to damage the crank,h.ft. Tepe
the screwdriver tip.
Ie)
Id)
Apply MP grease to a new oil seal lip.

Using SST and a hammer. tap in the oil seal until its
surface is lush with the rear oil seal retainer edge.
SST 09223-5601 0
.,,,,,
\.-_SST

ASSEMBLY
1.
(a)
--
ASSEMBLE PISTON AND CONNECTING ROO

Install a new snap ring on one side of the piston pin
hole.
EG-83
~
Q
Front Mark
IA"ow)
sooe (176F).
(b)
Gradually heat the piston to
(e)
Coat the piston pin with engine oil.
(d)
Align the front marks of the piston and connecting

rod. and push in the piston pin with your thumb.
(8)
Install a new snap ring on the other side of the piston
Front Mark
(Protrusion)
\"
\'-'
~
~
pin hole.
2.
(a)
(b)
INSTALL PISTON RINGS

Install the coil by hand.
Install a piston ring expander. install the oil ring.
HINT: Face the end gap of the oil ring in the opposite
direction of coil joint.
Oil Ring Ends
EG-84

(0)
Using a piston ring expander. install the No.1 and No.
2 piston rings with the code mark facing upward.

Code mark:
Code
Mark
No.1
T1
No.2
2T
Code
Mark
MUll I"22J1.
Front Mark (Arrow)
(d)
Position the piston rings so that the ring ends are as

shown.
NOTICE: Do not align the ring ends.
3.
INSTALL CONNECTING ROD 8EARINGS
(a)
Align the bearing claw with the groove of the connecting rod or connecting rod cap.
Install the bearings in the connecting rod and connecting rod cap.
(b)
CYLINDER BLOCK ASSEMBLY

HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts. apply new engine oil

to all sliding and rotating surfaces.
Replace all gaskets. O-rings and oil seals with

new parts.
1.
INSTALL OIL NOZZLES AND CHECK VALVES
(See step 1 in oil nozzles installation in Lubrication

System)
2.
(a)
(b)
INSTALL MAIN BEARINGS
HINT: Upper bearings have an oil groove and oil hole;

lower bearings do not.
Align the bearing claw with the claw groove of the
cylinder block. and push in the 7 upper bearings.
Align the bearing claw with the claw groove of the
main bearing cap. and push in the 7 lower bearings.

3.
EG-85
PLACE CRANKSHAFT ON CYLINDER BLOCK
EG
4.
INSTALL THRUST WASHERS
(a)
Push the crankshaft toward the front (rear) side.
(b)
Install the 4 thrust washers to the No.4 journal posi-
tion of the cylinder block with the oil grooves facing

outward.
5.
A.
INSTALL MAIN BEARING CAPS

Place main bearing cap on cylinder block
(a)
Remove any old packing (FIPG) material and be careful not to drop any oil the contact surfaces of the main
bearing cap and cylinder block.
the loose material.
(b)
. . . .-
0:
. .
0
. .
0
Seal Width 4 - 5 mm

surfaces.
Apply seal packing to the cylinder block as shown in

the illustration.
$eal packing:

(0.16 - 0.20 in.) opening .
"-"

application. Otherwise the material must be removed and reapplied.
"""
(e)
(d)
B.

reinstall cap.
Install a new cylinder block hole gasket.

Place the main bearing cap on the cylinder block.
Install main bearing cap bolts (12 pointed head)
HINT:
The main bearing cap bolts are tightened in 2
progressive steps (steps (b) and (d)).

If anyone of the main bearing cap bolts is broken
or deformed. replace it.
EG-88
(a)
(b)
Apply a light coat of engine oil on the threads and

under the heads of the main bearing cap bolts.
Install and uniformly tighten the 14 main bearing cap
bolts in several passes. in the sequence shown.
If anyone of the main bearing cap bolts does not meet

the torque specification. replace the main bearing cap
bolt.
(e)
(d)
Mark the front of the main bearing cap bolt with paint.
Retighten the main bearing cap bolts 90 in the nu-
merical order shown above.

(9)
(f)
C.
6.
Check that the painted mark is now at a 90 angle to

the front.
Check that the crankshaft turns smoothly.
Install main bearing cap bolts (6 pointed head)

Install the 15 main bearing bolts.
Torque: 18.' Nm (185 kgfcm. 13 ftlbf)
CHECK CRANKSHAFT THRUST CLEARANCE
(See step 5 in cylinder block disassembly)
7.
INSTALL PISTON AND CONNECTING ROO

ASSEM8L1ES
Using a piston ring compressor, push the correctly

numbered piston and connecting rod assemblies into
each cylinder with the front mark of the piston facing
forward.
8.
INSTALL CONNECTING ROD CAPS
A.
(a)
Piece connecting rod cep on connecting rod

Match the numbered connecting rod cap with the
connecting rod.
Install the connecting rod cap with the front mark
facing forward.
(b)
B.
EG-87
Install connecting rod ClIp bolts

HINT:
The connecting rod cap nuts are tightened in 2

progessive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed.
replace it.
(a)
(b)
Apply a light of engine oil on the threads and under

the heads of the connecting rod cap bolts.
Install and alternately tighten the bolts of the connecting rod cap in several passes.
Torque: 36.8 Nm {375 kgfcm, 27 ftlbfl
(d)
If anyone of the connecting rod cap bolts does not

meet the torque specification. replace the cap bolt.
Mark the front of the connecting rod cap bolt with
paint.
Retighten the connecting rod cap bolts 90 as shown.
(e)
Check that the painted mark is now at a 90 angle to
(c)
the front.
Check that the crankshaft turns smoothly.
CHECK CONNECTING ROD THRUST CLEARANCE
(See step 2 in cylinder block disl!IISsembly)
10. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the
retainer and cylinder block.

all the old packing (FIPGl material from the
the loose material.

surfaces.
(b) Apply seal packing to the retainer as shown in the
illustration.
S..I packing:
(f)
9.
Seal Width
2-3mm
~O
o=sr

(0.08 - 0.12 in.) opening.
HINT: Avoid applying an excessive amount to the
surface.

application. Otherwise the material must be re
reinstall
Install the retainer with the 6 bolts.
Torque: 6.4 Nm (65 kgfcm. 57 In.. lbfl
(c)
EG
:EG
EG88
POST ASSEMBLY
1.
--.
INSTALL ENGINE MOUNTING 8RACKETS

Torque: 68.6 Nm (700 kgfcm. 51 tt.lbf)
2.
3.
INSTALL TURBO OIL HOSE

INSTALL OIL PRESSURE SENDER GAUGE
(See oil pressure check in Lubrication System)
4. INSTALL OIL COOLER ASSEMBLY. OIL DIPSTICK
AND GUIDE
(See oil cooler installation in Lubrication System)
5. INSTALL OIL STRAINER. TIMING GEAR CASE (OIL
PUMP) AND OIL PAN
(See oil pump installation in Lubrication System)
6. INSTALL INJECTION PUMP STAY
Torque: 69 Nm (700 kg'cm. 51 ft-lbf)
7. INSTALL NO.1 CYLINDER BLOCK INSULATOR
8. INSTALL INJECTION PUMP
(S.e injection pump Installation in Fuel System)
9. INSTALL ALTERNATOR AND BRACKET
ASSEMBLY
Torque: 68.6 Nm (700 kgfcm. 51 ft-Ib'l
10. INSTALL WATER INLET AND THERMOSTAT
(See thermostat installation in Cooling System)
11. INSTALL WATER PUMP. TURBO WATER PIPE AND

ALTERNATOR ADJUSTING BAR
(See water pump installation in Cooling System)
12. INSTALL TIMING GEARS
(See timing gears installation)

13. INSTALL CYLINDER HEAD
(See cylinder head installation)
14. INSTALL TIMING BELT AND PULLEYS
(See timing belt installation)
15. DiSCONNECT ENGINE FROM ENGINE STAND
16. INSTALL REAR END PLATE
Install the rear end plate with the bolt.
Torque: 18.1 Nm (185 kgfcm. 13 ttlbf)
17. MIT:
(a)
(b)
INSTALL FLYWHEEL
Install the flywheel on the crankshaft.
Install and uniformly tighten the bolts in several
passes. in the sequence shown.
Torque: 127.4 Nm (1.300 kgfcm. 94 ft.lbf)
18. A/T:
INSTALL FLYWHEEL. DRIVE PLATE AND REAR
PLATE (See procedure step 17)
EG-89
oooco_,.
SERVICE DATA
at 250 rpm
Compression
STo
Minimum
pressure
Diflerence of prlluur. between .ach cylinder
Exhaust
cle.rance
Injection
Europe
Plunger stroke
Austr'''.
timing
MfT
Idl, splIed
AfT
Maximum
2.452 kPa (25.0 kgf/cm', 358 psil

490 kP. (5.0 kgf/cm", 71 psi) or Iiss
Intake
et cold
V.rve
3.432 kP. (35.0 k.,f/cm', 498 psi) or more
0.17 - 0.23 mm (0.007
0.009 in.)
0.47 - 0.53 rnm (0.019 - 0.021 in.)

1.52 - 1.58 mm (0.0598 - 0.0622 in.)
1.37 - 1.43 mm (0.0539 - 0.0563 in.)
700 50 rpm
800 50 rpm
4.400
100 rpm
sp. .d
PS KIt.
650 - 750 rpm
"P
speed
Ale idle "P
775 - 850 rpm
sptlad
Timing belt
9.0
Protrusion from houling end
9.8 mm (0.354 - 0.388 in.)
tensione,
Timing gur
Ieller gllr thrust clrance
STo
MIlt:imum
Idl,r ga.r inside
d~meter
0.15 mm (0.0020
0.0059
in.,
0.30 mm (0.0118 in.)

45.000 - 45.025 mm (1.7717 - 1.7726 in.)
44.950 - 44.975 mm (1.7697 - 1.7107 in.l
Idler g..r sheft die meter

Idler g..r oil elelrlnee
STO
MllCimum
Geer bleklesh
Cylinder head
0.05
STO
W.rp.ge
0.025 - 0.075 mm (0.0010 - 0.0030 in.)

0.20 mm (0.0079 in.l
0.05 - 0.15 mm (0.0020 - 0.0059 in.)
Mlximum
0.30 mm (0.0118 in.l
MllCimum
0.20 mm (0.079 in.l
V.lv, sellt
R,f.eing lingle
Intlk.
Exhlust
25".45".65"
45'
Cont.eting Ingle
Contleting width
Cylindlr heed bolt threed inside di.meter
lntlkl
1.4 - 1.8 mm (0.055 - 0.071 in.}
Exh'Ull
1.6 - 2.0 mm (0.063 - 0.079 in.)
STO
Minimum
Vllv. guid.
25".45",70"
10.600 - 11.000 mm (0.4252 - 0.4331 in.l

10.55 mm (0.4154 in.)
7.010 - 7.030 mm (0.2760
In,id. di.met.r
0.2768 in.)
bushing
Vllv.
V.lve overlll length
STo
Minimum
Stlm dilmltlr
Intlke
126.85 - 127.45 mm (4.9941 - 5.0177 in.)
Exheust
126.43 - 127.03 mm (4.9775 - 5.0012 in.l
Int.ke
126.85 mm (4.9941 in.)
Exheust
128.43 mm (4.9775 in.)
lnt.ke
6.970 - 6.985 mm (0.2744 - 0.2750 in.)
Exh.Ull
6.960 - 6.975 mm (0.2740 - 0.2746 in.l
EG
EG-90
V,lvilcont'd)
ENGINE
ENGINE MECHANICAL
STO
Stem oil elr.nc.
V,lvl rocke,
.rm end shih
0.035 - 0.070 mm (0.0014 - 0.0028 in.)

0.08 mm (0.0031 in.1
"""'~.
0.10 mm (0.0039 in.)
STO
1.00 mm (0.0394 in)
Minimum
0.83 mm (0.0327 in.)
MlfSJin thicknflu
EG
0.025 - 0.060 mm (0.0010 - 0.002" in.)
mt.k,
M.ximum
V,lv, spring
lnl.k,
ExheUit
Mlximum
Deviation
49.8 mm (1.9527 in.)
Inslllled tension.t 32.9 mm (1.295 in.)
237 - 263 N (24.2 - 28.8 kgf. 53.4 - 59.1 Ibfl
V,lvl rocker .rm inside diameter
20.012
Valvi rocker
,hltt diameter
STO
Mlximum
Thrust cle.rance
STO
Mlximum
Joumll oil cll1r.ncl
STO No.1
Othl"
MIl(imum
Journll dilmltlr
No.1
Othl"
Circll runout
CIIm 10M hlight
20.033 mm (0.7879
M'limum
Sf0
Int.kI
Ex:h.usl
MiNmum
0.019 - 0.081 mm (0.0007 - 0.0024 in.1

0.10 mm (0.0039 in.l
0.100
0.200 mm (0.0039 - 0.0079 In.)
0.30 mm (0.0118 in.)

0.022 - 0.074 mm (0.0009 - 0.0029 In.)
0.023 - 0.075 mm 10.0009 - 0.0030 in.)
0.10 mm (0.0039 in.)
34.969 - 34.985 mm (1.3767 - 1.3774 in.)
27.986 - 27.998 mm (1.1018 - 1.1023 in.)
0.10 mm (0.0039 in.)
48.498 - 48.598 mm (1.9094 - 1.9133 n.)
50.734 - 50.834 mm (1.9974 - 2.0013 n.)
Int.kI
47.998 mm (1.8897 in.)
Ex:h.usl
50.234 mm (1.9777 in.)
M.n;fold
WIrPlgl
MIl(imum
0.40 ITWTl (0.0157 in.)
Cylinder block
Cylinder hlad .urf.ce w.rPlg.
MIl(imum
0.20 mm (0.0079 in.)
Cylinder bore di.meter
0.7887 in.)
19.972 - 19.993 mm (0.7863 - 0.7871 in.)
Oil clear.nee
Cemsn.ft
2.0 mm (0.079 in.)
Freelen;th
STO STO
Mertc 1
94.000 - 94.010 mm (3.7001 - 3.7012 in.)
M.rlo: 2
94.010 - 94.020 mm (3.7012 - 3.7016 in.)
Mertc 3
94.020 - 94.030 mm (3.7016 - 3.7020 in.)
M'l(imum STO
94.23 mm 13.7098 in.)
O/S 0.50
94.73 mm (3.7295 in.)
Main bee ring up lIud bolt tension portion diameter

STO
Minimum
Pislon end
Piston diemetar
piston ring
PiSlon
o~
clllr.nce
STO
11.50 mm (0.4528 in.)
Mlrk 1
93.845 - 93.855 mm (3.8947 - 3.8951 in.)
Mirit 2
93.855 - 93.865 mm (3.695\ - 3.6955 in.)
Mirit 3
93.865 - 93.875 mm (3.6955 - 3.6959 in.)
O/S 0.50
94.345 - 94.375 mm (3.7144 - 3.7155 in.)
STO
Minimum
Pilton ring groove clllr.nce
1\.800 - 12.000 mm (0.4848 - 0.4724 in.)
STO No.1
0.145 - 0.165 mm (0.0057 - 0.0085 in.)

0.215 mm (0.0085
in.,
0.050 - 0.095 mm 10.0020 - 0.0037 in.)
No.2
0.060 - 0.100 mm (0.0024 - 0.0039 in.)
Oil
0.030 - 0.070 mm (0.0012 - 0.0028 in.)
MIl(imum
0.20 mm (0.0079 in.)

Pi.ton Ind
Piston ring end glp
STO No.1
pi.ton ring
(cont'd)
0.470 mm (0.0106 - 0.0185 in.)
No.2
0.400 - 0.650 mm (0.0157 - 0.0256 in.)
O'
Muimum No.1
0.200 - 0.500 mm (0.0079 - 0.0197 in.)
No.2
O'
Connec:ting
STO
Mlximum
'""
0.270
STO
STO
U/S 0.25. U/S 0.50
Mlximum
0.85 mm {0.0335 in.}

0.90 mm (0.0354 in.)
0.88 mm (0.0346 in.)
0.100 - 0.200 mm (0.0039 - 0.0079 in.)
0.30 mm (0.0118 in.)
0.036 - 0.054 mm (0.0014 - 0.0021 in.)
0.037 - 0.077 mm (O.COl IS - 0.0030 in.)
0.10 mm (0.0039 in.)
Connectin9 rod belrin9 centlr Wl1I1hickne..

STO
Mlrk 2
1.484 - 1.489 mm (0.0585 - 0.0586 in.)
Mlrk 3
1.489 - 1.492 mm (0.0586 - 0.0587 in.)
Mlrk 4
1.492 - 1.495 mm (0.0587 - 0.0589 in.)
Merk 5
1.495 - 1.498 mm (0.0589 - 0.0590 in.l
Mark 6
1.498 - 1.501 mm (0.0590 - 0.0591 in.)
Rod bend
Maximum
plr 100 mm (3.94 in.)
0.03 mm (0.0012 in.)
Rod twist
Mlximum per 100 mm (3.94 in.)
0.15 mm (0.0059 In.)
8ushing inside dilmltlr
33.008 - 33.020 mm (12.995 - 1.3000 inJ
Pi.ton pin diemeter
33.000 - 33.012 mm (1.2992 - 1.2997 in.)
BU$hing air d ..renel
STO
Maximum
Connecting rod bolt ten.ion portion diemeter
STO
Minimum
Crlnklhlft
STO
Thrust crelrlnce
Mlllimum
Thru.t wI.her thickne..
Mlin journll oil clllrince
0.004 - 0.012 mm (0.0002 - 0.0005 in)

0.03 mm (0.0012 in.)
8.300 - 8.400 mm (0.3268 - 0.3307 in.)
7.95 mm (0.3130 in.)
0.040
0.240 mm (0.00'" - 0.0094 in.)
0.30 mm {0.0118 in.}

2.930 - 2.980 mm (0.1154 - 0.1173 in.)
STO
STO
0.036 - 0.054 mm (0.0014 - 0.0021 in.)
U/S 0.25, U/S 0.50
0.037 - 0.077 mm (0.0015 - 0.0030 in.)
Mlllimum
Main journll diameter
0.10 10m (0.0039 in.)
STO
88.982 - 87.000 mm (2.8371 - 2.8378 in.)
U/S 0.25
88.745 - 88.755 mm (2.8278 - 2.8281 in.)
U/S 0.50
88.495 - 66.505 mm (2.6179 - 2.8183 in.)
Main bllring center will thickne.. (ReferencI)

STO
Mlrk 2
1.979 - 1.982 mm (0.0779 - 0.0780 in.)
Mlrk 3
1.982 - 1.985 mm (0.0780 - 0.0781 in.)
Mlrk 4
1.985 - 1.988 mm (0.0781 - 0.0783 in.)
Mlrk IS
1.988 - 1.991 mm (0.0783 - 0.0784 in.)
Mlrk 8
Crlnk pin dilmeter
1.991 - 1.994 mm (0.0784 - 0.0785 in.)
STO
58.982 - 59.000 mm (2.3221 - 2.3228 in.)
U/S 0.25
58.745 - 58.755 mm (2.3128 - 2.3132 inJ
UIS 0.50
58.495 - 58.505 mm (2.3029 - 2.3033 in.)
Circle runout
Muimum
0.08 mm (0.0024 in.)
Mlin journlJ tlper Ir'Id out-aI-round
Mlximum
0.02 mm (0.0008 in.)
Crlnk pin tlplr Ind out-of-round
Muimum
0.02 mm (0.0008 in.)
EG-91
EG-92
--..
TORQUE SPECIFICATION
Nm
kgfem
fHbf
18
58
185
700
13
Plug boll x Distributive he.d plug on injection pump
25.5
Injection pipe x Injection pump
24.5
'80
250
1.coo
Pert tightened
Injection pump x Timing gler c
Injection pump x Injection pump allY
98
No.1 camshaft timing pulley I Camlhett
EG
No.2 clmlheft timing pulley x Injection pump drive ge.r
3'
34.5
Idler pulley x Timing gl.r cover
Timing belt len,iO"lr II Timing gill' cover
'3
98
88
Injection pump drive ge" x Injection pump

Idler g r x Cylinder block
Timing g.er COVlr,
O~
pip. x Timing gllr CISI
Vacuum pump x Timing ge.r cover

O~
pipe
x Vacuum pump, Cylinder block
Crank,heft pulley x Crlnksh,ft
,,,
Cylinder head x Cylinder block
'"'
3.'
Camsh.ft bearing Clp x Cylinder h. .d
Camahelt oft I'" retainer
Cylinder Med
315
350
130
51
"
'8
72
'3
25
10
1,000
72
89.
50
19.8
'00
39
18
.30
400
185
4.400
"
'9
13
317
68.6
700
51
Tum 90
Tum 90
Turn 90
Tum 90
Tum 90
Turn 90
'5
250
18
19.8
Cylinder hlld cover
It
Cylinder held
8A
'00
85
57 in..lbf
Rear engine hlnger
It
Cylinder held
39.2
400
'9
19.6
'DO
'DO
,."
Water outlet
It
Intake manifold
Intlke pipe
It
It
Cylinder head
It
Cylindlr heed
19.6
Inlake manifokl
EGR v.lve Idapter
Exhault mlnifold
It
EGR vllve bracklt It EGR v.lve dapter, Cylinder Mid (wI EGR 'Vltem)
Intake pipe
It
I,.take hl.tlr (w/o EGR IYltlm)
Main billing cap
It
Cylinder block
12 pointed hlad
,,,
'"'
,,,
'"'
8 pointed head
Connecting rod cap
Connecting rod
It
Rear oil ...1retainer
It
Cylinder block, Mlin bI.ri"il c.p
E"iIine mounting bracket
It
Cylinder bloc:k
Injection pump llay
It
Altarn.tor bt.ckat
Cylinder block
Aeet and pl.1I
It
It
Cylindlr block
Cylinder block
Flywheel (MfTl. Drive pllte (AfT) II Cr.nksh.ft
"
19.8
'00
40
400
'0
7.5
103
'00
75
88 in.lbf
1,050
78
Turn 90
Turn 90
Turn 90'
18.1
185
13
"
'8
15
38.8
375
27
Tum 90
Tum 90
Turn 90
8.'
88.8
89
85
700
57 in.lbf
51
5'
18.1
700
700
185
127.4
1,300
9.
68.6
5'
13
EG-93
ENGINE - TURBOCHARGER SYSTEM
TURBOCHARGER SYSTEM
PREPARATION
_ _K

09992 00241
Turboeharger Preuure Gauge
EOUIPMENT
Dial indicator
Torque wrench
Impeller wheel
EG-94
PRECAUTION
1.
2.
EG
3.
4.
00 not stop the engine immediately after pullr;;g--;

trailer or .fter high speed or uphill driving. Idle the
engine for 20 - 120 seconds. depending on how

hard the vehicle hal been driven.
Avoid sudden acceleration or ,acing immediately
after starting 8 cold engine.
00 not run the engine with air cleaner removed. as
this may eause foreign material to enter and
damage the impeller wheel operating at high speed.
If the turbocharger is found to be defective and
must be replaced. check for the cause, and repair or
replace these items 8S necessary:
5.
6.
7.
8.
9.
..
Engine oil level and quality

Conditions under which the turboch8rger was used
Oil lin Iding to the turbochargar
Use caution when removing and reinstalling the turbocharger assembly. Do not drop it or bang it aga
inst anything or grasp it by easily-deformed parts.
such as the actuator or rod. when moving it.
Before removing the turbocharger. plug the intaka
and exhaust ports and oil inlet to prevent entry of
dirt or other foreign material.
If replacing the turbocharger. check for accumula

tion of sludge particles in the oil pipes. and if necessary. replace the oil pipes.
Completely remove the gasket adhered to the lubri
cation oil pipe flange and turbocharger oil flange.
When replacing bolt or nuts. use only anthorized
replacement parts to prevent breakage or deforma
tionA
~"
10. If replecing the turbocharger. put 20 cm 1 (1.2 cu in.)

of oil into the turbocharger oil inlet and turn the
impeller wheel by hand to spread oil to the bearing.
11. If overhauling or replacing the engine. cut the fuel
supply after reassembly and crank the engine for 30
seconds to distribute oil throughout the engine.
Then allow the engine to idle for 60 seconds.
EG-95
TROUBLESHOOTING
HINT: Before troubleshooting the turbocharger. first check the engine itself. (Valve c1ear~c:.
engine compression. ignition timing etc.)
INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL

CONSUMPTION
lCheck Procedure end Correction Method)
(Possible Cause)
1. TURBOCHARGING PRESSURE TOO
LOW
Check turbocharging pressure. (See page EG-971
Turbocharging pressure:
38.6 - 50.0 kP.
10.39 - 0.50 kgf I cm 2 5.6 - 7.3 psi)
If the pressure is below specifications, begin

diagnosis from item 2.
2. RESTRICTED INTAKE SYSTEM
Check inlake air system, and repair or replace parts

as necessary. (See page EG-97)
3. LEAK IN INTAKE AIR SYSTEM
Check intake air system, and repair or replace parts

as necessary. ISee page EG-97)
4. RESTRICTED EXHAUST SYSTEM
Check exhaust system, and repair or replace parts

as necessary. (See page EG-97)
5. LEAK IN EXHAUST SYSTEM
Check exhaust system, and repair or replace parts

as necessary. (See page EG-971
6. ERRATIC TURBOCHARGER
OPERATION
I---
Check rotation of impeller wheel. Jf it does nOI

turn on turns with a heavy drag, replace the
turbocharger assembly.
Check axial and radial plays of turbine shaft.
(See page EG-1 01)
Maximum axial play:
0.13 mm 10.0051 in.) or less
Maximum radial play: 0.18 mm 10.0071 in.) or less
If not within specification, replace the turbocharger
assemblv
EG-96
ABNORMAL NOISE
(Check Procedure and COffeetion Methodl
(Possible Caus.)
1. TURBOCHARGING HEAT INSULATOR
RESONANCE
I-
Check for loose. improperlv installed or dedormed

insulator mount bolts, and repair or replace as
necessary.
EG
2. EXHAUST PIPE LEAKING OR
I-
Check for deformed exhaust pipe, loose mount
bolts or damaged gasket. and repair or replace 85
VIBRATING
necessery.
3. ERRATIC TURBOCHARGER OPERATION
I-
Refer 10 Item 6 of INSUFFICIENT ACCELERATION,

LACK OF POWER OR EXCESSiVE FUEL
CONSUMPTION.
EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST

(Possible Cause)
FAULTY TURBOCHARGER OIL SEAL
(Check Procedure and Correction Method)
I-
Check for oil leakage in exhaust system.

Remove the turbine elbow from (he turbocharger
and check for excessive carbon deposits on the turbine

wheel. Excessive carbon deposits indicate e faulty
turbocharger.
Check for oil leakage in intake air system.
Check for axial and radial plays in turbine wheel,
and replace the turbocharger if necessary.
(See page EGl011
Maximum axial play: 0.13 mm 10.0051 in.) or less
Maximum radial play: 0.18 mm 10.0011 in.} or less
NOTICE: Some oil mist in the blowby from
the PCV is normal.
Do not mistake it for an 011 leak from the
turbocharger.
TURBOCHARGER
ON - VEHICLE INSPECTION
1.
wI
EGR System
3.
(a)
(b)
(c)
w/o EGR System
.....-.
INSPECT INTAKE AIR SYSTEM

Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the turbocharger outlet and cylinder head.
2.
EG-97
Clogged air cleaner .... Clean or replace element
Hoses collapsed or deformed

Repair or replace
Leakage from connections
Check each connection and repair
Cracks in components .... Check and replace

INSPECT EXHAUST SYSTEM
Check for leakage or clogging between the cylinder
head and turbocharger inlet and between the turbocharger outlet and exhaust pipe.
Deformed components .... Repair or replace
Foreign material in passages

Remove
Leakage from components

Repair or replace
Cracks in components .... Check and replace

CHECK TURBOCHARGING PRESSURE
Warm up engine.
Using a 3 -way connector. connect SST (turbocharger pressure gauge) to the hose between the vacuum
pipe and intake pipe.
SST 09992-00241
Press in the clutch pedal. then press the accelerator
pedal down as far as it will go. Measure the turbocharging pressure at maximum speed (4.400 rpm).
Standard preure:
38.6 - 50.0 kPa (0.39 - 0.50 kgf/cm", 5.6 - 7.3 p.i)
If the pressure is less than that specification. check
the intake air and exhaust systems for leakage.
If there is no leakage. replace the turbocharger assembly.
If the pressure is above specification, check if the
actuator hose is disconnected or cracked. If not. replace the turbocharger assembly.
EG-98
ENGINE
TUR80CHARGER SYSTEM

INSTALLATION
w/o EGR System
., ' ,
~
~~":.,,.. b
Gasket
.
~'
I'
0,.
,'"
~. ,~
Engine
wI EGR System
Intake Pipe Assembly.
,,
<
Vacuum Hose
Ground
Strap
0,
Clamp
Exhaust Manifold --~
. . .....,
r~ ~
Turbine Outlet
Elobow
'.
"1
'...
.....
..
,'1",/1" Gasket
Turbo Heat Insulator
Non-reusable part
('
~~il~.,
.Li:
"
r--
No.1 T~UrbowaterPiPe
+ Gasket
.... i~ rd.Gasket ~
~
G.i
...
Water Bypass Hose
Ga~Sket""
~~
'..
~-- -- - '
,
'"
"
,,
,,
,
,
,
i::
..
.
=,--Turbo Oil Pipe
--
--
TURBOCHARGER REMOVAL
EG-99
--.
1.
2.

REMOVE INTAKE PIPE
(See step 2 or 3 in cylinder head removal in
3.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR

Remove the 4 bolts and heat insulator.
REMOVE TURBOCHARGER HEAT INSULATOR
Remove the 2 bolts and heat insulator.
DISCONNECT WATER BY PASS HOSES FROM
NO.1 TURBO WATER PIPE
Engine Mechanical)
4.
5.
B.
REMOVE TURBINE OUTLET ELBOW

Remove the 4 nuts. turbine outlet elbow and gasket.
7.
REMOVE TURBOCHARGER STAY

Remove the 3 bolts and turbocharger stay.
8.
(a)
(b)
REMOVE TURBOCHARGER AND EXHAUST

MANIFOLDS ASSEMBLY
Disconnect the turbo oil hose from the cylinder block.
Remove the union bolt and 2 gaskets holding the
turbo oil pipe to the cylinder block.
EG
EG'OO

(c)
Remove the 12 nuts. the turbocharger. exhaust manifolds assembly and 2 gaskets.
9.
REMOVE TURBO OIL PIPE

Remove the 2 nuts, turbo oil pipe and gasket.
EG
10. REMOVE TURBOCHARGER FROM

EXHAUST MANIFOLDS
Remove the 4 nuts, turbocharger and gasket.
'1. REMOVE NO.1 TURBO WATER PIPE

Remove the 2 nuts. No.1 turbo water pipe and gasket.
TURBOCHARGER INSPECTION
1.
"""
--.
INSPECT IMPELLER WHEEL ROTATION

Grasp the edge of the turbine wheel and turn it. Check
that the impeller wheel turns smoothly.
If the impeller wheel does not turn or jf it turns with a
heavy drag, replace the turbocharger assembly.

2.
EG-l0l
INSPECT AXIAL PLAY OF TURBINE SHAFT

Insert a dial indicator into the exhaust side hold the
turbine wheel edge by hand. and check the axial play.
Maximum oil cla.rance:
0.13 mm (0.0051 in.) or I
If the axial play is not as specified. replace the turbocharger assembly.
EG
3.
(a)
(b)
INSPECT RADIAL PLAY OF TURBINE SHAFT

From oil outlet hole. insert a dial indicator through the
hole in the spacer bearing and set it in the center of
the turbine shaft.
Move the impeller shaft in a radial direction. measure
the radial play of the turbine shaft.

Maximum oil clearance:
0.1a mm (0.0071 in.) or I
If the radial play is not as specified. replace the turbocharger assembly.

Dial Indicator
Spacer Bearing
SST_--G'%
Valve Closed
4.
(a)
(b)
INSPECT ACTUATOR OPERATION

Disconnect the actuator hose.
Using SST (turbocharger pressure gauge). 88 - 96
kpa (0.90 - 0.98 kgf/em'. 12.8 - 13.9 psi) of pressure to the actuator and check that the rod moves.
If the rod does not move, replace the turbocharger
assembly.
SST 09992 - 00241
NOTICE: Never apply mora than 124 kPa (1.26 kgf/cm'
18 psi) of pressure to the 8ctu8tor.
TURBOCHARGER INSTALLAnON
NOTICE: After replacing the turboch8rger 8ssembly.
pour 8pprox. 20 em' (1.2 cu in.) of fresh oil into the oil
inlet and turn the Impeller wheel by h8nd to aplesh oil on
the bearing.
EG-'02
1.
INSTALL NO.1 TURBO WATER PIPE

Install a new gasket and the water pipe with the 2
nuts.
Torque: 7.8 Nm (80 kgt-em. 69 In..lbf)
EG
2.
INSTALL TURBOCHARGER TO EXHAUST

MANIFOLDS
Install a new gasket and the turbocharger to the
exhaust manifolds with the 4 nuts.
Torque: 52 Nm (530 kg'.em, 38 ft.lb')
3.
INSTALL TURBO OIL PIPE

Install a new gasket and the oil pipe with the 2 nuts.
Torque: 18.1 Nm (185 kg'cm. 13 'tlb')
4.
INSTALL TURBOCHARGER AND EXHAUST

MANIFOLDS ASSEMBLY
Install 2 new gasket to the cylinder head.
Install the turbocharger and exhaust manifolds assembly with the 12 nuts.
Torque: .'.7 Nm (425 kgfcm. 31 ftlb')
(a)
(b)
(d)
.)
0'
Install 2 new gaskets and the union bolt of the turbo

oil pipe.
Torque: 24.5 Nm (250 kgt-em. 18 f1-lbf)
(e)
5.
Connect the turbo oil hose to the cylinder block.

INSTALL TURBOCHARGER STAY
Torque: 117.7 Nm (1200 kgt'em, 87 ftlb')
EG-l03

6.
INSTALL TURBINE OUTLET ELBOW

Install a new gasket and the outlet elbow with the 4
nuts.
Torque: 52 Nm (530 kgfcm, 38 ft.lbf)
7.
8.
9.
CONNECT WATER BY PASS HOSES TO

NO.1 TURBO WATER PIPE
INSTALL TURBOCHARGER HEAT INSULATOR
Torque: 7.8 Nm (80 kgfcm. 69 in.lbf)
[E~'
INSTALL EXHAUST MANIFOLD HEAT INSULATOR
10. INSTALL INTAKE PIPE

(See step 18 or 19 in cylinder head installation in
Engine Mechanical)
14. CHECK ENGINE OIL LEVEL
SERVICE DATA
38.6
Turbocharging pressure
Turbocharger
50.0 kPa
(0.39 - 0.50 kgflcm', 5.6 - 7.3 psi)

Impeller wheel ,xial play
Mnimum
0.13 mm (0.0051 in.) or less
Impeller wheel fadial play
Maximum
0.18 mm (0.0071 in,) or less
TORQUE SPECIFICATIONS
Part tightened
No.1 turbo wllter pipe, Turbocharger he8t insuletor
II:
Turbocharger
Nm
kgfcm
ftlbl
7.8
80
69 in.fbl
52
530
38
Turbo oil pipe x Turbocharger
18.1
185
13
Elthaust manifold
41.7
425
31
24.5
250
18
117.7
1200
87
52
530
38
18.1
185
13
Turbocharger x Exhaust manifold
Turbo oil pipe
It
It
Cylinder head
Cylinder block
Turbocharger stay
It
Turbochafgar, Cylinder block
Turbine outlet albow x Turbochargar

Exhaust manifold haat insulator x Exhaust manifold
EG'04
ENGINE - FUEL SYSTEM
FUEL SYSTEM
PREPARATION
--..

EG
c;?
~~~~
o
s-
09228-64010
FUll Filter Wrenth
09236-00101
Water Pump Overhaul Tool Set
....
(09237-00070) Shalt -C'
-.- ...
Gov.mot ....... plug
ce-;?
!~l~
q)
~e-=-
09241-76022
Injection Pump Stend Sel
09245-54010
Injeetion Pump Sttnd Arm
09260-54012
Injection Pump Tool Sel
Qi5i'S !l1l
...
(09262-54010) Oi$tributor H..d P11Jl1 Wrench
.....
ID)
... -
. ........ ........
.....
.- ....
....
(09269-54020) Socket 14 mm
aD
'"""
... (09269-54030) Tweeze,.
....... ......
...
~
.... ,
(09269-54040)
Governor LIve, SYppor1 Bolt
Wrench
-...
(09262 -54020) Regul.tor V.Iv. Wrench
elD
@3 IiI 6
09268-17010
2 Spring Nonl. Tool .tt
..
EG'05

09268-17020
Muter Spring Seu
09950-40010
Pull.r B Set
~
~~~'i]
- _ _ "6>~~
'G"
~"'"*"
~~~~
(09957-04010) Att.ct1m.nt
Inj.ction pump
EG
t9
:::$~
,.-;
;.,:..,
......
.<#-.
r.DlJ'O""
CoO """..,
~T
09950 - 500 Ia
Pull.r C
s.t
~
[@ @J
~
~
9~o
(09951-05010) H.ng.r 150
Injec:tion pump
(09952-05010) Slid, Arm
Injection pump
(09953-05020)
Injection pump
Center Bolt 150
(09954-05030) Ct.w No.3
09992-00241
Inj.Ktion pump
Turbochafllef Pressure G.ugtl
""C_CI
RECOMMENDED TOOLS
'~~-'
09082-00050
TOYOTA EI.ctriul Tn"r SeL
09200 - 000 I0
Engine Adjust Kit .
09258-00030
Hose Plug Set .
~-~
=
~
~ ...
q~~
~ .<f'.,.
6Y
Plug lor fuel hose
EG-106
EQUIPMEMT
Angle gauge
Brass brush
Diel indicator with magnetic base
EG
Graduated cylinder
Injection nozzle tester
Injection pump tester

Inner pressure gauge
Micrometer
Steel square
Timer measuring device

TorClue wrench
Vernier calipers
Wooden stick
__w
EG-107
FUEL FILTER
1.
2.
(a)
DISCONNECT FUEL FILTER WARNING SWITCH-CONNECTOR

DRAIN FUEL FROM FUEL FILTER
Install a vinyl hose to the drain cock. and insert the
(b)
other end of the vinyl hose in a container.

Loosen the drain plug, and drain the fuel.
3.
A.
REPLACE FUEL FILTER

Remove fuel filter
Using SST. remove the fuel filter.
SST 09228-64010
SST
B.
C.
(a)
(b)
(c)
--
Remove fuel filter werning switch from fuel filter

Using pliers. remove the warning switch and 0 - ring.
NOTICE: B. car.ful not to dam.g. the werning switch.
Inltell fuel filter wlrning switch to new fuel filter
Install a new 0 - ring to the warning switch.
Apply fuel to the O-ring of the warning switch.

Install the warning switch to a new fuel filter by hand.
D. Inlten new
(a)
(b)
(c)
(d)
4.
5.
8.
fuel filter
Check and clean the fuel filter installation surface.
Apply fuel to the gasket of a new fuel filter.
Lightly screw the fuel filter into place. and tighten it
until the gasket comes into contact with the seat.
Tighten it additional 3/4 turn by hand.
FILL FUEL FILTER WITH FUEL

Operate the hand pump until you feel more resistance.
CONNECT FUEL FILTER WARNING SWITCH
CONNECTOR
START ENGINE AND CHECK FOR FUEL LEAKS
EG'08
FUEL HEATER SYSTEM
--.
COMPONENTS INSPECTION
Ohmmeter
00
o lofI--l-.
1.
REMOVE FUEL HEATER
2.
(a)
INSPECT FUEL HEATER

Apply a vacuum of 34.7 5.3 kPa (260
10.24
port.
0.5 - 2.0 Q
(b)
3.
A.
Ohmmeter
oo
No continuity
40 mmHg.
1.57 in.Hg) or more to the vacuum switch
Using an ohmmeter. measure the resistance between
terminal 1 and and the switch body.

R.,lat.nee:
At 20'C (SS'F), 0.5 - 2.0 0
If the resistance is not as specified. replace the fuel
heater and vacuum switch assembly.
INSPECT VACUUM SWITCH
In.pect .witch continuity

Using an ohmmeter. check that there is no continuity
between terminal 1 and the switch body.
If continuity is not as specified. replace the fuel heater
and vacuum switch assembly.
Ohmmeter
00
B.
In.pect .witch operation
(a)
Apply a vacuum of 34.7 5.3 kPa (260 + 40 mmHg,

10.24 1.57 in.Hg) or more to the vacuum switch
port.
Using an ohmmeter. check that there is continuity
If operation is not as specified. replace the fuel heater
and vacuum switch assembly.
REINSTALL FUEL HEATER
r:::o lofI--l-.
o
(b)
4.
FUEL HEATER RELAY

1.
REMOVE FUEL HEATER RELAY
--

Ohmmeter
2.
0Ll No
OD
(a)
0:
0: .1-
Ohmmeter
Continuity
Continuity
~'~
4
"....,
Ohmmeter
INSPECT RELAY CONTINUITY

between terminals 1 and 3.

(b)
Check that there is no continuity between terminals 2

and 4.
If continuity is not as specified. replace the relay.
DO
f0.,
EG-'09
Continuity
3.
(a)
(b)
INSPECT RELAY OPERATION

Apply battery voltage across terminals 1 and 3.
If operation is not as specified. replace the relay.

4.
4
REINSTALL FUEL HEATER RELAY
EG"O
INJECTION NOZZLE
INSTALLATION
--.
wI EGR System
w/o EGR System
C---EGR Valve
~~...
Bracket
Intake
Pipe
Intake
Vacuum-+-~~
~_-.
~>
, p-----@'::---",---+Gasket
Heater
.'
Hose
l!.},
-:::_1
~"------Intake
Pipe
Assembly
-----+ Gasket
Injection Nozzle
Gasket
.....
,,
,
...' . '
1fP
I
Throttle Position Sensor Connector

Non-reusable part
(Except Australia MIT)
INJECTION NOZZLES REMOVAL

1.
_..
EGo" ,
REMOVE INTAKE PIPE

(5 step 2 or 3 in cylinder he.d removal in Engine
Mechanical)
2.

(S.8 step 11 in cylinder head removal in Engine
Mechanical)
3.
REMOVE ACCELERATOR LINK ASSEMBLY
(a)
w/o Australia MIT:

Disconnect the throttle position sensor connector
from the bracket.
(b)
Disconnect the accelerator link from the injection

pump.
----"'."
(e)
Remove the 2 bolts. nut and the accelerator link assembly.
4.
REMOVE NO.' NOZZLE LEAKAGE PIPE
(a)
Disconnect the fuel return hose from the No.1 nOlzle

leakage pipe.
Remove the nut holding the No.1 "oule leakage pipe
to the cylinder head.
Remove the 6 hollow bolts. 7 gaskets and No.1 nOlzle
leakage pipe.
(b)
(e)
5.
(a)
Remove the bolt holding the No.3 nozzle leakage pipe

to the intake manifold.
(b)
Remove the 4 nuts and 2 clamps from the intake

manifold.
Remove the 2 nuts and 2 clamps.
(c)
(d)
Loosen the 6 union nuts of the injection pipes from

the injection nozzles.
EG112

(e)
Loosen the 6 union nuts of the injection pipes from
(f)
the injection pump.

Remove the 6 injection pipes.
Remove the 2 intake manifold insulators.
(g)
EG
6.
REMOVE NOZZLE HOLDER SEALS

Using a screwdriver, pry out the nozzle holder seals
from the cylinder head.
7.
(a)
REMOVE INJECTION NOZZLES

Remove the bolt holding the nozzle holder clamp to
the cylinder head.
Remove the 6 injection nozzles and seats from the
cylinder head.
Remove the O-ring from the injection nozzle.
HINT: Arrange the injection nozzles in correct order.
(b)
(c)
INJECTION NOZZLES TEST

1.
Good
Faulty
"'".
2.
(a)
(b)
Good
Faulty
Faulty
Faulty
_-0
LEAKAGE TEST
While maintaining pressure at about 981 - 1.961 kPa
(10 - 20 kgf/cm 2 142 - 284 psi), below No.1 open
ing pressure (adjust by tester handle), check that
there is not dripping for 10 seconds from the injection
hole or around the retaining nut.
If the nozzle drips within 10 seconds. replace or clean
and overhaul the nozzle assembly.
SPRAY PATTERN TEST
The injection nozzle should shudder at a certain pumping speed between 15 - 60 times (old nozzle) or 30
- 60 times (new nozzle) per minute.
Check the spray pattern during shuddering.
If the spray pattern is not correct during shuddering,
the nozzle must be replaced or cleaned.
EG-113
.~-

ASSEMBLY
No 2 Pressure Spring
. htp'i n " , " " - "I
Stralg
Nozzle Assembly
hie
Y
TIp
NO.2 P,mu" __
Spring Seat ....
Nozzle Body
Nozzle Holder
Retaining Nut
: No.1 P"ss"e
: SPdn,
S"~
v~
c:>'
i
I
No"" Hold" Body
Adjusting Shim
I No.1 Pressure Spring
Pressure Pin
Adjusting Shim
INJECTION NOZZLE DISASSEMBLY
_..
DISASSEMBLE INJECTION NOZZLES
(a)
Remove the nOlzle holder retaining nut.

NOTICE: When disassembling the nozzl., b. careful not
to drop the inner parts.
(b)
Disassemble the injection nOlzle.
INJECTION NOZZLES CLEANING AND

INSPECTION
I.
(a)
NOZZLE CLEANING
To wash the nozzles. use a wooden stick and brass
brush. Wash them in clean diesel fuel.
HINT: Do not touch the nozzle mating surfaces with
your fingers.
EG-114

(b)
Using 8 wooden stick. remove the carbon adhering to

the nozzle needle tip.
(e)
Using a brass brush. remove the carbon from the

exterior of the nozzle body (except lapped surface).
(d)
Check the seat of the nozzle body for burns or corro-
sion.
(e)
Check the nozzle needle tip for damage or corrosion.

If any of these conditions are present, replace the
nozzle assembly.
One third of
its lenglh
2.
INSPECT NOZZLE ASSEMBLY
(a)
Wash the nozzle in clean diesel fuel.

HINT: Do not touch the nozzle mating surfaces with
(b)
Tilt the nozzle body about 60 degrees and pull the
your fingers.
needle out about one third of its length.

About 60 degrees
(el
When released. the needle should stick down into the

body vent smoothly by its own weight.
(d) Repeat this test, rotating the needle slightly each time.
If the needle does not sink freely, replace the nozzle
assembly.
EG-' '5
INJECTION NOZZLES ASSEMBLY AND

ADJUSTMENT
1.
--
ADJUST NEEDLE-LIFT AND PRE-LIFT

NOTICE: Ndle-lift and pre-lift adjustment requir
grt precision. 10 when doing this operation. make
everything I, cln and that no foreign sub.tance
trapped.
Adjust needle-lift
.ur.r.
3.0mm
~unll
''''''
A.
(a)
(b)
Using SST. install the SST to the dial indicator so that

the protrusion shown in the illustration is 3.0 mm
(0.118 in.) or less.
SST 09266-1701 0
Using SST. set the dial indicator scale to 0 mm (0 in.)
on top of the SST or the surface plate.
SST 09266-17010
SST
(e)
SST(A)~~
(A).
(d)
lIFT
Dimension t
'-1._ _V---
Using a micrometer. measure dimension t of the SST

SST(A) 09266-17020
Using SST. place the nOlzle assembly and SST (A) on
the SST (BI as shown in the illustration.
SST(A) 09268-17020
(8) 09266-17010
SST IBI
"""
(e)
(f)
tj--SST
@-SST
Dimension L1
l-----roimensicn A
- SST
PU31t
pune
Zl53'l1
Using SST. set the SST above the nozzle. and measure
dimension A.
SST 09268-1701 0
Dimenlion L 1 = t - A
Remove the SST and needle tip from the nozzle body.
SST 09268-17020
EG
EG-116
ENGINE
~~
S1J
"-- I
FUEL SYSTEM
(9)
Place the tip packing and straight pins on the nozzle

body as shown in the illustration.
NOTICE: POlitlon the tip packing on top of the nozzle
body in the direction shown In the illustration.
(h)
Using SST. install SST holes to the straight pins. and

set dial indicator scale to 0 mm (0 in.) on top of the
nozzle assembly.
SST 09268-17010
Upward
LLLJ
Oowow"d
-SST
EG
"""
(i)
Using SST. set the dial indicator above the SST or the
surface plate. and measure dimension L2.
SST 09268-1701 0
DiJensi on l2
~ SST
P13320
P2un
PZJ330
''''''
Dimension L3
tF.?>i'.r~ ~
)l.8>-.~
If the needle - lift dimension is not as specified.

change the adjusting shim.
Adjusting shim thickness mm (In.):
Upward
CI:IJ
Downward
~o
SST (A\
B.
II
~SSTIB)~
Using a micrometer. measure dimension L3 of the

adjusting shim.
Needle-lift = (11 + l2) - L3
Needle-lift: 0.23 - 0.28 mm (0.0091 - 0.0110 in.)
(a)
1.900 (0.0748)
1.925 (0.0758)
1.950 (0.0768)
1.975 (0.0778)
2.000 (0.0787)
HINT: If the shim is made thicker. the needle-lift is

decreased.
Adjust pre-lift
(See steps (a) to (c) in step A)
Using SST. place the nozzle assembly. the adjusting
shim selected step A and SST (A) on the SST (B) as
SST(A) 09268 -17020
(8) 09268-17010
EG117

(b)
l,,/--SST
IT
Using SST. set the SST above the nozzle. and measure
dimension B.
SST 09268-17010
t ..... Dimension of the SST (AI (See step (c) in step A)
Dimension C = B - t
SST
EG'
SST
P23319
P2332J
(e)
1
Dimension 0
T
Using a micrometer. measure dimension 0 of the tip
packing.
Dimension L4 = 0 - C
-l
~mension
OO~~
"""
Dimension E
Dimension F
~~;
J,':t~~;;;:; T Dimension l5
(dl
Using a micrometer. measure dimension E and F of

the NO.2 pressure spring seat.
Dimension l5 = E - F
Pre-lift = L4 - L5
Pre-lift: 0.085 - 0.105 mm (0.00335 - 0.00413 in.)
If the pre-lift dimension is not as specified. change

the adjusting No.2 pressure spring seat.
Adjusting spring .8.t thickness mm (In.):
3.09 (0.1217)
3.12 (0.1228)
3.15 (O.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287}
HINT: If the shim is made thicker. the pre-lift is

decreased.
EG-118

2.
(a)
CHECK NO.2 OPENING PRESSURE

Assemble these parts:
(1) Nozzle holder body
(2) No.1 pressure spring seat
(3) Adjusting shim
(4) No.2 pressure spring
(5) SST
(6) Tip packing
(7) Straight pins
(8) Adjusting shim selected in step 1. A above
(9) Nozzle assembly
(10) Retaining nut
SST 09268- 1 7020
NOTICE: Do not ....mbl. the No.1 pre.aur. spring, No.1
pressure pin and adjusting shim for adjustment of the No.
1 opening pre.aur.
HINT: Align the holes of the nozzle body. tip packing

and nozzle holder body.
(b)
Using a 14 mm deep socket wrench. torque the retaining nut.

Torque: 30 Nm (300 kgfcm. 22 ftlbfl
NOTICE: O.... r torquing could caul. the nozzl. deformation and the ne.dle adhesion or other defects.
14 mm
Deep
Socket
(e)
(d)
(e)
(f)
Install the injection nozzle to the injection nozzle hand

tester and bleed air from the union nut.
CAUTION: Do not piece your finger over the nozzle Injection hole.
Pump the tester handle a few times as fast as possible
to discharge the carbon from the injection hole.
Pump the tester handle slowly and observe the pressure gauge.
Read the pressure gauge just as the injection pressure
begins to drop.
No.2 opening pressure (Inspection pressure):
23.046 - 24.028 kpe (235 - 245 kgf/cm l 3.342 3.485 psi)
HINT: Proper nozzle operation can be determined by a
swishing sound.
EG-119
If the opening preSSure is not as specified. disassemble the nozzle and change the adjusting shim on the
top of the NO.2 pressure spring.
Adjusting shim thickness mm (in.):
0.700 (O.O278)
0.850 (0.0335)
1.000 (0.0394)
1.025 (0.0404)
1.150 (0.0453)
1.175 (0.0463)
1.275 (0.0502)
1.300 (0.0512)
1.425 (0.0561)
1.450 (0.0571)
1.575 (0.0620)
1.500 (O.Oe30)
1.725 (O.oe79)
1.750 (O.O689)
1.900 (0.0748)
2.050 (0.0807)
fi
'.
Faulty
(9)
Good
(h)
3.
(aJ
(b)
HINT:
Varying the adjusting shim thickness by 0.025

mm (0.0010 in.) changes the injection pressure
by about 470 kpa (3.8 kgf/cm 2 54 psi).
Only one adjusting shim should be used.

There should be no dripping after injection.
After checking the No.2 opening pressure, disassemble the nozzle.
ADJUST NO.1 OPENING PRESSURE
Assemble the nozzle holder body. adjusting shim for
adjustment of No.1 opening pressure. No.1 pressure
spring, No.1 pressure pin. adjusting shim, No.1 pressure spring seat. adjusting shim selected in step 2
above, No.2 pressure spring, adjusting No.2 pressure
spring seat selected in step " B, tip packing, straight
pins, adjusting shim selected in step 1. A and nozzle
assembly, and finger tighten the retaining nut.
HINT:
Align the holes of the nozzle body. the distance

piece and the nozzle holder body.
When the thickness of the originally used adjusting shim is not known. use a shim 1.5 mm (0.59
in.) thick instead.
Read the pressure gauge just as the injection pressure
begins to drop.
(See steps (b) to (f) in step 2 above)
No.1 opening pressure:
17.652 -18.633kpa(180 - 190kgf/cm', 2.560 2.702 psi)

HINT: Proper nozzle operation can be determined by a
swishing sound.
If the opening pressure is not as specified. disassemble the nozzle and change the adjusting shim on the
top of the No.1 pressure spring.
EG
EG-120

Adjusting shim thickn mm (in.):
EG
0.825 (O.O325)
0.900 (0.0354)
0.975 (0.0384)
1.050 (O.0413)
1.125 (0.0443)
1.200 (0.0472)
1.275 (O.O502)
1.350 (0.0532)
1.425 (0.0561)
1.500 {O.OSSl)
1.575 (0.0820)
1.650 (0.0650)
1.725 (0.0679)
1.800 (0.0709)
1.875 (0.0738)
1.950 (0.07681
2.000 (0.0787)
2.100 (0.08271
2.175 (0.0856)
HINT:
(c)
Varying the adjusting shim thickness by 0.025

mm (0.00 10 in.) changes the injection pressure
by about 470 kpa (3.8 kgf/cm 2 , 54 psi).
Only one adjusting shim should be used.
There should be no dripping after injection.

(See step (g) in step 2 above)
INJECTION NOZZLES INSTALLATION

1.
(a)
(bl
\\ :---
--
- '"""
(c)
--.
INSTALL INJECTION NOZZLES

Install a new a-ring to the injection nOlzle.
Place 6 new nozzle seats into the injection nOlzle
holes of the cylinder head.
Install the injection nozzles with the nozzle holder
clamp. washer and bolt to the cylinder head.
Torque: 25 Nm (255 kgfcm. '8 ft.lbf)
(d)
2.
3.
(a)
(b)
(c)
Inspect the valve clearance.

(See steps 2 to 4 in valve clearance inspection and
adjustment)
INSTALL NOZZLE HOLDER SEALS
Install the e new nozzle holder seals to the cylinder
head with your hand.
INSTALL INJECTION PIPES

Place the 2 intake manifold insulators on the intake
manifold.
Attach the 6 injection pipes to the injection nozzle and
injection pump.
Tighten the 6 union nuts to the injection pump.
EG121

(d)
Tighten the 6 union nuts to the injection nozzle.

Torque: 24.5 Nm (250 kgtem. 25 ftlbf)
EG
(e)
Install the 2 clamps with the 2 nuts.

Torque: 8.... Nm (65 kgtem. 56 in.lbf)
(f)
Install the 2 clamps with the 4 nuts to the intake

manifold.
Torque: 6.4 Nm (65 kgfem. 56 in.lbfl
(g)
Install the NO.3 nozzle leakage pipe with the bolt.

Torque: 10.6 Nm (200 kgt.em, 15 ftlbf)
4.
(a)
INSTALL NO.1 NOZZLE LEAKAGE PIPE

Install the 7 new gaskets, No.1 nozzle leakage pipe to
the cylinder head. injection nozzle with the 6 hollow

screw and nut.
Torque:
Hollow scraw: 18 Nm (176 kgfem. 13 in.lbf)
Nut:
19 Nm (186 kgtem. 14 ft.lbf)
NOTICE: Inst.1I the gaskat (A) ao that it. connecting part

ia between the pipe a hown in the illustration.
(b)
Using SST. apply the SST to the fuel return side of the
No.1 nozzle leakage pipe. and maintain 49 kPa (O.5
kgf/cm 2.7.1 psi) of pressure for 10 seconds to check
that there are no leaks.
SST 09992 - 0024 1
~~~'"
\
NO.1 Nozzle 1"-_-1
leakage Pipe
(c)
Connect the fuel return hose to the No.1 nozzle leak

age pipe.
5.
INSTALL ACCELERATOR LINK ASSEMBLY
(a)
Install the accelerator link assembly with the 2 bolts

and nut.
Torque: 1S.6 Nm (200 ksfem, 14 in .. lbf)
(b)
(c)
6.
Connect the accelerator link to the injection pump.

w/o Australia MIT:
Connect the throttle position sensor connector to the
bracket.
INSTALL CYLINDER HEAD COVER
(See step lOin cylinder head installation in Engine

Mechanical)
7.
INSTALL INTAKE PIPE
(See step 18 or 19 in cylinder head installation in

Engine Mechanical)
8.
START ENGINE ANO CHECK FOR FUEL LEAKAGE
EG-122
INJECTION PUMP
INSTALLATION
wi EGR System
w/o EGR System
"" ~EGR Valve Brackel

Intake
Pipe
,
,
Gask,~e:..t:'::-7C-"'~
Intake Heater
....
,.,=",:
"'"0';'
if
\-:~~::'_~)-_'-,,;-._ _ + Gasket
.: : ~--' Intake Pipe Assembly
...
Gasket:::'
No.2 Flange
liming Belt CO\ler--,\
. \ - - - Timing Belt
Seal Washer---c=,.\
Clamp --"<;l)I~
Vacuum Hose
Non-reusable part
~-==--Gasket
--
ENGINE -
EG-123
FUEL SYSTEM
Injection Pipe-----------:-~;:?~
clamp--j'~-~~'?~
,,,
~-I
"'~clampr
............
Inlake Manifold
: Accelerator link
....
I Assembly
Insulator-------'.~:~~~~t ----rea'
,,
,I
--
,r
:
,
No.3 Nozzle leakage Pipe---;,----i------::':::liidt\,
,,
I
-I
1 I
::
"f
II
II
Clamp
I 1
"
'
I (II,.
II
~rI
I . -:-..;-'..;-_
I
11K'
~t'
L~2:~
J
III
... -t
.-U
.,
1!'t--...
~--,.-l
I
... _ - -
r
I
-~
I t I
:~.J'"
:I
I __
I 'J--
'
llt-,
-,.::-;
I~
q~[5\~.
)#~;j
~ : .. ;
,,;:::>-
,
t
I I I
III
~l
D-Ring

Connector
Clamp
Boost Compensator Hose

SICS Vacuum
Hose
,-- --
w/BACS
_:::::~BACS Vacuum Hose
No.1 Cylinder Block

Insulator
-~
Non-reusable part
----~~- \f
-""'i,l~~1I --
a-Ring
--
~6Il
Injection Pump
Water Bypass Hose
EG124
INJECTION PUMP REMOVAL

1.
_..
(See coolant replacement in Cooling System)

2.
REMOVE TIMING BELT
(See steps 1 to 3 in timing belt removal in Engine

Mechanical)
3.
EG
(See step 5 in timing belt removal in Engine

4.
wI EGR System
Mechanical)
REMOVE INJECTiON PIPES
(See steps 1. 3 end 5 in injection nozzle removal)

5.
6.
DISCONNECT WATER BYPASS HOSES FROM

THERMO WAX
DiSCONNECT HOSES
Disconnect these hoses from the injection pump.
(1) SICS vacuum hose
(2)
Boost compensator hose
(3)
wi BACS:
SACS vacuum hose
w/o EGA System
P13:l8<1
"''''
7.
(a)
Hold the crankshaft pulley, and remove the injection

pump drive gear set nut.
NOTICE: Do not turn the crank,heft pulley. The valve
h..d, will hit egainst the piston top.
(b)
Remove the O-ring from the injection pump drive
gear.
(c)
."".
Remove the 2 bolts holding the injection pump to the

injection pump stay.
(d)
EG-125
Before removing the injection pump. check if the

period lines are aligned.
If not, place new match marks for reinstallation.

(e)
Remove the 2 nuts holding the injection pump to the
timing gear case.
(f)
Using SST. remove the injection pump.

SST 09950-40010 (09957-040101,
09950-50010 (09951-05010, 09952-05010,

09953-05020,09954-050301
NOTICE:
(9)
(h)
Tighten the 2 bolts more than 8 mm (0.31 in.).

$at SST ao that it I. balanced.
Do not hold or carry the injection pump by the
adjusting leyer.
Do not put the injection pump at an angle more than
45 0 from the horizontal.
Remove the No.1 cylinder block insulator.

Remove the O-ring from the injection pump.
EG-'26
--.

ASSEMBLY
seat
Spring
Dlaphragm--,
Throttle Posltlon SenIOr
Spring 5081--,
Adjusting
Lever
~
.10 BACS
-j......
lever Retum'---
Spring
~'" """Rod~.
" ,
Boost Compensator
Rubber Cap
~~..screw
::.7SICSLeverTI',j
I "'...
t
"
"
-T~!' :~I-I~
i
, ,
I
"",
Govemot~er
:,
"~
- ;- - ::
::;~
..._-,
......
No,2 SICS Lever
"'"
R80ulalor~
Valve
.
,,
o-R"" ~ _
i"", "'-,
/
+ O-Ring
" .....:
"
+Gasltet
~
~
Control
.'"
....
...
ca
~ cap
" '.....+ORlng
~ .... Gasket'"
+GISkOlll
'
.. j'
-'f
Lever
') '" '~SupportPjn
'~+Gasket
'"
Europe
Adjusting
1!'r.::=;:;,:----,
<- .
AU.tr.II.~'>t'mg
seat
~~~oamperSpring
Sho.
c......... Control
I~
AdiU""" """""
Fuel Inlet
Pipe,
I
:
Hollow Screw
Lever
"',..
Fuel Inlet
+ Gasket
AI
"
I...... ~ ,.".,' -v
j;8Sner...
,
1dIe_
_,",Sc,_
.o-~..
: c/-
" -'
-~
----."'-
1,....-c.. ...
'" I '
Pickup Sensor---j/
.J
I" . . . . " ' ,

. . . . . . '"
I
I'"
..., I
...,
<:_Inn
',I
......
I
...........
"
... "
+ORlng---'<Q
'{,
"'----.Gasl<el
~:il
Bushing
~~'
~~
Washer
"dl1
<~
~~CoII"
I
F~lload
~. ~ ... -::~.~k81/~
SetScrew
L/t-~,
... ...
L_Control
.J
.. :
~"'''''-1'
~'O)
~ ,GuJe"...... /
1 Q.
- :: ,
I l
ConnectingPIn~"''''_;'
. . . .,'I
...
Maximum Speed
Adjusting SCrew
,;;;;:.;
"
:?;Jlod<-
...~'"
~/
Gasket
...... '" /
SICSAdJuS\lngSCrew~'" ~IY
"
,'"
SICS Actuator - - - ' - - /
~ ... ..
"I
"...
;,
\.ever Shaft
'I /'
<,
/.
/ __
w "'... _
' ...."
Idle-Up
"'"'~
Idle-Up
Leve~ctuator
EG-' 27
Roller and Washar

Timer Shim
Timer Adjusting 5aew
LH
rmer Covel'
EG-128
INJECTION PUMP DISASSEMBLY
--
MOUNT PUMP ASSEM8LY TO SST (STANDI

SST 09241-76022. 09245-54010
REMOVE SET KEY OF DRIVE PULLEY FROM DRIVE
SHAFT
wi A/C:
REMOVE IDLE-UP ACTUATOR
REMOVE FUEL PIPES
Remove the cap nut, bolts. fuel inlet pipe and 2 gas-
kets.
Remove the union bolt. No.2 nozzle leakage pipe and 2
gaskets.
5.
REMOVE IDLE - UP LEVER
(a)
Remove the idle - up lever link from the adjusting
lever.
(b)
Using a 5 mm hexagon wrench. remove the 3 bolts
and idle-up lever.
5 mm Hexagon Wrench
8.
(a)
REMOVE THERMO WAX

Using a 5 mm hexagon wrench. temporality install the
bolt (AI.
(b)
ld4----(A)
Using a screwdriver. turn the cold starting lever coun-
1erclockwise.
(0)
Using a 5 rnm hexagon wrench. remove the bolt (B).
(d)
Put a metal plate (thickness of 5.0 - 8.0 mm (0.20 -
5 mm Hexagon
Wrench
Melal Plate
0.31 in.)) between the cold starting lever and thermo

(e)
r-: :-: .
5 mm Hexagon Wrench
.",n
wax plunger.
Using a 5 mm hexagon wrench. remove the 2 bolts.
thermo wax and 0 - ring.
w/o Australia MIT
C-n
7.
EG-129
w/o Australia MIT:

REMOVE THROTTLE POSITION SENSOR AND
BRACKET ASSEMBLY
the throttle position sensor and bracket assembly.
B.
REMOVE SICS ACTUATOR
(a)
(b)
Remove the SICS adjusting screw.

Remove the clip.
Ie)
(d)
Disconnect the wire harness.

Remove the nuts and SICS actuator.
(e)
Remove the lock plate.
(f)
(g)
Remove the maximum speed adjusting screw.

and SICS actuator bracket.
9.
REMOVE NO.1 SICS LEVER

Remove the nut and NO.1 SICS lever.
10. REMOVE CAP

Remove the cap and gasket.
EG-130

11. REMOVE FUEL CUT SOLENOID
(a) Disconnect the lead wire connector from the bracket.
(b)
Disconnect the wire harness from the wire clamp.
(c)
Disconnect the dust cover from the fuel cut solenoid.
(d)
(a)
Remove the nut. lead wire and dust cover.

Remove the fuel cut solenoid. O-ring, spring, valve.
strainer and wave washer.
12. REMOVE PICKUP SENSOR

(a) Remove the pickup sensor and O-ring.
(b) Disconnect the sensor lead wires from the connector.
13. REMOVE ADJUSTING LEVER

(a) Place the match marks on adjusting lever and shaft.
(b) Remove the nut, adjusting lever and return spring.
14. REMOVE GOVERNOR COVER

(a) Remove the idle speed adjusting screw.
(b)
5mm
Hexagon
Wrench

Europe
EG-131
(c)
Europe:
Disconnect the adjusting lever shaft assembly from
the governor link, and remove the governor cover and
gasket.
(d)
Australia:
Disconnect the speed control spring from the spring
seat. and remove the spring seat, damper spring,
speed control spring. the governor cover. adjusting
lever shaft assembly and gasket.
W:618
Australia
FU2~2
-215519
15. REMOVE GOVERNOR ADJUSTING LEVER SHAFT

FROM GOVERNOR COVER
(a) Remove the adjusting lever shaft assembly from the
governor cover.
(b) Disassemble these parts:
(1) O-ring
(2) Washer
16. DiSASSEMBLE BOOST COMPENSATOR

A. Remove lever control spring
Remove the bolt. gasket and lever control spring.
B.
(a)
5mm
Hexagon
Wrench
Remove boost compensator diaphragm

Using a 5 mm hexagon wrench, remove the 4 bolts.
EG-132
ENGINE -
(b)
(b)
FUEL SYSTEM
Remove these parts:

(1) Diaphragm cover
(2) Diaphragm assembly
(3) Spring
(4) Boost compensator shim
Remove the nut, and disassemble these parts;

2 spring seats
Diaphragm
(1)
(2)
-<::-
--.Q~~--t-{2)
(3) Push 'od
1-----1--< 3)
4mm
He)lagon
Wrench
C.
Remove guide bushing
D.
(a)
Remove control lever

and gaskets.
M,.
(bl
Using a small screwdriver. push out the support pin
and remove the control lever.

(e)
EG133
Using needle nose pliers. remove the connecting pin.

NOTICE: Be careful not to damage the connecting pin.
Tapa the tip of the plier.
E.
Remove No.2 SICS lever
(a)
Remove the No.2 SICS lever. O-ring and washer

assembly from the governor cover.
(b)
Disassemble these parts from the No.2 SICS lever. 0
-ring and washer assembly.

(1)
(2)
F.
(a)
(b)
Voila BACS
G.
(b)
5mm
Hexagon,--~~~
FU2811
Remove overflow screw

w/o BACS:
Remove the rubber cap and overflow screw.
wi BACS:
Remove the overflow screw and gasket.
Remove full load set screw
17. CHECK FLYWEIGHT HOLDER THRUST

CLEARANCE
(See step 16 in injection pump assembly)
Thrust cl rance:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
18. REMOVE GOVERNOR SHAFT AND FLYWEIGHT
HOLDER
(a) Remove the governor shaft lock nut by turning it
clockwise.
NOTICE: The governor shaft and lock nut have LH
threads.
wi BACS
Wrench
O-ring
Washer
(1 )
""~
Using a 5 mm hexagon wrench. remove the governor

shaft. 0 - ring clockwise and remove these parts:
(1) Flyweight holder assembly
(2) No.1 flyweight washer
(3) Governor gear adjusting washer
HINT: Be careful not to drop the 2 washers into the
pump housing.
EG134
r-
ftIP)
~W~
A~
~
(3)
EG
(e)
Remove these parts from the flyweight holder:

(1)
(2)
(3)
Governor sleeve
No.2 flyweight washer
4 flyweights
(2)
"""
'-
19. REMOVE INJECTION PUMP STAY AND FUEL PIPE

BRACKET
(a) Using a 5 mm hexagon wrench. remove the 4 bolts
and injection pump stay.
(b) Remove the bolt and fuel pipe bracket.
5mm
Hexagon
Wrench
20. REMOVE DISTRIBUTIVE HEAD PLUG
Using SST. remove the distributive head plug and Dring.

SST 09260-54012 (09262-54010)
5mm
Hexagon
Wrench
21. REMOVE DISTRIBUTIVE HEAD

(a) Using a 5 mm hexagon wrench. remove the 4 bolts
and wire clip.
(b)
Remove the distributive head and these parts:

(1)
(2)
(3)
(4)
(5)
2
2
2
2
2
lever support springs

plunger spring guides
plunger spring shims
upper spring seats
plunger springs
111-----0
(2)~
EG-135
22. REMOVE PUMP PLUNGER

Using SST, remove the pump plunger and plunger
SST
adjusting shim together with these parts:

(1)
(2)
(3)
(4)
SST
(3)------@
(4l------<;l
"""1
Shim_
Pllll86
Spill ring
Lower spring seat
Upper plunger plate
Lower plunger plate
09260-54012 (09269-54030)
NOTICE: Do not touch the sliding lurfac of the pump
",m
plunger with your hand.
23. REMOVE GOVERNOR LINK

Using SST. remove the 2 support bolts. gaskets and
governor link.
SST 09260-54012 (09269-54040)
SST
24. REMOVE FACE CAMP LATE AND COUPLING

Remove the face camplat8 and coupling.
25. REMOVE ROLLER RING AND DRIVE SHAFT

(a) Remove the timer clip and stopper pin.
(b)
Slide Pin
P121'lEl
Push the slide pin toward inside.
11q]
EG136

(c)
Push the drive shaft. and remove the roller ring. 4

rollers and shims assembly.
NOTICE,
8. car.ful not to drop the roller.
00 not .It.r the position or mbly of the rolle,..
(d)
Using vernier calipers. measure the protrusion of the
'EG
coupling spring.
Protrusion:
1.0 - 1.4 mm (0.03937 - 0.05512 in.)
If the protrusion is not as specified. replace the coupling spring.

NOTICE: Do not remove the coupling spring unlit,. neees..,y. If you remove the coupling spring, replace it with.
new one.
Joint Rubber
(e)
Remove the drive shaft. governor drive gear. 2 joint

rubbers assembly, set key and drive shaft washer.
(1)
Remove the drive gear and 2 joint rubbers from the

drive shaft assembly.
Drive Shaft Assemblv
26. REMOVE TIMER

(a) Using a 5 mm hexagon wrench. remove the 4 bolts.
5mm
Hexagon
Wrench

(bl
~~c<' ( ~
(~~~ to 1\1
19)
Il}
13}
~ 9~"fJ..~ ~3
(4)
Remove these parts:

(1 ) LH timer cover, timer adjusting screw and nut
assembly
(2) O-ring
(3) Shim
(4)
17116)
Outer spring
(5) Inner spring
(8)
AH timer cover
O-ring
Piston
(9)
Sub-piston
(6)
(8)
(2)
EG-137
(71
mm
(c)
Remove the nut from the LH timer cover.
(d)
Using a 5 mm hexagon wrench. remove the timer

adjusting screw.
(e)
Remove the O-ring from the timer adjusting ring.
Plum
27. REMOVE FUEL FEED PUMP
(a)
(b)
(e)
~
o
r:t
Remove the 2 screws.

Using a piece of wire. remove the feed pump cover.
Remove the feed pump rotor, 4 blades and liner.
NOTICE:
Be careful not to interchange the blade positions.
B. careful not to damage the pump body.
28. REMOVE REGULATOR VALVE

Using SST. remove the regulator valve and 2 O-rings.
SST 09260-54012 (09262-54020)
SST
29. REMOVE FUEL INLET HOLLOW SCREW

Remove the hollow screw and gasket.
EG-13B
INJECTION PUMP COMPONENTS

INSPECTION
1.
(a)
(b)
--.
INSPECT DELIVERY VALVES

Attach the nozzle tester to the delivery valve holder of
the pipe you wish to measure.
Use the nozzle tester to check the valve opening
pressure of the delivery valve.
Standard velve opening pr...ur.:
7.350 - 8.330 kP.
(75 - 85 kgf/cm', 1.087 - 1.208 pall
If the valve opening pressure of the delivery valve is
not within specification. replace the delivery valve
assembly.
SST 09260-54012 (09269-54020)
Torque: 159 Nm (800 kefem, 43 ft-Ib')
NOTICE: Do not 10'. the It1 bill! when doing en oyer
haul.
2.
(0)
(b)
(e)
"",m
(d)
3.
Deviation ~f-
....
INSPECT PUMP PLUNGER. SPILL RING AND

DISTRIBUTIVE HEAD
Tilt the spill ring (distributive head) slightly and pull
out the plunger.
When released. the plunger should sink down smoothly into the spill ring (distributive head) by its own
weight.
Rotate the plunger and repeat the test at various
positions.
If the plunger sticks at any position. replace the parts
as a set.
Insert the governor link ball pin into the spill ring and
check that it moves smoothly without any play.
INSPECT PLUNGER SPRINGS FOR DEVIATION

Using a steel square, check the deviation of the plunger springs.
M.ximum devi.tion:
2.0 mm (0.079 in.)
If deviation is greater than maXimum, replace the
springs.

4.
EG-139
INSPECT SPRING LENGTH

Using vernier calipers. measure the fre8 length of
each spring.
Spring fr length:
Oelinry vain .prlng
12.8 mm (0.488 In.)

Plunger .pring
34.09 mm (1.342 In.)
Boo.t compenutor .prlng
19.4 mm (0.784 In.)
If the free length is not as specified. replace the spring

(s).
5.
INSPECT ROLLER RING AND ROLLERS

Using a dial indicator. measure the roller height.
Mn:imum roll.r height variation:
6.
(a)
..a
. ~~
3;--<;
(b)
1
(f)
0.02 mm (0.0008 In.'

If the variation is greater than specification. replace
the roller ring and roller as a set.
INSPECT FUEL CUT SOLENOID
Connect the solenoid valve body and terminal to the
battery terminals.
You should f881 the click from the solenoid valve when
the battery power is connected and disconnected .
If the solenoid valve is not operating properly. replace
it.
Battery
",,,.
7.
INSPECT PICKUP SENSOR

the terminals.
Riat.nc.:
860 - 970 Q
If resistance is not as specified. replace the sensor.
,
"''''
8.
(a)
IF NECESSARY, REPLACE OIL SEAL

Using a wrench. pry out the oil seal.
NOTICE: B. c.r.ful not to d.m.g. to th. pump body.
EG-140
(b)
(e)
Apply MP grease to the tip of a new oil seal.

Using a 22 mm socket wrench. tap in the oil seal until
its surface is flush with the pump housing.
INJECTION PUMP ASSEMBLY

1.
--.
INSTALL FUEL INLET HOLLOW SCREW

Install a new gasket and the hollow screw.
2.
(a)
(b)
INSTALL REGULATOR VALVE

Install 2 new 0 - rings to the regulator valve.
Using SST. install the regulator valve.

SST 09260-54012 (09262-540201
Torque: 8.8 Nm (90 kgfcm. 78 in.lb')
d11
'--' -111
er
w~.o~b
Q
, 0
If -I
II '
-I
...,
) -~,)
o@
.
~/
~~~""'''
3.
(a)
INSTALL FUEL FEED PUMP

Install the liner. rotor and 4 blades.
(b)
Check that the liner and blades are facing in the

correct direction. as shown.
Check that the blades move smoothly.
(c)
(d)
(e)
(f)
Align the fuel outlet holes of the cover and liner.

Install the pump cover with the 2 screws.
Torque: 3.0 Nm (31 kgfem, 27 in.lbf)
Check that the rotor moves smoothly.
4.
Joint Rubber
Drive Gear
(al
'i~
o~~y
(b)
EG-141
INSTALL DRIVE SHAFT

Install the drive gear on the drive shaft assembly as
shown.
Install 2 new joint rubbers into the drive gear.
1~~
Drive Shaft Assembly
EG
""ro
(e)
(d)
Drive Shaft
Washer
Position the key groove of the feed pump rotor

upward.
Install the drive shaft washer and set key on the drive
shaft and insert the drive shaft assembly into the
pump housing.
Sel Key
(8)
Check that the drive shaft turns without catching.
5.
(a)
(b)
(el
INSTALL TIMER PISTON

Apply grease to the timer piston.
Install the sub-piston into the timer piston.
Insert the timer piston into the pump housing.
EG142

6.
(a)
(c)
INSTALL ROLLER RING

Install the slide pin. 4 rollers and 4 washers on the
roller ring.
Check that the roller is facing the flat surface of the
washer.
Install the roller ring into the pump housing.
(d)
Carefully install the slide pin into the sub-piston.
(e)
Install the stopper pin and clip.
7.
(a)
(b)
INSTALL TIMER SPRING

Install a new a-ring to the timer adjusting screw.
Using a 5 mm hexagon wrench. install the timer adjusting screw to the LH timer cover and temporarily
install the nut.
(e)
Install these parts:
(b)
Slide Pin
o ..
"--===:.--C/
l~1f
(6)
(4)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
NewO-ring
RH timer cover
Inner spring
Outer spring
Shim
New O-ring
LH timer cover, timer adjusting screw and nut
assembly

(dl
EG-143
Using a 5 mm hexagon wrench. install the 4 bolts.

5 mm
Hexagon
Wrench
8.
PRESET TIMER ADJUSTING SCREW
(a)
Using vernier calipers. measure the protrusion of the

adjusting screw from the timer cover.
Protrusion:
7.5 - 8.0 mm (0.295 - 0.315 In.)
(b)
Using a 5 mm hexagon wrench. adjust the protrusion

of the adjusting screw from the timer cover.
Tighten the nut.
Ie)
Torque: 14.2 Nm (145 kgfcm, 11 ft-lbf)

5mm
Hexagon
Wrench
"""
C61~
o
C41 -.._=.._-
5)
9. ADJUST PLUNGER SPRING SHIM

(al Install these parts to the distributive head:
-1
[C31
@-C 21-@
J1-
C11
-a
""'~
(b)
(c)
(1)
2 plunger spring guides
(2)
(3)
(4)
(5)
(6)
(7)
2 upper spring seats

2 plunger springs
Lower spring seat
Upper plunger plate
Lower plunger plate
Pump plunger
HINT: Do not assemble the plunger spring shims at

this time.
Using vernier calipers. measure clearance A indicated
Determine the plunger spring shim size by using these
formula and chart.
New plunger spring shim thickness = 7.0 - A
A ... Measured plunger position
EG-144

Plunge' spring shim .election chert:
mm (in.)
M...ur.clel'lr.ne.
Shim thiekn...
MOl" than 6.5 (0.256)
0.5 (O.020)
6.2 - 6.4 (0.248 - 0.252)
0.8 (O.031)
6.0 - 8.1 (0.236 - 0.2(0)
1.0 (0.039)
5.8 - 5.9 (0.228 - 0.232)
1.2 (0.047)
5.5 - 5.7 (O.217 - 0.224)
1.5(0.059)
5.2 - 5.4 (0.205 - 0.213)
1.8(0.071)
L... thin 5.0 (0.1971
2.0 (0.079)
HINT:
For a measurement between listed sizes. use the

next larger size. For example. if thickness is 1.1
mm (0.043 in.) by calculation. use a 1.2 mm
(0.047 in.) shim.
Select 2 shims which have the same thickness.

10. INSTALL COUPLING
Install the coupling.
11. INSTALL FACE CAMPLATE

(a) Face the drive shaft with the key groove facing
(b)
upward.
Install the camplate with the camplate pin facing the
governor cover side.
",.ro
12. INSTALL GOVERNOR LINK

Using SST, install the governor link with 2 new gas
(a)
(b)
kets and the 2 support bolts.

Torqu.: 14 Nm {1.0 kgfcm, 10 ftlbfl
SST 09260-54012 (09269-540401
Check that the governor link moves smoothly.
13. INSTALL PUMP PLUNGER

(a) Place the previously used plunger adjusting shim on
the center of the camplate.
NOTICE: Do not .pply gr to the .him.

(b)
(3)
EG-145
Install these parts to the pump plunger:

(1) Lower plunger plate
(2) Upper plunger plate
(3) Lower spring seat
(4) Spill ring
HINT: Face the spill ring with the hole facing the lower
spring seat.
(e)
(d)
(e)
Align the pin groove of the plunger with the pin of the
face camplate.
Align the ball pin of the governor link with the pin hole
of the spill ring.
Using SST. install the pump plunger and 2 plunger
springs.
SST 09260-54012 (09269-540301
14. INSTALL DISTRIBUTIVE HEAD

(a) Apply grease to these parts and install them to the
distributive head:
(1)
(2)
(3)
(4)
(5)
fU0210
FU021l
2 plunger spring guides

2 new selected plunger spring shims
2 upper spring seats
2 lever support springs
New 0 - ring
mlD7
5mm
Hexagon
Wrench
(b)
Install the distributive head.

NOTICE: Be careful not to damage the pump plunger.
(el
Using a 5 mm hexagon wrench. install the 4 bolts and

wire clip.
HINT: Use the bolt which is 45 mm (1.77 in.) in length.
EG-146
r
.-<l
15. INSTALL GOVERNOR SHAFT AND FLYWEIGHT
~~3)
(0)
t-
f{~
~
HOLDER
Install these parts to the flyweight holder:
(1) 4 flywo;ght
(2) NO.2 flyweight washer
(3) Governor sleeve
HINT: Replace the 4 flyweights as a set.
G
""'~
~U2825
5mm
HeXagOn~
Wrench
t.-"'"<-
(b)
Install a new a-ring to the governor shaft.
(e)
Place the flyweight holder assembly (1) in position,

and install the governor gear adjusting washer (2) and
No.1 flyweight washer (3) between the flyweight
holder and pump housing,
(dl
Install the governor shaft through the governor gear

adjusting washer. No.1 flyweight washer and fly
weight holder assembly.
(e)
Using a 5 mm hexagon wrench. turn the governor
(1)
""'"
shaft counterclockwise.
16. CHECK FLYWEIGHT HOLDER THRUST
CLEARANCE
Using a thickness gauge. measure the thrust clearance between the housing pin and flyweight holder.
Thrust cle.r.nce:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
If the thrust clearance is not as specified. adjust with
a governor gear adjusting washer.
Goyernor ge.r .dJustlng w.sher thickness:
1.05 mm (0.0413 in.)
1.25 mm (0.0492 in.)
1.65 mm (0.0650 in.l
1.85 mm (0.0728 in.)
1.45 mm (0.0571 in.l
17. ADJUST PROTRUSION OF GOVERNOR SHAFT

(a) Using vernier calipers. measure the protrusion of the
governor shaft.
Protrusion:
0.5 - 2.0 mm (0.020 - 0.079 In.)
If the protrusion is not as specified. adjust by turning
the governor shaft.
(b)
5mm
Hexagon
Wrench
..
",
Using a 5 mm hexagon wrench. install and tighten the

nut while holding the governor shaft with a 5 mm
hexagon wrench.
Torque: 27 Nm (275 kgfcm. 20 ftlbfl
EG-147
18. ASSEM8LE 800ST COMPENSATOR

A. InstaU overflow screw
(a) wi BACS:
Install the overflow screw with a new gasket.

Torque: 24.55 Nm (250 kgfcm. 18 ftlbfj
(b)
w/o BACS:
Install the overflow screw.
(e)
w/o BACS:
Install the rubber cap facing the arrow downward.
B.
Install No.2 SICS lever
(a)
Assemble these parts to the No.2 SICS lever.

(1) Washer
(b)
(2) New a-ring

Install the No.2 SICS lever. washer and 0 - ring as-
sembly to the governor cover.
1'23523
C.
Install control lever
(a)
Insert the connecting pin into the governor cover.
(b)
Using a small screwdriver. install the control lever

with the support pin.
(c)
Using a 4 mm hexagon wrench. install 2 new gaskets
and the 2 bolts.

Torque: 6.85 Nm (70 kgf-cm. 61 in .. lbf)
4 mm
Hexagon
Wrench
EG148

19. INSTALL ADJUSTING LEVER SHAFT TO
GOVERNOR SHAFT
(a) Install these parts to the adjusting lever shaft.
(1) Washer
(2) New O-ring
(b) Install the adjusting lever shaft. washer and O-ring
assembly to the governor cover.
EG
20. INSTALL GOVERNOR COVER
(a) Europe:
Install a new gasket to the groove of the governor
cover.
(b) Europe:
Connect the adjusting lever shaft to the governor link
Europe
and twist the shaft lightly_
(cl
Australia:
Install the speed control spring to the adjusting shaft.
(d)
Australia:
Install a new gasket to the groove of the governor

cover.
(e)
Australia:
Install the damper spring and spring seat, and connect
the speed control spring to the spring seat.
{fl
Using a 5 mm hexagon wrench. install the governor

cover with the 4 bolts.
115519
Torque: 8.3 Nm (85 kgfcm. 74 In..tbf)
HINT: Use the bolt which is 35 mm (1.38 in.) length.
5mm
Hexagon
Wrench
(9)
Install the idle speed adjusting screw and lock nut.

Torque: 6.9 Nm (70 kgfcm. 61 in..lbfl
EG-149
21. INSTALL ADJUSTING LEVER

(a) Place the return spring on the governor cover.
(b)
Hook the return spring to the adjusting lever. and turn

and place the adjusting lever on the governor shaft.
(c)
Align the lines of the adjusting lever shaft and adjust-
(d)
ing lever.
Install the nut.
22. INSTALL PICKUP SENSOR

(a) Connect the sensor lead wires to the connector.
(b)
Install a new O-ring and pickup sensor.

Torque: 22.1 Nm (225 kgfcm. 16 ftlbfl
""'"
23. ADJUST PLUNGER PRE - STROKE
Using SST. install SST to the fuel cut solenoid installation screw section.
SST 09275-17010
(b) Set the dial indicator so that the tip of the dial indicator push rod touches the upper surface of the plunger.
(e) Install the set nut to the drive shaft.
(d) Rotate the drive shaft. set the plunger to BOC and set
the scale on the dial indicator to 0 mm (0 in.).
(e) Apply a few drops of light oil (diesel fuel) to the top
surface of the plunger. and when 49 kpa (0.1 kgf/cm 2 ,
1.4 psi) of air is applied to SST. bubbles appear on the
upper surface of the plunger.
(f) Slowly rotate the drive shaft in the pump rotation
direction (clockwise) and read the dial indicator when
the bubbles on the top of the plunger disappear.
Pre-stroke: 0.48 - 0.52 mm (0.0189 - 0.0205 in.)
If the pre - stroke is not as specified. replace the
plunger adjusting shim under the plunger with a dif
ferent sized shim.
HINT:
Shims are available in 131 sized in increments

0.01 mm (0.004 in.), from 1.90 mm (0.0748 in.) to
3.20 mm (0.1260 in.).
If the shim is made thicker, the pre-stroke is

decreased.
(g) Remove the SST from the fuel cut solenoid installation
screw section.
(h) Remove the set nut from the drive shaft.
(e)
Air
EG
EG150

(i)
r--
riltWf
EG
If-- t~
~ .. ~ (P)J)
After completing the pre stroke adjustment. check

that dimension B is within the specifications.
Dimenlion B: 3.4 - 3.8 mm (0.134 - 0.'42 in.)
If dimension B is not within the specification. replace
the distributor head.
mo,
24. INSTALL DISTRIBUTIVE HEAD PLUG

(a) Install a new O-ring to the head plug.
(b) Using SST. install the head plug.
SST 09260-54012 (09262-540101
25. ASSEMBLE BOOST COMPENSATOR
A.
Inltell guide bushing

Install and adjust the guide bushing to the dimension
"A" as shown in the illustration.
Dimension ".":
Euro~
17.3 - 17.4 mm (0.881 - 0.885 in.)

Austr.li. 18.9 - 19.0 mm (0.744 - 0.748 In.)
C::=:-I~c;;;~;(Shjm
B.
(a)
Inltell boost compen tor diaphragm

Adjust boost compensator shim.
Place the shim on the guide bushing.
Using vernier calipers, measure the dimension -Bas shown in the illustration.
Dim.nsion 8:
Euro~
3.8 - 3.8 mm (0.142 - 0.150 In.)
Austr.lI. 3.1 - 3.3 mm (0.122 - 0.130 in.)
If the dimension is not within specification. select and

install the correct shim.
HINT: Shim are available in sized in increments 0.2
mm (0.008 in.), from 1.1 mm (0.043 in.) to 3.3 mm
(0.130 in.).

(b)
EG-15!
Assemble these parts with the nut.

(l)
(2)
(3)
Push rod
Diaphragm
2 spring seats
I f--t-{1l
FU3034
(e)
Adjust the installation direction of boost compensator

diaphragm assembly.
Install the shim and diaphragm assembly.

HINT: Do not assemble the spring.
e
Using vernier calipers. while pushing on the diaphragm assembly dimension X" with vernier calipers as shown.
Dimension X:
wI SACS: 8.8 - 9.0 mm (0.346 - 0.354 in.)

w/o SACS: 8.5 - 8.7 mm (0.335 - 0.343 in.)
HINT: Measure at the center of the hole.
Place match marks on the diaphragm assembly
and governor cover.

Shim
Remove the diaphragm assembly.
FU27JS
81200
'.5-2.5~
(d)
Insert 1.5 - 2.5 cc (0.09 - 0.15 cu in.) of engine oil

into the bushing hole.
~(41
(e)
Install these parts to the governor cover.

(1) Boost compensator shim
(2) Spring
(3) Diaphragm assembly
(4) Diaphragm cover
Matchmarks
II
131
..
(2)
~(11
FU2843
ZI'io'l17
EG-152

(f)
Using a 5 mm hexagon wrench. install the diaphragm
cover with the 4 bolts.

5mm
Hexagon
Wrench
EG
"""
C.
In.tell lever control .pring

Install the lever control spring with a new gasket and
the bolt.
Torque: 11.3 Nm (115 kgfcm. 8 ftlbt)
26. INSTALL INJECTION PUMP STAY

27. INSTALL FUEL CUT SOLENOID

(a) Install a new O-ring on the fuel cut solenoid.
(b) Install the wave washer. strainer. valve. spring and
fuel cut solenoid.
Ie)
Install the lead wire to the fuel cut solenoid with the
nut.
Torque: 1.7 Nm (17 kgfcm. 15 inAbf)
(d)
(e)
Install the dust cover to the fuel cut solenoid.

Install the wire harness to the wire clip.
Install the lead wire connector to the bracket.

28. INSTALL CAP
Install a new gasket and the cap.
(f)
Torqu.: 11 Nm (115 kgfcm, 8 ftlbf)
29. INSTALL NO.1 SICS LEVER

Align the lines of the levers.
(b) Install the nut.
Torqu.: 8.9 Nm (70 kgfcm. 81 in.lbf)
(a)
EG-153
30. INSTALL SICS ACTUATOR

(a) Using a 5 mm hexagon wrench. install the SICS ac
tuator bracket with the 3 bolts.
Torque: 8.3 Nm (95 kgtem. 82 in..lbf)
(b)
(c)
Install the maximum speed adjusting screw.
Install the lock plate to the maximum speed adjusting
screw.
EG
(d)
(e)
(f)
Install the SICS actuator with a nut.

Torque: 9.35 Nm (95 kgfem, 83 in.lb')
NOTICE: In.t.1I 2 actuator adju.ting wa,h.,. on the .id.
with the nut.
Install the clip.
Install the SICS adjusting screw.

Torque: 6.9 Nm (70 kgt-em. 61 In..lbt)
(g)
Melal Plale ~h":::::J
-'
Connect the wire harness.
31. INSTALL THERMO WAX

(a) Using a screwdriver. turn the cold starting lever coun-
terclockwise approx. 20 0
(b)
(c)
(d)
(e)
(f)
Put a metal plate (thickness of 5.0 - 8.0 mm (0.20 0.31 in.)) between the cold starting lever and thermo
wax plunger.
Install a new O-ring to the pump body.
Using a 5 mm hexagon wrench, temporality install the
thermo wax with the 2 bolts.
Using a screwdriver, turn the cold starting lever coun
terclockwise.
Using a 5 mm hexagon wrench, install the bolt (B).and
removal the bolt (A).
Torque: 8.35 Nm (85 kgfcm. 74 In..lbf)
(g)
5 mm Hexagon, ~':.-"~./\<:'I....\
Wrench
Using a 5 mm hexagon wrench. tighten the bolt.

Torque: 8.35 Nm (85 kgfcm, 74 in..lbf)
32. INSTALL IDLE-UP LEVER

Using a 5 mm hexagon wrench. install the idle-up
lever with the 3 bolts.
Torque:
Short bolt: 8.35 Nm (85 kgfcm. 74 in.lbf)
Long bolt: 11.75 Nm (120 kgfcm. 9 ft.lbf)
33. REMOVE INJECTION PUMP FROM SST (STANO)

SST 09241-76022. 09245-54010
5 mm Hexagon Wrench
EG-154
34. PERFORM AIR TIGHT TEST
Plug
(al
(bl
(e)
wi BACS:
Install a bolt and gasket to the overflow port.
w/o BACS:
Install a bolt to the overflow port.
Install the plug to each port of the boost compensator
and SICS actuator.
EG
"""
49 kPa - 490 kPa
(e)
Connect an air hose to the fuel inlet pipe and place the
(d)
injection pump into diesel fuel.

Apply 49 kPa (0.5 kgf/cm'. 7 psi) of pressure and
confirm that there are no leaks.

Next check that there are no leaks with 490 kPa (5.0
kgf/cm'. 71 psi) of pressure applied.
35. INSTALL SET KEY OF INJECTION PUMP DRIVE
PULLEY ON DRIVE SHAFT
(e)
~,
INJECTION PUMP ADJUSTMENT

1.
(a)
--.
PRE-TEST CHECK AND PREPARATION

The specifications for t8St nOlzle and nOlzle holders
are as follows.
Test noule:
..-
DN12SD12 (NIPPONOENSO)
Test nozzle opening pressure:

14.220 - 15.200 kPa
(b)
(145 - 155 kgf/cm', 2,062 - 2.205 psi)

Check the accuracy of the tachometer.
Allowable error:
40 rpm
(c)
(d)
Install the angle gauge stand.

Mount the injection pump body on the pump tester.
HINT: Place a mark on the key groove portion of the
coupling.
NOTICE:To prevent vibration or dislocation of the injection pump. fix in place the distributive head of the injec
tion pump.
(e)
Install an injection pipe with these specifications.

Outer diameter:
6.0 mm (0.236 in.)
Inner diameter:
2.0 mm (0.079 in.)
length:
840 mm (33.07 in.)
Minimum bending radius:
25 mm (0.98 in.) or more
EG-155

(f)
(9)
Remove the fuel inlet hollow screw.

Connect the fuel inlet pipe with an adapter.
(h)
Install an overflow hose with 2 gaskets and union bolt.

HINT: Always use the overflow screw installed on the
pump to be adjusted.
(i)

and RH timer cover.
OJ
Install the inner pressure gauge with the timer meas-
""'"
Timer
Measuring
Device
uring device.
Part No. 95095-10231 and 95095-10480
Air Bleed
Screw
(NIPPONOENSO)
(k)
"""
HINT: Bleed the air by the air bleed screw.

Connect SST (turbocharger pressure gauge) to the
boost compensator.
SST 09992-00241
Turbocharger
Pressure Gauge
(SST)
Inner
Pressure
Gauge
Fuel
Pressure
Gauge
NOlzle
FEDCBA
tC:Jl:~~__-,~
1~A~dj~U~S1ing Valve
~------.,
o
o
o
..
Me85UfingO
Cylinder
Fuel Filter
Fuel Feed
Pump
o
o
t+----j
Fuel Tank
"""
EG-156

(I)
Apply about 6 volts of DC power to the fuel cut

solenoid.
NOTICE:
n~lfU0211
When applying yoltage to the lolenoid. pOlition the

battery far away from the lolenold a. poibl. 80
that. Ipark do not occur.
When connecting the battery ubi connect the
lolenold ,Id. fir.t.
(m) The pressure for feeding fuel to the injection pump

should be 20 kPa (0.2 kgfjcm l 2.8 psi). The fuel
temperature for pump testing should be 40 - 45 C
(104 - 113'F).
(0) Install an angle gauge to the stand and set it to the
adjusting lever.
Part No. 95095-10360 (Stand wi angle gauge)
(0) Secure the adjusting lever fully on the maximum
speed side.
(p)
Check the installation direction of the camplate as

follows:
Disconnect the injection pipe from the position

marked "C" on the distributive head.
Using SST, remove the delivery valve holder as

sembly and gasket.
SST 09260-54012 (09269-54020)

fun:n
"""
Check that fuel is flowing out when the mark is in

the position shown in the illustration.
If not, it is improperly assembled.
Disassemble and change the camplate position

180 in the opposite direction.
HINT: At this time. disconnect the fuel cut solenoid
wire harness.
W21 J1
fU2J05
m,,,
Using SST. install a new gasket and the delivery

valve holder assembly.
SST 09260-54012 (09269-54020)

Torqu.: 59 Nm {600 kgfcm. 43 ftlbf)
'l1528'l
Connect the injection pipe.
ENGINE
(q)
Bleed the air from the injection pipes.
(r)
Measure the injection volume.
-s-
\~_l m:Q;-~
~II_-
IT'
(5)
FU1716
FU2709
Pump
No. of mtlBluring
Each injection volume
'Pm
stroke.
cc (cu in.)
1.080
200
14.92
16.52
(0.91 - LOll
Race the injection pump for 5 minutes at 1.200 rpm.

NOTICE: Check that there i, no tuelle.keg. or abnormal
HINT:
Measure the volume of each injection cylinder

with a measuring cylinder.
Before measuring the injection volume. first hold
30 Seconds
fU0636
EG-' 57
FUEL SYSTEM
lOOl12
2.
the cylinder tilted for at least 30 seconds to

discard all the fuel.
PRE-SET FULL LOAD INJECTION VOLUME
(a)
Set the adjusting lever to maximum position.
(b)
Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hg) of vacuum

to the SICS actuator.
w/o BACS:
(e)
(d)
(e)
(f)
Apply 79 kPa (0.81 kgfjcm', 11.5 psi) of pressure to

the boost compensator.
wi BACS:
Apply 121.9 kPa (1.24 kgfjcm 2 , 17.7 psi) of pressure
to the boost compensator.
Pump
No. of menuring
Each injection yolume
,pm
strokes
cc Icu in.)
1,080
200
14.92
16.52
(0.91 - 1.01)
Remove the collar seal as follows:
Hold the full load set screw, and release the collar
seal from the spot weld by turning the lock nut
counterclockwise by 90" or more.
Using a screwdriver, pry out the collar seal.
EG-'58
5 mm Hexagon
Wrench
fU2981 FU0242
zml19
(g)
Adjust by turning the full load set screw.

HINT: The injection volume will increase about 3 cc
(0.18 cu in.) with each 1/2 turn of the screw.
3.
w/o BACS:
4.
(a)
(bl
(e)
(d)
(e)
PRE-SETTING OF LOAD SENSING TIMER

Using a 5 mm hexagon wrench. adjust the protrusion
of the governor shaft.
Protrusion:
0.5 - 2.0 mm (0.020 - 0.079 in.)
PRE - SET MAXIMUM SPEED
w/o BACS:
Apply 79 kPa (0.81 kgf/cm'. 11.5 psi) of pressure to
wi BACS:
Apply 121.9 kPa (1.24 kgf/cm',17.7 psi) of pressure
Pump
No. of measuring
Eeeh injection yolume
"""
2.200
.troke.
ce leu in.)
200
4.0-6.0 (0.24
0.37)
Maximum Speed Adjusting Screw
(f)
(g)
Remove the lock plate.

Adjust the injection volume with the maximum speed
adjusting screw.
5.
(a)
ADJUST PUMP INNER PRESSURE

Measure the pump inner pressure at the below listed
rpm.
Pump
Inner prellure
<pm
\.080
1.800
kP, (kgf/cm', psi)

402.1
813.9
460.9 (4.1
872.8 (8.3
4.7.58.3 - 66.8)
8.9.1\8.3 - 126.8)
EG-159
FU0244
(b)
If the pressure is low. adjust by lightly tapping the

regulator valve piston while watching the pressure
gauge.
HINT: If the pressure is too high or if the regulator
valve was tapped in too far. the regulator valve must
be replaced.
6.
CHECK OVERFLOW VOLUME

Measure the overflow volume at the below listed rpm.
flJ024S
Pump
Overflow volume
'Om
cc/min. (eu in.fmin.)
1.800
'.292 - 1,942 (78.8 - 118.5)
HINT: Always use the overflow screw installed on the

pump to be adjusted.
7.
(a)
(b)
RELEASE COLD STARTING SYSTEM FOR NEXT

INSPECTIONS
Using a screwdriver. turn the cold starting lever counterclockwise approx. 20.
Put a metal plate (thickness of 5.0 - 8.0 mm (0.20 -
0.31 in.)) between the cold starting lever and thermo

wax plunger.
HINT: Keep the cold starting system released until all
measurements and adjustments are finished.
6.
(a)
(b)
ADJUST TIMER
Set the timer measuring device at zero.
Measure the timer piston stroke at the below listed
rpm.
Ilem
Pump.pm
1.080
w/o BACS
~,.
wI BACS
5 mm
--<~:::::'f-- Wrench
Hel(agon
(c)
1.440
1,800
2.000
1,080
1.440
1.800
2.000
Piston strokes mm lin.)

0.63 - 1.6310.025 - 0.064)
3,24 - 4,2410. 128 - 0.167)
5.85 7.7 0.22 2.83 5.44 7.7 -
8.8510.230 - 0.2701
8.7 (0.303 - 0.3431
1.22 (0.009 - 0.0481
3.83 (0." 1 - O. 1511
6.44 (0.214 - 0.2541
8.7 (0.303 - 0.343)
HINT: Check that the hysteresis is within 0.3 mm

(0.012 in.).
Using a 5 mm hexagon wrench. adjust by turning the
timer adjusting screw.
EG-160

r-- ,,
;;:
EG
FU3102
Long Spring-+I
,
,,
,, , , ,
, ,, ,
"
,
,,
(d)
,/\
HINT: Turn clockwise to reduce the stroke. turn counterclockwise to increase the stroke.
Check the timer stroke for characteristic tendency.
Short Spring
Pump rpm
"p"
~ ~'OO"
~!
~~
If tendency is not as specified. select and replace the

Innef spring.
Time' spring fr.e length:
34.4 mm (1.35 in.)
34.0 mm (1.34 in.)
33.6 mm (1.32 in.)
'P';"'
@O
~"
"
HINT: The timer stroke wllJ increase with a long spring

and decrease with a short spring.
PI2'>I'l
9.
(a)
(b)
CHECK BOOST COMPENSATOR FOR AIR

TIGHTNESS
Apply 98 kPa (1.00 kgfjcm', 14.2 psi) of pressure to
Measure the time it takes for pressure to drop to 95
kPa (0.97 kgf/cm'. 13.8 psi).
Pressure drop:
10 seconds or more
O'
B, A
10. ADJUST FULL LOAD INJECTION VOLUME

(a) The adjusting lever angle for the adjustment below
should be as shown in the illustration.
Adjusting lever .ngl.:
A (Meximum speed side)
Plus
(b)
(c)
(d)
21
31
I
I
B (Idle speed side)

wlo BACS:
Apply 79 kPa (0.81 kgf/cm 2 11.5 psi) of pressure to
wi 8ACS:
Apply 121.9 kPa (1.24 kgf/cm 2 17.7 psi) of pressure
EG-161

(e)
Measure the full load injection volume.

Adjusting lever
Pump
angle
.pm
Plus21-31"
I."'"
(t)
(g)
(h)
Inject10n volume of each cylinder
2PO
14.92- 16.52 (0.91 - 1.011
cc (eu in.)
Adjust by turning the full load set screw.

HINT: The injection volume will increase about 3 co
(0.18 cu in.) with each 1/2 turn of the screw.
Release the vacuum from the SICS actuator.
Pump
No. of meuring
.pm
Itrokel
100
(i)
No. of messurl"g
strokes
cc leu in,)
11.3
200
12.7
(0.69 - 0.77)
Adjust by turning the SICS adjusting screw.

HINT: By screwing in the adjusting screw, the injection volume is increased; unscrewing the adjusting
screw decreases the injection volume.
Ul
Check that when the actuator rod for SICS is withdrawn the most, the gap between SICS lever and SICS
adjusting screw is 3 mm or more. If it less than 3 mm,
add 1 adjusting washer on the nut side and check that
the gap is 3 mm or more.
(k) Check that when the actuator is not operating, the
gap between SICS lever and SICS adjusting screw is 0
mm.
II. ADJUST MAXIMUM SPEED
lal w/o BACS:
Apply 79 kPa (0.81 kgf/cm 2 , 11.5 psi) of pressure to
Ibl wi BACS:
Apply 121.9 kPa (1.24 kgf/cm 2,17.7 psi) of pressure
(c) Apply 67.2 kPa (503.8 mmHg, 19.83 in.Hg) of vacuum
(d) Measure the injection volume at each pump rpm.
Adjusting
lever engle
Pump
Plus21-31"
2.200
Minus 12 - 22"
2,200
.mp
No. of menuring
strokes
200
Injectiorl volume of each cylinder

cc (cu in.)
Remerks
4.0 - 6.0 10.24 - 0.37)
Adjust
1.0 (0.061 or 16SS
EG-162

(8)
Maximum Speed Adjusting Screw
Adjust by turning the maximum speed adjusting
screw.
12. CHECK INJECTION VOLUME
(a) Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hg) of vacuum

(b)
Measure the injection volume at each pump rpm and
boost pressure.
Item
w/BACS
Adjusting
Pump
lever angle
'pm
Boost
pressure
kPa Ikg/cm2 psi)
1.080
121.9
11.24,17.71
100
41.2
(0.42,6.0)
720
OtO,O)
1,800
121.9
(1.24, 17.7)
1,080
79
(0.81,11.5)
Plus 21- 3'
Sirokes
200
17.74
Plus 21_31
200
010,0)
720
1.800
7.
C:--
SST
r S l e e v e Plug
@--m
@-----E-Ring
Remarks
1.610.101
Basic ful1-load
injection volume
1.6tO.l0)
Volume during
starting
Basic full-load
injection volume
Volume during
Starting
="
It,,)
Variation
limit
cc (cu in.)
If the injection volume at 100 rpm is not as specified.

replace the governor sleeve plug as follows:
Using SST and a press, press out the sleeve plug

assembly from the governor sleeve.
SST 09236-00101 (09237-00070)
-----,
14.00 - 15.00
(0.85 - 0.92)
8.02 - 9.22
10.49 - 0.56)
17.74
IUS}
10.81,11.5)
j
'-
cc ieu in.)
14.92 - 16.52
(0.91-1.01)
15.60 - 19.60
10.95 - 1.20)
7. '4 .34
(0.44 - 0.51)
(1.081
14.92 - 16.52
(O.g, -1.01'
0(0,0)
'00
w/o SACS
Each injection
No. of
measuring
volume
(1)
(2)
Remove the E- ring and following parts from the

sleeve plug:
Stop ring
Bearing and 2 bearing retainers
EG-163
Measure the head thickness of the sleeve plug,

and select a new sleeve plug.
Governor .Ive plug head thickn...:
mm (in.)
Head Thickness
,flU
'-----
1.7 (0.067)
2.1 (0.083)
2.9 (O.114)
3.3 (0.130)
3.7 (0.14B)
4.\ (0.161)
4.5 (0.177)
4.9 (0.193)
HINT: Lengthening the plug by 0.1 mm (0.004 in.) will
"""
decrease injection volume by 0.6 cc (0.04 cu m.).
If the variation limit is greater than specified. replace

the delivery valve.
Install these parts to the new sleeve plug with a
r S l e e v e Plug
&'1
(3j--121
P13524
1.310.051)
2.5 (0.098)
new E-ring:
Bearing and 2 retainers
(1)
(2)
Stop ring
Using a press, press in the sleeve plug assembly
@---E-Ring
to the governor sleeve.

13. ADJUST FULL LOAD MINIMUM INJECTION
VOLUME
(a) Set the adjusting lever to maximum position.
(b) Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hgl of vacuum
(c)
wlo BACS:
Release the pressure from the boost compensator.
F\.I2112
(dl
wi
(e)

wI
BACS:
BACS:
Pump
No. 01 melluring
.pm
Itrokes
720
200

cc lcu in.)
7.14 - 8.34
(0.44 - 0.51)
w/o BACS:
5mm
---fr=~
Hexagon
Wrench
~~'\:::::;_
Timer
dSlide Pin
(f)
Pump
No. of melluring
.pm
strokll
cc (cu in.)
720
200
8.02 - 9.22
(0.49 - 0.58)
Using a 5 mm hexagon wrench. adjust by turning the

timer slide pin.
EG-164

14_ ADJUST BOOST COMPENSATOR
CHARACTERISTIC
(a) Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hg) of vacuum

(b)
(e)
,EG
(d)
w/o BACS,
Apply 40 kPa (0.41 kgf/cm 2 , 5.8 psi) of pressure to
w/ BACS,
wI
BACS:
Pump
No. of musuring
'Pm
Itrok...
720
200
Elch injection volume
cc Icu in.}
12.56
14.16
(0.76 - 0.86)
w/o BACS:
Pump
No. of m...uring
,pm
strokes
720
200

cc (cu in.)
12.70
14.30
(0.17 - 0.87)
(e)
IL
'0'
_____ +b _
-np~u=m=p~,=p=m:-----'-a
e~-f-
E
,
-0 '--l'b,,-/
>,
.9
'-~
'2
BACS:
Pump
No. of mfIBiuriog
beh injection volume
'Pm
strokls
ee leu in.)
720
200
8.02 - 9.22
10.49 - 0.56)
_
Boost Pressurefal "'<11"" lultlM<I ,,,,,.;1_
~.~
Adl",'lu~
w/o BACS:
Pump
No. of mllsuring
rleh injection volume
'pm
strokes
ee leu in.)
720
200
..........".,
"'1'_ """'_
(cl ........'c""'''.. ''''!1~
11011
wi
II>J
.....
Using a screwdriver. adjust the injection volume by

the guide bushing.
HINT: When the guide bushing is turned clockwise, as
seen from above, the injection volume will increase.
15. CHECK FOR CHARACTERISTiC TENDENCY
(a) Apply 67.2 kPa (503.7 mmHg, 19.83 in.Hg) of vacuum
(b) w/o BACS,
Apply 15.7 kPa (0.16 kgf/cm 2 , 2.3 psi) of pressure to
(e) w/ BACS,
Apply 41.2 kPa (0.42 kgf/cm 2 , 6.0 psi) of pressure to
(d) Measure the injection volume.
(dl""'''''_c_
_
-~
1.1 c........."''''
AdI
_OCOfr"llOC'_"""
",
8.80
10.00
(0.5.4 - 0.611
EG-165
16. CHECK HYSTERESIS

w/o BAGS:
Compare the injection volume when the boost compensator pressure is lowered from 79 kPa (0.81 kgfj
em'. 11.5 psi) to 0 kPa (0 kgf/cm 2 , 0 psi) and. conversely. when it is raised from zero.
(b) wi BAGS:
Compare the injection volume when the boost compensator pressure is lowered from 127 kPa (1.25 kgf/
em', 18.3 psi) to 0 kPa (O kgf/cm'. 0 psi) and. conversely, when it is raised from zero.
HINT: Make measurements after moving the adjusting
lever between idle and maximum 3 times for each
lowering of the pressure.
(0)
Pump
Item
Boost pressure
kPa Ikgf/cm 2 psll
'pm
121.911.24, 17.7)
7910.81. '1.51
41.2 (0.42, 6.0)
0(0,0)
79 (0.81. 11.5)
40 (0.41, 5.8)
15.7 to.16, 2.3)
010,0)
720
wI BACS
wlo BACS
720
No. of meesuring
sltokes
Injection volume of
8ach cylinder cc (eu in.)
14.04 - 15.64 (0.86 - 0.951

12.56 - 14.16 (0.76 - 0.861
8.02 - 9.22 (0.49 - 0.56)
7.14 - 8.34 (0.44 - 0.511
14.04 15.64(0.86 - 0.95l
12.70 14.3010.77 - 0.87)
8.80 - 10.00 (0.54 - 0.611
8.02 - 9.22 (0.49 - 0.56)
200
200
Hysteresis
cc leu 1n.1
0.6 (0.10) or less
0.6 10.10l or less
....,
If not within standard value. check each sliding part of

the boost compensator and check whether or not
there is any oil.
17. ADJUST LOAD SENSING TIMER
-i5mm
(0)
'--1 Hexagon
Wrench
* _
,
\,,,
(b)
(e)
(d)
Using a 5 mm hexagon wrench, adjust the starting

and end points of the load sensing timer by turning
the governor shaft.
Apply 67.2 kPa (503.7 mmHg, 19.83 in.Hg) of vacuum
w/o BAGS:
Apply 79 kPa (0.81 kgfjcm'. 11.5 psi) of pressure to
(e)
wi
(I)
Apply 121.9 kPa (1.24 kgfjcm 2 17.7 psi) of pressure

Starting point 01
the load sensing timer
End point of the
loaytimer
BAGS:
AdjUlLIting lever
Pump rpm
Idle
Side
:~~{
S';_;;;~-=====~MM;;;allimum
Speed Side
Ad/ustlng
lever
Position
position
.....
M'llimum .pe.cl side
No. of meesuring
strokes
1.0
1.800
200
EG-'66

(g)
(h)
Slowly move the adjusting lever from the maximum

speed side to the idle speed side. and secure it at the
point where the pump inner pressure begins to drop.
Measure the injection volume at the drop point (start-
ing point).
EG
Pump rpm
No. of measuring
strokes
',BOO
200
Injection velums of each cylinder
cc leu in.}
Measured value at step (f) minus
1.0 fO.061 0.3 fO.021
"""
(i)
5mm
Hexagon
Wrench
Using a 5 mm hexagon wrench. adjust the load sensing timer by turning the governor shaft. and do the
measurement again as specified.
HINT: The injection volume will increase approx. 3 cc
(0.2 cu in.) with each 1/2 turn of the governor shaft.
Governor Shaft
Item
Pump
'pm
No. of mesuring
strokes
w/BACS
',440
200
w/o BACS
',440
200
Injection volume of each cylinder

cc leu in.)
Measured value at step If) minus
3.8 (0.231 1.0 (0.06)
Me8Sured value a1 step 10 minus
3.810.231 1.0 (0.061
(k)
Timer piston stroke

mmlin.1
1.56 2.56
(0.061 - 0.1011
'.29 2.29
(0.051 - 0.090)
HINT: The end point is hard to identify, so use the

methods used in the chart above.
When the adjusting lever is moved slowly from the
maximum speed side to the idle speed side.
wI
BACS:
Pump rpm
1.440
Tim.r pilton Itroll.

0.77
1.77 (0.030
mm(in.)
0.069)
wlo BACS:
Pump rpm
1M.
Timer pillon Itrokl

1.45 - 2.45 (0.057
mm (in.)
0.096J
If the timer stroke is not as specified when the load

sensing is at maximum retard Zlngle, select a new
governor sleeve.
EG-167

Governor alve hole diem.t.r:
Governor Sleeve
Item
Diameter mm fin)
Europe
0.45 (0.0177)
0.50 (0.0197)
0.55 (0.0217)
Item
Diameter mm (in)
0.55
0.60
0.625
0.65
Australia
(0.0217)
(0.0236)
(0,0246)
(0.0256)
EG
AOO"
HINT: A large hole diameter decreases the timer

stroke and a smaller hole diameter increases the timer
stroke.
(I)
Governor Shalt
fU298-t fU0242
2091l1
Adjusting
lever angle
Item
Europe
Australia
MIT
Australia
AIT
Pump
cpm
Full position
Minus 12 - 22
Full position
,,"
Minus 12
Full position
Minus 12 _ 22 0
400
350
400
350
400
400
Check the protrusion of the governor shaft.

Protruaion:
0.5 - 2.0 mm (0.020 - 0.079 in.)
18. ADJUST IDLE SPEED

(a) Measure the injection volume for each pump rpm.
No. of
measuring
strokes
200
200
200
Injection volume of
each cylinder cc teu in.1

7.86 q 0.70
7.86 q .. 0.70
7.86 q_0.70
10.6610.48 - 0.65)
1.10 (0.04 - 0.07)
10.66 (0.48 - 0.65)
- 1.10 (0.04 - 0.07)
10.66 10.48 - 0.65}
- 1.10(0.04 - 0.07)
Variation
limit
Remarks
cc (eu in.!
0.51O.03}
Adjust
0.510.03)
Adjust
0.5 (0.03)
Adjust
"""
Idle Speed
Adjusting
(b)
Adjust injection volume by turning the idle speed

adjusting screw.
~~~~~~~2screw
19. ADJUST COLD STARTING SYSTEM

(a) Remove the overflow screw and check the fuel temperature in the fuel pump.
Fuel temper.ture:
15 - 35C (59 - 95FI
(b) Check that the cam part of the camplate is not on top
of the roller ring.
(c) Set the scale of the timer measuring device to zero.
EG'68
(d)
(e)
(f)
Melal Plale
-.5
i
a;
i=
3 3 (O 13)
20(079)
f--""",,-
-----~i----,
25
: :,
(32)
(77)
Fuel Temperature CrF)
Check the adjustng lever opening angle and consider

this angle as zero.
Measure the clearance between the idle-up lever and
idle - up lever bracket.
CI ranca: 1.95 - 2.05 mm (0.077 - 0.0.081 in.)
Adjust by turning the fast idle adjusting screw.
(g)
Remove the metal plate between the cold starting

lever and thermo wax plunger.
(h)
Loosen the nut from the cold starting lever.
(i)
Measure the clearance between the adjusting lever

and idle speed adjusting screw.
Fuel lemperltUrl
CIrenee
2SC (68"F)
0.95 mm (0.037 in.)
SOC C12rFj
o mm (0 in.)
GJ
Adjust by turning the cold starting adjusting screw.
(k)
Measure the timer piston stroke.
Fuel tempereture
Timer pilton .troke
mm(in.)
2S-C (n-F)
1.9 - 2.1 (O.07S
0.083)
EG-169

(I)
Adjust by turning the timer adjusting screw.

HINT: Screw in for stroke decrease.
(m) Torque the nut to the cold starting lever.

Torque: 27 Nm (215 kgfcm, 20 ft.lbf)
EG
20. POST ADJUSTMENT CHECK
(a) Check th8t injection stops when the fuel cut solenoid
harness is removed.
Pump revolution:
150 rpm
q = 3.1 cc (0.' 9 cu in.) or I
(b)
Check the adjusting lever movement.

Adjusting lever engle:
38 - 48 0
21. w/o AUltrelie MIT:
(a)
INSTALL THROTTLE POSITION SENSOR AND

BRACKET
Europe:
Set the adjusting lever to the angle for the injection
volume shown below.
Pump
No. of measuring
strokes
Injection volume of each cylinder

cc leu in.)
1,000
200
6.66 (DAG6)
"."
(b)
Attach the portions of the throttle position sensor and

adjusting lever.
(e)
Using a 5 mm hexagon wrench. install the throttle

position sensor with the 3 bolts.
EG-170
(d)
Loosen the 2 screws holding the throttle position

sensor to the bracket.
EG
(e)
Apply 5
(1)
Connect the tester probes of a voltmeter to terminals
0.01 V across terminals VC and E2.
VTA and E2 of the throttle position sensor.
Maximum
Speed
Adjusting
Screw
Full Load
Set Screw
(g)
Europe:
(hi
Gradually turn the throttle position sensor, so that its

output will be 2.754 0.025 V.
Australia:
Secure the adjusting lever fully on the maximum

speed side so that its output will be 0.6 + 0.025 V.
(i) Tighten the 2 screws holding the throttle position
sensor to the bracket.
22. SEAL PARTS
(a)
(b)
Seal the full load set screw with new lead seal.
Install the lock plate to the maximum speed adjusting
screw.
23. INSTALL FUEL PIPE BRACKET

Install the fuel pipe bracket with a bolt.
24. INSTALL FUEL PIPES

(a)
Install the nozzle leakage pipe No.2 and 2 new gaskets

with the union bolt.
Torque: 24.65 N-m (250 kgtem. 18 ft-Ibf)
(b)
Install the fuel inlet pipe and 2 new gaskets with the
cap nut and bolt.
Torque:
Cep nut: 24.55 Nm (250 kgtem, 18 ftlbf)
Bolt:
19.6 Nm (200 kgtem, 15 ftlbf)
25.
wi
A/C:
INSTALL IDLE - UP ACTUATOR

Torque: 9.35 Nm (95 kafem, 83 in.lbf)
EG-171
INJECTION PUMP INSTALLATION

1.
--.
INSTALL INJECTION PUMP

NOTICE: Do not put the injection pump at an angle more
than 45 0 from the horizontal.
(a)
(b)
(c)
Install a new O-ring to the pump.

Apply a light coat of engine oil on the 0 - ring.
Align the set key on the drive shaft and groove of the
injection pump drive gear.
(d)
Align the period lines (or matchmarks) of the injection
pump and timing belt case.

(8)
Install the 2 nuts holding the injection pump to the

timing gear case.
Torque:
(f)
1a Nm (185 kgfcm. 13 ftlbf)
Install the injection pump stay with the 2 bolts.

Torque:
69 Nm (700 kgfcm. 51 'tlbt)
NOTICE: B.for. tightening to the .tandard torque, check
whether the pump .tay i. up against the injection pump.
(9)
(h)
(i)
If there is a gap, loosen the bolts joining the pump stay

to the cylinder block and set the pump stay against
the injection pump.
Install a new 0 - ring to the injection pump drive gear.
Install the injection pump drive gear set nut.
Hold the crankshaft pulley, and torque the set nut.
NOTICE: Do not turn the cranck,haft pulley. The valve
heada will hit ag.inat the piaton top.
(j)
PU193
Check the thrust clearance of the injection pump drive

shaft.
(See injection timing inspection and adjustment in
Engine Mechanical)
EG-172

2.
wI EGR System
3.
EG
4.
CONNECT HOSES
Connect these hoses to the injection pump.
(1) Boost compensator hose
(2) SICS vacuum hose
(3) wi BACS:
BACS vacuum hose
CONNECT WATER BYPASS HOSES TO THERMO
WAX
(Se8 step 3 in timing belt installation in Engine
w J0 EGR System
5.
Mechanical)
INSTALL TIMING BELT
(See steps 5 to 10 in timing belt installation in

6.
Engine Mechanical)
CHECK INJECTION TIMING
(See injection timing adjustment and inspection in

7.
Engine Mechanical)
(Se8 steps 3. 5 and 7 in injection nozzle

installation)
''''''
8.
9.
FILL WITH ENGINE COOLANT

START ENGINE AND CHECK FOR FUEL LEAKAGE
STARTING INJECTION CONTROL

SYSTEM (SICS)
___M
INSPECT SICS
(a) With the engine stopped after it is warmed Up. check
(b)
tha the SiCS lever and SICS adjusting screw are in

contact with each other.
After restarting the engine. check that the SICS lever
and SICS adjusting screw are apart from each other.
SICS COMPONENTS INSPECTION
wf EGR System
EG-173
_-0
1.
REMOVE SICS VSV
2.
A.
INSPECT SICS VSV

Inspect VSV for open circuit
between the terminals.
Resistance:
At 20'C (88'F): 38.5 - 44.5 Q
If there is no continuity. replace the VSV.
B.
Inspect VSV for ground

SICS VSV
wlo EGR System
SICS VSV
Ohmmeter
DO
Continuity
Ohmmeter
00
No continuiTy
between each terminal and the body.

If there is continuity. replace the VSV.
C.
Inspect VSV operation
(a)
Check that air flows from pipe E to the filter.
EG-174

(b)
Apply battery voltage across the terminals.
(e)
Check that air flows from pipe E to F.

If operation is not as specified. replace the VSV.
3.
REINSTALL SiCS VSV
Battery
_.-
SERVICE DATA
FUll h.,ter
.t 20C (BSeF)
Rilt1ne.
Inj.etion
NOln. type
noul
Noul. opening pNl"ur.
O.S
2.0 0
DLLA 1"Spe39
No.1
17.652 - 18.633 kP,
(lSO - 190 kgf/em', 2.560 - 2.702 psi)

No.2
23.144 - 24,124 kP,

(238 - 248 kgf/cm', 3,358 - 3,498 p.ij
0.23 - 0.28 mm (0.0091 - 0.0119 in.)
Ndle-lift
Adjusting ,him thickn...
1.900 mm (0,07.8 in.)
1.925 mm (0.0758 in.)
in.,
2.000 mm (0.0787 in.,
1.975 mm (0.0778 in.)
1.950 mm (0.0788
Pre-lift
0.085 - 0.0105 mm (O.OO335 - 0.00413 in.)
Adjusting No.2 pr... ur. 'P4'"ing .I.t thickn...
3.09 mm (0.1217 In.)
3.12 mm (0.1228 in.)
3. t 5 mm (0.1240 in.)
3.18 mm {0.1252 ".'
3.21 mm (0.12&4 in..1
3.24 mm (O.1276 ".)
3.27 mm (0.1287 in.1

No.2 openinll
p~..urdju.tinll
.him thickn...
No.1 opening pr...ure .dju.ting .him thickn...
0.700 mm (O.0278 in.)
0.850 mm (O.0335 in.)
1.000 mm (0.0394 in.)
1.025 mm (0.040<4 in.)
1.150 mm (O.0453 in.)
1.175 mm (0.0483 in.)
1.275 mm (0.0502 in.)
1.300 mm (O.0512 in.)
1.425 mm (0.0581 in.)
1.450 mm (0.0571 in.)
1.575 mm (0.0820 in.)
1.800 mm (0.0830 in.)
1.725 mm (0.0879 in.)
1.750 mm (0.0689 in.)
1.900 mm (0.0748 inJ
2.050 mm (0.0807 in.)
0.825 mm {0.0325 in.1
0.900 mm (0.0354 in.)
0.975 mm {0.03&4 irL}
1.050 mm (0.0413 in.1
1.125 mm (0.0443 in.)
1.200 mm {O.0472 in.,
1.275 mm (0.0502 in.)
1.350 mm (0.0532 in.)
1.425 mm (0.0581 in.)
1.500 mm (0.0591
1.575 mm (0.0820 in.)
1.850 mm (O.08S0 in.)
1.725 mm (0.0679 in.)
1.800 mm (0.0709 in.)
1.875 mm (0.0738 in.)
1.950 mm (0.0768 in.)
2.000 mm (0.0787 in.)
2.100 mm (0.0827 in.)
2.175 mm (0.0858
in.,
in.,
EG-175

Europe
22100 17880
Australi' MIT
22100-17890
AfT
22100-18010
Patt No.
Injection pump
Direction of rotation
Clockwise as sun from drive side
Injection order
1-4-2-6-3-5~-B-C-D-E-~
Coupling spring protrusion
0.10 - 0.14 mm (0.0394 - 0.0551 in.)
Delivery velve opening pressure
7,350 - 8,330 kPe
(75 - 85 kgf/cm" 1,067 - 1,209 psi)

2.0 mm (0.079 in.)
Plunger spring devilllion

Spring free langth
Delivery valve spring
12.6 mm (0.496 in.)
Plunger spring
34.09 mm (1.342 in.)
Boost compensator spring
19.4 mm (0.764 in.)
Roller height variation
0.02 mm (0.0008 in.)
Pickup sensor resistance
650 - 970 Q
Timer adjusting screw protrusion pre-setting
7.5 - 8.0 mm (0.295 - 0.315 in.)
Plunger spring shim thieknl&l
0.5 mm (0.020 in.)
0.8 mm (0.031 in.)
1.0 mm 10.039 in.1
1.2 mm (0.047 in.)
1.5 mm (0.059 in.)
1.8 mm (0.071 in.)
2.0 mm (0.079 in.)

0.15 - 0.35 mm (0.0059 - 0.0138 in.)
FIVWllight holder thtUIl clearenee

Governor glir adjusting wlllher thickness
1.05 mm (0.0413 in.)
1.25 mm (0.0492 in.)
1.45 mm (0.0571 in.)
1.65 mm (0.0650 in.1
1.85 mm (0.0728 in.)

Governor shaft protrusion
0.5 - 2.0 mm (0.020 - 0.079 in.)
Plunger pre-'trak"
0.48 - 0.52 mm (0.0189 - 0.0205 in.)

Shim ara aveilable in 131 sized in increments
Adjusting shim thickness
0.01 mm (0.004 in.), from 1.90 mm (0.0748 in.)

to 3.20 mm (0.1280 in.)
BOOSI compensator diaphrlgm adjusting shim

thickness
Shim ere available in 12 sized in increments

0.2 mm (0.008 in.), from 1.1 mm (0.043 in.)
to 3.3 mm (0.130 in.)
_."
Parl tightened
Fuel filter
l(
Fual filtar bracket
Fuel hose clamp
l(
Fuel filter bracket
Nozzle holder body x Nozzle holder retaining nut

Injection nozzle x Cylinder heed
Injection pipe x Injection nozzle, Injection pump
Injection pipa clamp
I(
Intake manifold, Injection pipe clamp
Nm
kgfcm
flolbf
18
185
13
12
30
25
120
300
255
22
24.5
250
25
6.4
65
56 in.lbf
200
176
1B6
14
No.3 nozzle leakage pipe
I(
Intake manifold
19.6
No.1 nozzle leakage pipe
I(
Injection nozzla
18
No.1 nonle leakage pipe x Cylinder head

Accelerator link assembly
Delivery valve holder
I(
Fuel inlat hollow screw

Regulator valve
I(
Feed pump cover
I(
intake manifold
Distributive head
I(
Injection pump body
Injection pump body

I(
Injection pump body
I.
19.6
5B
37
B.B
3.0
18
13
14
14
200
600
43
375
BO
78 in.lbl
31
27 in.lbf
27
EG176
Time' eovlr,lnjletiol"l pump atly, Th,rmo WI. x InjKtion pump body
8.35
Tim" adjusting "rew
'4.2
74 in.-Ibf
..
"5
Govemor link IUpport x Ini-ction pump body
,.
Distributive h. .d )( InjKtion pump body
12
12.
9
2.
18
Tim.r cover
Governor .h.ft x InjKtiotl pump body

Overflow screw II Govemor cover
EG
85
,.
II
27
275
24.55
15.
11
Control 'Iver x Governor cover
6.85
7.
8\ in,.lb'
Governor covllr x Injection pump body
8.3
85
74 in.lbf
screw. NO.1
8.9
70."
61 in.lbf
Adjusting lever x Governor covllr
8.35
74 in.lbf
Piekup nsor x lnjeetion pump body
22.1
85
225
800
.5
Idle spe.d adjusting
SICS lever x Governor cover
..
Distributive h..d plUV x Distributive MId
15.S
7.35
75
65 inAbt
a.phr.gm cover x Governor cove,
7.35
75
85 inAb'
LIver control spring x Governor COYlr
11.3
115
225
,.
15 in.lbf
D~phr.gm
x Push rod
FUll c!Jt lo"noid Distributive hd
22
LI.d wire )( FUI' cut solenoid
1.7
17
C.p II Injeclion pump
11
115
SICS .ctu.tor br.ckl! II Governor cov.r
9.3
82 inAbt
SICS 'Clultor II SICS .clullor br.ckel
9.35
95
95
7.
.5
12.
7-4 in.lbt
SICS .dju,ting .cr.w II SICS .ctuetor br.ck.t

Idl. up I.v.r II Inj.clion pump body
Short bolt
long bolt
No.2 noul. I"keg. pipe. Fu.l inl.t pipe II In!e<:tion pump
.8
8.35
11.75
2-4.55
Fu.1 inll! pipe II 8recket
19.8
ldl. up .ctu.tor llldl.-up Iev.r
9.35
Injeclion pump
Pump 'l.y
Jl
Jl
Timing gr CIS.
Inje<:tion pump
Injection pump drive gllr II Injection pump
18
'.3
83 in.lbl
81 inAbf
,.
25.
200
95
185
700
83 inAbf
1050
7.
15
13
5\
EG-l77
ENGINE - COOLING SYSTEM
COOLING SYSTEM
PREPARATION
."0-'"
--
~OO
. '.P
~
00
09230-00010
R.dillor Service Tool Set
09230-01010
Radiator Serviee Tool Set
(09231-00060)
No.3 Plug
~OO
.
@PO 0
.........
........ -For inspection water leakage
00
.'''''_<10
EQUIPMENT
Heater
Aadiator cap tester
Thermometer
Torque wrench
COOLANT
Ethylene
Engine coolant
wi Front lind fe., heaters

wi
Front heater
w/o Heeter
Clnsificetion
Capacity
Item
MIT
AIT
MIT
AIT
MIT
AIT
glycol bas'
12.0 liters (12.7 US qts. 10.7 Imp. qts)

11.8 liters (12.5 US qls, 10.4 Imp. qts)
11.1 liter. (11.7 US qls, 9.8 Imp. qts)
10.9 liters (11.5 US qts, 9.6 Imp. qts)
10.4 liters (11.0 US qts, 9.2 Imp. qts)

\0.2 liters (11.1 US qlS, 9.0 Imp. qts)
."'_M
SSM (SERVICE SPECIAL MATERIALS)

08826 00100
Seal Pack.ing 12828,
Engine dr.in plug on oil cooler
THREE BOND 12828 or equivalent
COVilr
(FIPG)
EG-178
ENGINE - COOLiNG SYSTEM
COOLANT CHECK
1.
-EG
2.
(a)
--.
CHECK ENGINE COOLANT LEVEL AT RADIATOR

RESERVOiR
The engine coolant level should be between the ..
LOW and "'FULL'" lines.
If low. check for leaks and add engine coolant up to
the "FULL"' line.
CHECK ENGINE COOLANT QUALITY
Remove the radiator cap.
CAUTION: To avoid the dangar of being burned. do not
remove the r.diator cap while the engine and radiator .r.
still hot. a. fluid and st.am can b. blown out under
prur.
(b)
(c)
There should not be any excessive deposits of rust or

scale around the radiator cap or water filler hole. and
the coolant should be free from oil.

If excessively dirty, replace the coolant.
Reinstall the radiator cap.
COOLANT REPLACEMENT
1.
(0)

Remove the radiator cap.
_..
CAUTION: To avoid the dangar of baing burned. do not

remove the radiator cap while tha engina and radiator are
,till hot. a, fluid and ,taam can be blown out under
pr...ur.
Ora i n --..e::";:~"'J
Plug
Seal Packing
(b)
Loosen the radiator drain plug (on the left side of the
radiator lower tank) and engine drain plug (on the oil
cooler cover), and drain the coolant.
(c)
Apply seal packing to 2 or 3 threads of the engine

drain plug.
Saal packing:
Close the drain plugs.
Torque (Engina): 29.4 Nm (300 kgfem. 22 ft.lbf)
Drain Plug
(d)
EG-179

2.
(a)
FILL ENGINE COOLANT

Slowly fill the system with coolant.
Use a good brand of ethylene-glycol base cool

ant and mix it according to the manufacturer's
directions.
Using coolant which includes more than 50 %

ethylene-glycol (but not more than 70 %) is
recommended.
NOTICE,
Do not us. an alcohol type coolant.

Th. coolant should be mixed with demineralized
wat.r or di.tilled wat.r.
Capacity:
wI
Front and rr h
t.,.
MIT
12.0 lit.,. (12.7 US qt.. to.7Imp. qt.)
AIT
11.8 lit.,. ('2.5 US qt , 0.4 Imp. qtl)
w/ Front ht.r
MIT
11.1 Iita"
AIT
10.9 lit.,.
w/o H t.r
MIT
10." lit.r.
AIT
10.2 Iiten
(b)
(e)
(d)
3.
(".7 US qt 9.8 Imp. qt.)
(11.5 US qt.. 9.6 Imp. qt.)
(11.0 US qt 9.2 Imp. qt.)
(11.1 US qt 9.0 Imp. qt.)

Install the radiator cap.
Start the engine. and bleed the cooling system.
Refill the radiator reservoir with coolant until it reaches the '"FULL'" line.
CHECK ENGINE COOLANT FOR LEAKS
El
EG,80
--.
WATER PUMP
INSTALLAnON
wI EGR System
w/o EGR System
EG
Intake Pipe
(/'~~<
t
:;;..;'
~,g~'J::I C? ~
if
i>
Gasket
Intake Heater
~.;)
~. -;.-~~
~.
"
"
- ..
Gasket
Valve Bracket
~. - -,'. -. --~,:::-".;...--.
>
J;~~,!;'~'~
Vacuum Hose
",. ~EGR
.'
Gasket
...J
Inlake Pipe
CYljn~~lnSulator
\.
Head C,over
~'.' . '~~~~fr~~~~~;~~~:
..::~~1S;:1
" , '!l><il.:
EQ}EQ)- "
Fluid Coupling
F.n---;=~::\l
No.1 Camshaft _ _-:-_~
Timing Pulley
Water Pump Pultey_+-
-,
Idler Pulley
Timing Belt
Tef)sioner---,e,
Clip---~
Timing Belt Cover
Seal
VVasher
\--_ _Timing Belt
Clamp-----'..,Jl\
Vacuum Hose
Clamp
d)'-----Gssket
-\\
---S
Seal Washer
Seat Washer
Non-reusable parI
Camshaft Oil
EG-1Bl
Seal--------I:;,;.~
Retainer
Camshaft Oil 5 e a l - - - - - - - '
Alternator
Adjusting
aoc
---=--
Turbo
Water-L~
Pipe
NO.2 Cylinder ~
a,oo' '",""0'
lP
,,
,,
,,,
,
,5
'
~J
'--aJ!--...
" '"'r-- Water Bypass Hose
Non-reusable part
_ _ 11
WATER PUMP REMOVAL

,.
2.

REMOVE DRIVE BELTS. FAN. FLUID COUPLING
AND WATER PUMP PULLEY
(a)
Loosen the 4 water pump pulley nuts.
(b)
Loosen the alternator pivot bolt and adjusting lock

bolt.
Loosen the adjusting bolt. and remove the 2 drive
belts.
Remove the 4 nuts, the fan. fluid coupling assembly
(c)
(d)
and pulley.
(e)
3.
4.
Remove the 4 nuts and fan from the fluid coupling.

REMOVE TIMING BELT
(See steps 1 to 3 in timing belt removal in Engine
Mechanical)
REMOVE IDLER PULLEY
Mechanical)
EG182

5.
REMOVE NO.1 CAMSHAFT TIMING PUllEY

(Se. Iteps 6 and 7 in timing belt removal in Engine
Mechanical)
6.
7.
REMOVE CAMSHAFT Oil SEAL RETAINER

(Se. step 14 in cylinder head removal in Engine
Mechanical)
REMOVE NO.2 CYLINDER 8l0CK INSULATOR
oG
, ..
Waler Pipe
-'
Adjusting
SO'
Water Bypass Hose
8.
(a)
(b)
REMOVE WATER PUMP

Remove the 3 bolts and alternator adjusting bar.
Remove the 2 nuts, and disconnect the turbo water
pipe from the wate, pump.
(c)
Disconnect the turbo water pipe from the water
(d)
bypass hose.
Remoye the 5 bolts, water pump and gasket.
WATER PUMP INSPECTION

1.
--.
INSPECT WATER PUMP
Turn the pulley and check that the water pump bearing moves smoothly and Quietly.
If necessary. replace the water pump.
2.
INSPECT FLUID COUPLING

Check the fluid coupling for damage and silicon oit
leakage.
If necessary. ,eplace the fiuid coupling.
EG-183
WATER PUMP INSTALLATION
--
1.
(a)
INSTALL WATER PUMP

Temporarily install a new gasket and the water pump
(b)
with the 5 bolts.

Connect the turbo water pipe to the water bypass
hose.
(c)
Temporarily install the turbo water pipe with the 2

nuts.
(d)
Temporarily install the alternator with the 3 bolts.
(e)
Uniformly tighten the 7 bolts and 2 nuts holding the
water pump to the cylinder block.

Torque:
12 mm head
19.6 Nm (200 kgf-em. 14 ftlbf)
14 mm head
2.
3.
39.2 Nm (400 kgfem. 29 ftlbt)

INSTALL NO.2 CYLINDER BLOCK INSULATOR
INSTALL CAMSHAFT OIL SEAL RETAINER
(See step 6 in cylinder head installation in

4.
Engine Mechanicsl)
(See steps 1 and 2 in timing belt installation in

5.
Engine Mechanical)
INSTALL IDLER PULLEY
(See step 4 in timing belt installation in Engine

Mechanical)
6.
INSTALL TIMING BELT
(See steps 5 to 10 in timing belt installation in

7.
(a)
(b)
(c)
(d)
8.
9.
Engine Mechanical)
INSTALL WATER PUMP PULLEY, FLUID
COUPLING. FAN AND DRIVE BELTS
Install the fan to the fluid coupling with 4 new nuts.
Temporarily install the pump pulley, the fluid fan and
coupling assembly with the 4 nuts.
Install and adjust the drive belt.
(See step 3 in on-vehicle inspection in Charging
System)
Tighten the 4 water pump pulley nuts.
Torque: 19.6 Nm (200 kgfcm. 14 ftlbfl
START ENGINE. AND CHECK FOR COOLANT
LEAKS
EG
,G
EG184
THERMOSTAT
INSTALLATION
'I \
":-------ThermOsIBt
,"'-----+
Gasket
,
/---"'<---Water
Inlet
,
,,
o
,,
'"
''til
,,
,
Non-reusable part
THERMOSTAT REMOVAL
--.
HINT: Removal of the thermostat would have an adverse effect. causing a lowering of cooling efficiency.
Do not remove the thermostat. even if the engine
tends to overheat.
1.
1--~----;:::::~77u:sM:\Y-tll 2_
(a)
(b)
(el
REMOVE WATER INLET AND THERMOSTAT

Remove the 3 bolts and water inlet.
Remove the thermostat.
Remove the gasket from the thermostat.
EG-' S5
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve
opening temperature.
EG
~:\
tal
Immerse the thermostat in water and gradually heat

the water.
(b)
Check the valve opening temperature.

V.lve opening tempereture:
7. - 7S"C 1165 - In"F)
--. -:~'-'
--- ----.--
f"
(-"\'\\A I' J
If the valve opening temperature is not as specified.

replace the thermostat.
Jif
'"""
(c)
Check the valve lift.

V.lve lift:
10 mm (0.39 In.) or mor t 90C 1194-FI
If the valve lift is not as specified. replace the thermo-
(d)
c:::;::;=>---i..
~
stat.
Check that the valve spring is tight when the thermostat is fully closed.
If not closed. replace the thermostat.
Valve Lift
THERMOSTAT INSTALLATION
'l
--.
1.
(a)
(b)
PLACE THERMOSTAT IN CYLINDER SLOCK

Install a new gasket to the thermostat.
Ins1all the thermostat with the jiggle valve upward.
2.
(a)
INSTALL WATER INLET

Temporarily install the water inlet with the 3 bolts.
Alternately tighten the 3 bolts in several passes.
Torque: t9.8 Nm (200 kgfcm. 14 ftlbfl
START ENGINE. AND CHECK FOR COOLANT
LEAKS
(b)
3.
4_
EG188
RADIATOR
RADIATOR CLEANING
--
Using water or a steam cleaner. remove any mud and
dirt from the radiator core.

NOTICE: If uling a high prur. type cl ner. be car.ful
not to d.form the fin. of the radiator core. If the cle.ner
nonl. pre'lur. i, 2.942 - 3.432 kP. (30 - 35 kgf/em l,
427 - 498 pai). keep. di,tance of .t I... t 40 - 50 em
(15.75 - 19.89 In.) b.tween the radiator cor. and cl ne,
EG
noul.
RADIATOR INSPECTION
I.
REMOVE RADIATOR CAP

CAUTION: To noid th. dange, of baing burned. do not
remove the radiator cap while the engine and r.dlator .,
till hot fluid and ,t.am can be blown out under
pr...ur.
2.
INSPECT RADIATOR CAP

NOTICE: If the radiator cap contain. water or foreign
lubt.nc alway. rin it with water.
Using ill radiator cap t8st8r. pump the tester and measure the relief valve opening pressure.
Sbnd.rd opening pr."ur.:
74 - 103 kP.
(0.76 - 1.05 kgf/cm l , 10.7 - 14.8 pail
Minimum opening pr.ssur.:
59 kP. (0.8 kgf/cm l , 8.5 pII)
Radiator Cap
HINT: Use the tester's maximum reading as the open-
COOOH
3.
(a)
(b)
(c)
4.
ing pressure.
If the opening pressure is less than minimum. replace
the radiator cap.
INSPECT COOLING SYSTEM FOR LEAKS
Fill the radiator and engine with coolant, and attach a
radiator cap tester to the water filler.
Warm up the engine.
Pump it to 118 kPa (1.2 kgfjcm t , 17.1 psi), and check
that the pressure does not drop.
If the pressure drops. check the hoses. radiator or
water pump for leaks. If no external leaks are found,
check the heater core, cylinder block and cylinder
head.
REINSTALL RADIATOR CAP
EG-187
. ' .. _M

ASSEMBLY
~~--AadiatorCap
~~--UpperTank
Support---------
l----Tank
Plate
~---+. D-Ring
Cushion -~----f,~,,-
f---Core
~~~~~~~-
D-Ring I
Q-Ring
Tank Plate
.,, '
'---Pipe
Oil Cooler ---~'"~
C\$&~Pipe
~.'"
-:.-_--
1-
Lower Tank
"'",
~~If---Support
----'>:
,,,
,
D-Ring
~~ __ ~",~--Drain Plug
~--.O-Ring
Non-reusable part
""'''
RADIATOR DISASSEMBLY
1.
2.
3.
4.
(a)
REMOVE CUSHIONS
REMOVE SUPPORTS
REMOVE DRAIN PLUG
REMOVE TANK PLATE
Raise the claws of the tank plates with SST in the
numerical order shown in the illustration.
SST 09230-00010
NOTICE: Ba careful not to damage the core plate.
~
P late
"""
EG-'88
(b)
5.
(a)
(b)
6.
(a)
(b)
(e)
Pull the tank plates outward.

REMOVE TANK
Pull the tank upward.
Remove the 0 - ring.
REMOVE OiL COOLER FROM LOWER TANK
Remove the 2 pipes.
Remove the 2 nuts. 2 spring washers. 2 plate washers
and oil cooler.
Remove the 2 a-rings from the oil cooler.
RADIATOR ASSEMBLY
,.
(a)
Install 2 new 0 - rings to the oil cooler.

Install the oil cooler to the lower tank.
(d)
~&v;iiCoili=":P:":l:'==~
2.
COON.
...
/~
-'~
-.-J
../
@~
~
~O-Ring
o Normal
INSTALL OIL COOLER TO LOWER TANK
(b)
(e)
3.
X Twisted
--
Install the 2 plate washers. 2 spring washers and 2

nuts.
Torque: 10 Nm (lOa kgt-em. 7 ftlbf)
Install the 2 pipes.
Torque: 15 Nm (150 kgfem. " ftlbf)
HINT: Face the pipes in the direction shown in the

illustration.
CHECK CORE PLATE FOR DAMAGE
HINT:
If the sides of the core plate groove are de

formed. reassembly of the tank will be impossible_ Therefore. first correct any deformation with
pliers.
Water leakage will result if the bottom of the core

plate groove is damaged or dented. Therefore.
repair or replace if necessary,
INSTALL TANK
Install a new 0 - ring and the tank.
HINT:
Clean the tank and core plate.

Take out any twists.
X Twisted
COOl! ,
4.
INSTALL TANK PLATE

Insert new tank plates from both ends in the direction
of the arrows. Firmly set the tank plates in the core
plate.
SST
~~B'"
~~ :LJE
S haft
Guide BLock
_ _..:;3_ _
5.
(a)
STAKE CLAWS OF TANK PLATES

Set the punch of SST to -LOW,
SST 09230-00010
(b)
Stake the claws of the tank plates with SST

numerical order shown in the illustration.
Punch -f~__
EG-189
3.. __-,-4_ _
am"
In
the
NOTICE: If the bottom of the cor. plate i. staked with the

SST on the guide block stopper. it may result in water
Tank Plate
Punch
leakage.
Tank
o
SST
SST
Guide Block
Stopper
C00043 C()()O.06
HINT:
Stake with just enough pressure to leave a mark
on the claw. The staked plate height (HI should

be as follows:
Plate height (H):
9.2 - 9.6 mm (0.362 - 0.378 in.)
Do not stake the areas protruding around the
ports or brackets.
Port
EG-190
~~.
t
.)
h" \ .
6.
The points shown in the illustration cannot be

staked with the SST. Use pliers and be careful not
to damage the core plates.
INSTALL DRAIN PLUG
Zl!631
7.
(a)
SST
o
o
(b)
CHECK FOR WATER LEAKS

Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230-01010 (09231-00060)
Using a radiator cap tester, apply pressure to the
radiator.
T.st pr...ur.:
147 kP. (1.5 kgt/em'. 21 psi)
""'''
(e)
Core Plate
Tank Plate
D-Ring
6.
9.
Check for water leaks.

HINT: On radiators with resin tanks. there is a clear
ance between the core plate and tank plate where a

minute amount of air will remain. giving the appearance of an air leak when the radiator is submerged in
water. Therefore. before performing the water leak
test, first swirl the radiator around in the water until all
air bubbles disappear.
PAINT TANK PLATE
HINT: If the water leak test checks out okay. allow the
radiator to dry completely and then paint the tank
plate.
INSTALL SUPPORTS
Torque: 12.7 Nm (130 kgfcm. 9 ft.lbfl
10. INSTALL CUSHIONS

Install the 2 cushions as shown in the illustration.
EG-191
ENGINE - COOLiNG SYSTEM
--..
SERVICE DATA
7.. - 78C (185 -
v.t.... opening temperltUf,
TheNTIOIllt
V,tv, lift
R.d~tor elp
R"Mf nlvi Ope1ling pre.lur.
at 90C (19.F)
OTO
Minimum
172"F)
10 mm (0.39 in.) or more
7. - 103 kP. (0.75 - 1.05 kot/cm", 10.7

59 kP, (0.8 kgf/em', 8.5
14.9 psi)
~i)
EG
--..
Part tighllnld
Drain plug x Oil cooler cover
W.ter pump
l(
Cylinder block
Nm
kgl-em
Itlbf
29.4
300
2DD
40D
22
12 mm hd
19.6
14 mm he.d
39.2
F,n II Fluid coupling
6.'
Fluid coupling II WeIer pump pulley
19.6
Watlr inlllll Cyli"der block
19.6
Wltlr inl.t II Altetnator brach!
19.8
O~ coo~r II
O~
Lower tank
coo'-r pipe II Oil cooler
Support
II;
Tlnk on IlIdi.ltOl'"
lD
15
12.7
"
2.
"
571nAbf
15D
13D
11
200
200
200
100
"
"
"
EG-192
ENGINE - LUBRICATION SYSTEM
LUBRICATION SYSTEM
PREPARATION
:EG
09032-00100
O~
Pen S..I Cutter
09228-10002
O~
Filt.r Wrench
tfW
---
RECOMMENDED TOOLS
~~~
~
09200-00010
Engin. Adjull Kit.
W<:a.
.....
.,
EQUIPMENT
Oil pressure gauge
Precision streight edge
Torque wrench
LUBRICANT
Capacity
Item
CI."itie.tion
API grad. CD or better
Engine oil
Dry fill
10.0 liters (10.6 US qll. a.Slmp. qts)
O,.in and r.fiIl
wI Oil tilt,r chenge
9.7Ilter. (10.3 US qu, 8.5 Imp. qts)
w/o Oil filter cheng.
e. 'it.r. (8.9
US qt.. 7.4 Imp. qte'
....-...
SSM (SPECIAL SERVICE MATERIALS)

08826-00080
08833-00080
Seal Pecking Bleck or equivetent
O~
pump
(FIPG)
O~
pen
Adhesive 1344,
THREE BONO 1344,
O~ pressure s.nd,r gauge

T.per screw plug on timing gee.
LOCTlTE 242
<0"
Of
equiv.lent
EG' 94

Car. should be t.ken. ther.for., when changing
angina oil to minimize the frequency and length of
tim. your akin i. expos.d to us.d engine oil. Protectiv. clothing and glov that cannot b. penetrated
by oilahould b. worn. Th. akin should b. thoroughly
w.. hed with soap end water. or us. water-less
hand cle.ner. to remova any us.d engine oil. Do not
u g oline. thinner. or solvents.
In order to pr rve the environment. used oil end

used oil filter. must b. dispos.d of only at d.,ignated disposal .it.
DRAIN ENGINE OIL
Remove the oil filler cap.
Remove the oil drain plug, and drain the oil into a
'EG
,.
(a)
(b)
.;':.;l;>,\\-SST
2.
(a)
container.
REPLACE OIL FILTER
Using SST. remove the oil filter.
SST 0922B-l 0002
(b)
Clean the oil filter contact surface on the oil filter

mounting,
(c) Lubricate the filter rubber gasket with clean engine
oil.
(d) Tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting.
(e)
3.
(a)
Using SST. give it an additional 3/4 turn to seat the

filter.
SST 0922B-l 0002
REFILL WITH ENGINE OIL
Clean the drain plug, and install a new gasket and it.
Torqu.: 34.3 Nm (350 kgfcm. 25 ftlbf)
(b)
Fill with new engine oil.

Capacity:
Drain and r.fill
wi Oil filt.r cheng.
9.7 lit.r. (10.3 US qu, 8.Slmp. qts)
w/o Oil filter chang.
8.4 liter. (8.9 US qt. 7.4 Imp. qt.)
Dry fill
10.0 lite,. (10.6 US qts, 8.8 Imp. qts)
(c)
Reinstall the oil filler cap.
4.
5.
START ENGINE AND CHECK FOR OIL LEAKS

RECHECK ENGINE OIL LEVEL

Recommended Viscosity (SAE) :
I.
,
I II I
III
" ., e m" "m ,m
IWlOE ANTlCPATtO
TDll'I\ATUlE
.
"~
,.~
OIL PRESSURE CHECK
Ilf.roAE ,.EXT 01. c:w.NGE
"=
Oil Pressure Gauge
2.
"
3.
4.
5.
6.
EG-193
--.
CHECK ENGINE OIL QUALITY

Check the oil for deterioration. entry of water, discoloring or
If the quality is visibly poor, replace the oil.
Oil grade:
API grade CD or bener
Recommended viscosity:
R.f., to Illustration
CHECK ENGINE OIL LEVEL
The oil level should be between the "L- and '"F- marks
on the dipstick.
If low. check for leakage and add oil up to "F" mark.
REMOVE OIL PRESSURE SENDER GAUGE
INSTALL OIL PRESSURE GAUGE
WARM UP ENGINE
Allow the engine to warm up to normal operating
temperature.
CHECK OIL PRESSURE
Oil pr...ura:
At idle
29 kP. (0.3 kgf/cm'. 4.3 psi) or more

At 3.000 rpm
250 - 600 kP.
(2.5 - 6.1 kgf/cm l , 38 - 87 pai)
Adhesive
7.
REMOVE OIL PRESSURE GAUGE
8.
(a)
REINSTALL OIL PRESSURE SENDER GAUGE

Apply adhesive to 2 or 3 threads of the oil pressure
sender gauge.
Adhesive:
Part No. 08833-00080. THREE BOND 1344.
LOCTITE 242 or equivalent
Install the oil pressure sender gauge.
START ENGINE. AND CHECK FOR OIL LEAKS
(b)
9.
OIL AND FILTER REPLACEMENT

CAUTION:
--.
Prolonged and reputed contact with mineral oil will

re.ult in the remonl of natural fat. from the skin.
le.ding to dryn.... irritation and dermatitis. In addition. ud engine oil contain. potentially harmful
contaminant. which may cause .kin cancer.
EG
EG-196
EG
o
0- Rm 9
,,
,
*-,-(j- _' - -
, -1.>lI
,,
:~=<:'~,~
,,
0;1 Pu";p 0';V81) ' ' ' ' Shaft Gear
-',
, ,,..-Idler Gear -i----------I

,,
,
Qr"'1$r' ~
Thrust Plate
,,
,,
,,
:'~Idler Gear Shaft

,-
,-
~-'
"
_ ... _
~---_
...
,,-
--
-- ,-
"
-------
",
Q",
'Q"---::;
,
"
Gear Oil Seal
:
,-~_ _+_nming Gear
Crankshaft Front Oil Seal
Vacuum Pump-----::--:1
,,
,,
,-
Q)---'
Gasket
,,
,
I
L' '
Cover
,-61~~::::~!J-----'OirPipe
El---
Non-reusable pan
,,,
--t';~c~'a~m:p~-+
l
Gasket
',-
,-
,-
-'
EG-195
OIL PUMP
INSTALLATION
wI EGR System
w/o EGR System
Cii\ ~
Intake Pipe
-,
'" " ,
'
Gaskel' ,
~EGR
~4i)
Valve Bracket
\~~~~~~~~--~>-'-"c,- -+ Gasket
vacuumHose}~;:::::~~~~~,
.GaSk~; ", ~
Intake Heater
Ir:>.
,,""""-
~- -r.'" " - - - ~lntakePipe
--,
,:,
,,
,
'-,
,
,
,,,
,,
,
~a:
Insutalor
------
F.n---::::jr5'~
,,."",-1nr
Drive 8elt
No.1 Camshaft liming
Pulley
Pulley Set Key
~ __ -------f$.1t.~
Clamp (wi EGA System)
Idler P u l l e y ' - - - - - -
\----Timing Belt
Clamp
Vacuum
--
,
-"'"
~Il'----- Gasket
Hose-------'\\
Clamp
,,
-,-
-'-
Seal Washer
Non-reusable part
EG-197
GaSket---;-r--:-:--"~~~;r- --'0
,
Water Outlet
'.
----"---- ---
Oil Pump
(Timing Gear Case)
rx,
Oil
Slrainer_~~==::~~~
4'
" \U.1Hfi \ ~_F
~~;~~~~~~m~uu
~.r
.~.~.
I If---Oil Pan
,
6--- '"
~.Gasket
..
~DrainPlug
Non-reusable parI
*. Precoated part
OIL PUMP REMOVAL
,.
2.
3.
4.
(a)
(b)
HINT: When repairing the oil pump. the oil pan and
strainer should be removed and cleaned.
DRAIN ENGINE OiL
REMOVE TIMING GEARS
(See steps 1 to 3 in timing gears removal in
Engine Mechanical)
REMOVE OiL PAN
Remove the 27 bolts and 3 nuts.
Insert the blade of SST between the cylinder block
and oil pan, and cut off applied sealer and remove the
oil pan.
SST 09032-00100
NOTICE:
Do not use SST for the oil pump body side and
oil seal retainer.
Oe car.ful not to damage the oil pan flange.
r88'
EG-198
ENGINE - LU8RICATION SYSTEM

5.
8.
REMOVE WATER OUTLET

(s tep 8 in cylinder he.d removel in Engine
Mechenieel)
REMOVE OIL PUMP (TIMING GEAR CASE)
la)
Remove the 2 nuts holding the injection pump to the
timing gear case.
EG
"""
(b)
Remove the 7 bolts holding the timing gear case to

the cylinder block.
(e)
Using a screwdriver. remove the oil pump by prying
(d)
the portions between the oil pump and cylinder block.

Remove the gasket and O-ring.
7.
REMOVE OIL STRAINER
Remove the 2 bolts. 2 nuts. oil strainer and gasket.
COMPONENTS FOR DISASSEMBLY AND-ASSEMBLY
Plug
Driven Aotor
~J1..
~-.G"k"
Timing Gear Case

Non-reusable part
EG'99
OIL PUMP DISASSEMBLY

1.
2.
REMOVE DRIVEN ROTOR

REMOVE RELIEF VALVE
Remove the plug, gasket. spring and relief valve.
"',,,
OIL PUMP INSPECTION
1.
INSPECT RELIEF VALVE

Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.

If it doesn't. replace the relief valve. If necessary.
replace the oil pump assembly.
2.
INSPECT DRIVE SHAFT
Turn the gear, and check that the drive shaft moves
smoothly and quietly.
If necessary. replace the oil pump assembly.
3.
INSPECT DRIVE AND DRIVEN ROTORS
A.
Inspect rotor tip clearance

Using a feeler gauge, measure the clearance between
the drive and driven rotor tips.

Standard tip clea,ance:
0.080 - 0.160 mm (0.0031 - 0.0063 in.)
Maximum tip cI8.,anc8:
0.21 mm (0.0083 in.)
If the tip clearance is greater than maximum. replace

the oil pump assembly.
B.
Inspect rotor body clearance

Using a feeler gauge. measure the clearance between
the driven rotor and body.
Standard body clearance:
0.100 - 0.170 mm (0.0039 - 0.0067 in.)
Maximum body clearance:
0.20 mm (0.0079 in.)
If the body clearance is greater than maXimum, replace the oil pump assembly.
EG-200
C.
Inspect rotor side clearence

Using a feeler gauge and precision straight edge. measure the clearance between the rotors and precision
straight edge.
Standerd .id. cl rence:
0.030 - 0.090 mm (0.0012 - 0.0035 in.)
Meximum ald. clrence:
0.' 5 mm (0.0059 in.)
If the side clearance is greater than maximum. replace
the oil pump assembly.
OIL PUMP ASSEMBLY

1.
(a)
(b)
--
INSTALL RELIEF VALVE

Insert the relief valve and spring into the installation
hole of the timing gear case.
Install a new gasket and the plug.
2.
INSTALL DRIVE AND DRIVEN ROTOR
OIL PUMP INSTALLATION

1.
INSTALL OIL STRAINER

Install a new gasket and the oil strainer with the 2
bolts and 2 nuts.
Torque: 8.8 Nm (90 kgfcm. 18 In..lbf)
2.
(a)
INSTALL OIL PUMP (TIMING GEAR CASE)

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the
timing gear case and cylinder block.
Using a razor blade and gasket scraper. remove


the loose material.
Using a non - residue solvent. clean both sealing

surfaces.

(b)
EG-201
Apply seal packing to the timing gear case as shown
S.al packing:
(e)

(0.08 - 0.12 in.) opening.
application. Otherwise the material must be re- [G:'


reinstall cap.
Place a new gasket into the groove of the timing gear
case as shown in the illustration.
(d)
install a new O-ring to the injection pump.
(e)
Install the timing gear case to the cylinder block with

the 7 bolts. Uniformly tighten the bolts in several
passes.
Torque: 19.6 Nm (200 kgfcm, 14 ft.lbf)
(f)
Install the 2 nuts holding the injection pump to the

timing gear case.
3.
POUR ENGINE OIL INTO OIL PUMP

Using a 5 mm hexagon wrench. remove the taper
(a)
(b)
(c)
screw plug.
Pour in approx. 10 cc (0.6 cu in.) of engine oil into the
oil pump.
Apply adhesive to 2 or 3 threads of the taper screw

plug.
Adhesive:
Pert No. 08833-00080. THREE BOND 1344.
tOCTITE 242 or equivalent
(d)
5 mm Hexagon Wrench
moO'
Using a 5 mm hexagon wrench. install the taper screw

plug.
EG-202

4_
5.
(a)
INSTALL WATER OUTLET

(See step 15 in cylinder head installation in
Engine Mechanical)
INSTALL OIL PAN
Remove any old packing (FIPGl material and be careful not to drop any oil on the contact surfaces of the
oil pan and cylinder block.
Using a razor blade and gasket scraper. remove

the loose material.
surfaces.
NOTICE: Do not use. solvent which will .ffect the paint.
ed lurfacel.
"
~~
Seal Width
4-5mm
A's
~A
(b)
Seal packing:
~.
Install a nOlzle that has been cut to a 4 - 5 mm

(0.16 - 0.20 in.) opening.

application, Otherwise the material must be removed and reapplied.

reinstall cap.
Install the oil pan with the 27 bolts and 3 nuts. Uni
formly tighten the bolts and nuts in several passes.
~.J"
Fie
Apply seal packing to the oil pan as shown in the

illustration.
"""
(cl
6.
INSTALL TIMING GEARS

(See steps 2 to 13 in timing gears installation in
Engine Mechanical)
7. FILL WITH ENGINE OIL
9. START ENGINE AND CHECK FOR OIL LEAKS
10. RECHECK ENGINE OIL LEVEL
EG-203
OIL COOLER
INSTALLATION
wi EGR System
w/o EGR System
~ ~
Intake
Pipe
Vacuum
Hose
,
,
r.:. ~EGR Valve Bracket
""0;"
'
.__~P'.
> '-~.
Gasket
Intake Heate r
::-o...:::-,~r.--~
G as kat
~--'
-::.-.
Gasket ~
,,
Vacuum Hose (wI EGR System)
No.2 Flange
Timing Belt Cover---"'\
\---liming Belt
)J)--=--Gasket
Vacuum Hose
Non-reusable part
--.
EG-204
_.
,
Clamp--+;---,
,,
,
,,
_;--_ _ Injection Pipe
.'
,r .. , --- ....
.. , t,,
.'
,,
0-
Oil Cooler Cover
.-,
,.,
,,
,
.'
"
-- =
):;;;~~;:-Accelerator
link
Assembly
,,,
,, ,,,
,.....~-+:-+1 Clamp
,, ,,
,
,
,,,
?z
Throttle Position
Sensor Connector
Except
)
( Australia MIT
," ...:""'ll
""IL_Oil Dipstick and
,
:
Guide
'~'-,
f1
~.ORing
J,
1 .J
.-~---
.. ----- _---- -
"
,. - - -
---;.:
I Water Bypass Hose
"'"-''l~'f<tc:----:::c!I~~''-----Tt(from Injection Pump)

\'}j ~
,.---: Gasket
.(';J _. I \J.J', "
I
.~.
'l',
I~
...........
r'fl-~
''.
'I
1 ('
/_.;'....
"
::
r0
:j '........
II
.....
.. ~I ..~I...... r"'1-"'~'
I"
~ib:::
I I
....... I '
QilFilter
_....to:?i
__ Check Valve
.... ~.
(.<1>-..
Gasket
-,
~::l~,
NO.1 Cylinder Block

Insulator
!: ~~.GaSket
,,,,
,
,,
"
~
c:o::::~~/'
Injection Pump-------I",---~:_J'j
D-Ring
lG
Oil
Cover Assembly
c9lcGl
:>_:'---
Water Bypass Hose

(from Injection Pump)
Non-reusable part
R,",fV.,.,
~~~erature
Sensor
EG-205
OIL COOLER REMOVAL

1.
2.
3.
"'-.,

REMOVE TIMING BELT
(See steps 1 to 3 in timing belt removal in
Engine Mechanical)

4.
5.
6.
7.
8.
Mechanical)
(See steps 3 and 5 in injection nozzles removal
in Fuel System)
(See steps 5 to 7 in injection pump removal
in Fuel System)
REMOVE OiL FILTER
(See step 2 in oil end filter replacement)
REMOVE RELIEF VALVE

Remove the relief valve and gasket.
REMOVE CHECK VALVE
Remove the check valve and gasket.

9.
REMOVE WATER TEMPERATURE SENSOR

Remove the sensor and gasket.
10. REMOVE OIL DIPSTICK AND GUIDE

(a) Remove the bolt. and pullout the dipstick guide together with the dipstick from the oil pan.
(b) Remove the 0 - ring from the dipstick guide.
11. REMOVE OIL COOLER AND COVER ASSEMBLY
Remove the 13 bolts. 2 nuts, the oil cooler. cover
assembly and gasket.
12. REMOVE OIL COOLER FROM OIL COOLER COVER
U-;;;;;;l;;;;;;~iii;;f'H Push
,-,---','Lj"
OIL COOLER AND RELIEF VALVE

INSPECTION
1.
INSPECT RELIEF VALVE

Push the valve with a wooden stick to check if it is
stuck.
If stuck. replace the relief valve.
EG
EG-206

2.
INSPECT CHECK VALVE

stuck.
;~~~~~Zh
If stuck. replace the check valve.
3.
INSPECT OIL COOLER

Check the oil cooler for damage or clogging.
If necessary. replace the oil cooler.
OIL COOLER INSTALLATION

,.
--
INSTALL OIL COOLER TO OIL COOLER COVER
Install 2 new gaskets and the oil cooler to the oil

cooler cover with the 4 nuts.
Torque: 15.7 Nm (160 kgfcm.12 ftlbf)
2.
INSTALL OIL COOLER AND COVER ASSEMBLY

Install a new gasket. the oil cooler and cover assembly
with the 13 bolts and 2 nuts. Uniformly tighten the
bolts and nuts in several passes.
3.
(a)
(b)
(c)
(d)
(e)

Bolt length:
A 20 mm (0.78 in.)
B 40 mm (1.57 in.)
INSTALL OIL DIPSTICK GUIDE AND OiL DIPSTICK
Install a new 0 - ring to the dipstick guide.
Apply soapy water to the a-ring.
Push in the dipstick guide end into the guide hole of
the cylinder block.
Install the oil dipstick guide with the bolt.
Install the dipstick.

4.
EG-207
INSTALL RELIEF VALVE

Install a new gasket and the relief valve.
5.
INSTALL CHECK VALVE

Install a new gasket and the check valve.
Torque: 27 Nm (275 kgf-em. 20 ftlbf)
6.
INSTALL WATER TEMPERATURE SENSOR

Install a new gasket and the sensor.
Torque: 19.8 Nm (200 kgfem. 14 ftlbf)
7.
INSTALL OIL FILTER

(See step 2 in oil and filter replacement)
6.
INSTALL INJECTION PUMP

(See steps 1 to 3 in injection pump installation
in Fuel System)
9.

(Se8 steps 3 and 6 in injection nozzle installation
in Fuel System)
10. INSTALL NO.2 CAMSHAFT TIMING PULLEY

(See step 3 in timing belt installation in Engine
Mechanical)
11. INSTALL TIMING BELT
(S88 steps 5 to lOin timing belt installation in
Engine Mechanical)

14. CHECK ENGINE OIL LEVEL
EG-208
ENGINE - LU8RICATION SYSTEM
OIL NOZZLE
INSTALLATION
OitNozzle
Check Valve'
----a
~,~O;IP.n
,
6--x 27
Non-reusable part
~. _ _ Gasket
9"""
Drain Plug
OIL NOZZLES REMOVAL

1.
2.
1.
fJ'~~~~ii;;;;;;;;:jPush
..
.",,,
....-.
REMOVE OIL PAN

(See steps 1 and 4 in oil pump removal)
REMOVE CHECK VALVE AND OIL NOZZLES
Remove the 6 check valves and 6 oil nozzles.
OIL NOZZLES INSPECTION
Ir
--.
--
INSPECT CHECK VALVES

stuck.
If stuck. replace the check valve.
EG-209

2.
INSPECT OIL NOZZLES

Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
""0-0'
OIL NOZZLES INSTALLATION

1.
(a)
(b)
INSTALL OIL NOZZLES AND CHECK VALVES

Align the pin of the oil nozzle with the pin hole of the
cylinder block.
Install the oil nozzle with the check valve. Install the 6
oil nozzles and 6 check valves.

2.
INSTALL OIL PAN
(See steps 5. 7. 9 and 10 in oil pump installation)
""A_OIl
SERVICE DATA
Oil pressure
Oil pump
81 idle speed
29 kP, (0.3 kgf/cm', 43 psi) or more
It 3.000 rpm
250 - 600 kPa (2.5 - 6.1 kgf/cm', 36 - 87 psi)
Tip clearance
STO
M.,dmum
Body clellrance
STO
Maximum
Side clearance
STO
Maximum
0.080
0.160 mm (0.0031
0.0063 in.)
0.21 mm (0.0083 in.)

0.100 - 0.170 mm (0.0039 - 0.0067 in.)
0.20 mm (0.0079 in.)

0.030 - 0.090 mm (0.0012 - 0.0035 in.)
0.15 mm (0.0059 in.)
Pari tightened
Nm
kgf-cm
Itlbf
34.3
350
2'
Relief valve x Timing geaf casa
.2
.25
31
Oil strainer x Main bearing cap
8.8
90
78 in.lbf
Timing gear case x Cvlinder block. Main bearing cap
Drain plug x Oil pan
19.6
200
Injection pump x Timing g88r case
18
18'
Oil pan x Main beering cap, Timing geaf case. Reef oil s8al retainer
9.8
100
87 in.lbf
Oil cooler cover x Oil cooler
15.7
180
12
Oil cooler cover. Oil dipstick guide x Cylinder block
19.6
200
39
.00
29
20
Relief valve x Oil cooler cover

Check velve x Oil cooler cover
Weter temperature sensor x Oil cooler cover
Oil nozzle x Cylinder block
27
275
19.6
200
27
275
"
"
"
"
20
'EG
EG-210
-MEMO-
ENGINE
LUBRICATION SYSTEM
ST.'
STARTING SYSTEM
PREPARATION ................................... 5T -
PRE-HEATING SYSTEM
5T- 3
STARTER ............................................ 5T- 8
STARTER RELAy 5T- 18

VOLTAGE CONVERTER TIMER 5T-19
(wI 24 V StBrter)
VOLTAGE CONVERTER RELAy 5T- 20
(wI 24 V Starter)
24 V HOLD WARNING RELAy .... .. 5T- 21
(wi 24 V Starter)
SERVICE SPECIFICATIONS ...................... 5T- 22
ST-2
STARTING SYSTEM - PREPARATION
PREPARATION
'.
~
5T
09286-46011
Injection Pump Spline Sh.ft

Pul~r
09820-00030
Alternator R.., Be.ri"'l! R.pI.c.,
ArlTMllur. ' " ' H.ring
RECOMMENDED TOOLS
09082-00050
TOYOTA Eleel"",1 Tnt,r Set.
.._-.
EOUIPMENT
Dial indicator
Comm",Utor
Magnetic finger
Pull scale
Bf\lsh spring
Sandpaper
Comrnutltor
TOrl:tue wrench
V block
Vernier calipers
Comrnutllor, Brush
ST-3
STARTING SYSTEM - PRE-HEATING SYSTEM
PRE-HEATING SYSTEM
--.
ON-VEHICLE INSPECTION
HINT: Refer to Diesel Electrical System Diagnosis for
inspection procedures.
(See troubleshooting in Engine Mechanical)
INSPECT LIGHTING TIME OF INTAKE HEATER
INDICATOR LIGHT
1.
Turn the ignition switch ON", measure the lighting

time.
light lighting time: Ref., to the chert graph
2.
INSPECT AFTER GLOW

Turn the ignition switch .. OW. measure the time bat
tery voltage is applied to terminal GREL of the preheating timer or emission Eeu.
After glow time: Refer to the chart graph
w J EGR System
Emission ECU
G7 EL
~!~
.._o~l~Dl
0 0 0 _.. _ 0 0 .. .,DDUDD
w/o EGR System

PreHeating Timer
"
!!!
E
Grl
F
~
c
:E
l'
::l
::l
II~:~~
10
'- "20
(4)
---
120
After
Glow
90
lime
60
light
U9hti"IQ
30
Time
20
(32)
(58)
40
(1041
60
(140)
80
(176)
"
~
Cl
"
:1
-
'"
!C.
Water Temperature "C(OF)
1'1"ll't1lI'U91.
2"1'
n=
PRE-HEATING TIMER OR EMISSION Eelr
INSPECITON
1.
DISCONNECT PRE-HEATING TIMER OR EMISSION

ECU CONNECTOR(S)
LOCATION: Under the instrument panel on the passenger seat.
ST
ST-4

2.
INSPECT PRE-HEATING TIMER OR EMISSION ECU

CIRCUIT
Check the connector on the wire harness side as
shown in these chart

Tester connection
Check for
+8. +81 - Ground
Voltage-'
IG - Ground
Voltage*2
Voltage
STA - Ground
VPWC - Ground
Voltage
Continuity
GREl
Ground
Continuity1
THW
E2
Continuity*2
THW -EG
Battery voltage
Ignition switch OFF
GINO - Ground
Voltage
Continuity*l
BAn - Ground
Voltage'
Specified value
Condition
No voltage
Ignition switch ON
Battery voltage
Ignition switch OFF
No voltage
Ignition switch ON
Battery voltage
Ignition switch OFF
No voltage
Ignition switch ON
Battery voltage
Ignition switch OFF
No voltage
Ignition switch START
Battery voltage
Ignition switch OFF
No voltage
Ignition switch ON
Battery voltage
Continuity
Continuity
Continuity
E1, E01, E02 - Ground
Continuity
wI EGR System
Wire Harness Side of Emission ECU
" K ,
/
/
M"
~
r"11l..
'" " /
f~
1/
1/ /
Ie sp,
.- .,
II
1/ '" ." / l- r-' / V

""
,.,
." u v.. 1/ ", " / '" ., 'G'
'"
,~,
'"
/
~~
n"'" mn2Il
w/o EGR System
I"P"'"
Wire Harness Side of Pre-Heating Timer
'"' / 11 :'" '" H'G
e-8-'
*1:
*2:
p-
wI EGA System
wlo EGA System
3.
,.,
RECONNECT PRE-HEATING TIMER OR EMISSION

ECU CONNECTOR(SI
ST-5
INTAKE HEATER RELAY INSPECTION
~1
Intake
1.
REMOVE INTAKE HEATER RELAY
2.
A.
(a)
INSPECT INTAKE HEATER RELAY

Inspect feley continuity
between terminals e and g.
Check that there is no continuity between terminals B
and G.
I-'cf-Heater
Relay
(b)
No Continuity
Continuity
B.
(a)
(b)
3.
Continuity
."
..
Inspect reley operation

Apply battery voltage across terminals e and g.
between terminals Band G.
REINSTALL INTAKE HEATER RELAY
ST-6
STARTING SYSTEM - PRE - HEATING SYSTEM
INTAKE HEATER INSPECTION

Components
w/o
EGR~.t.m
-'-
~ ~ .. ~"
~,
ST
Gasket
" ~ :::::t'
Intake Heater
Lead Wire
,~-:TA. -..._1
r~
Engine
Ground
Vacuum Hose
Strap
Intake Pipe
Intake Heater
'P'~
'-ba
Gasket
" " .....
'.
. ,
'.
Clamp
..
wI EGR Syatem
1t
,
.....
~EVRV Connector
. .~~TUrbo
~,
"tl... ',"
", ....,..
..
....
~'~ "
..
~.
"
Pressure SensOr Connector
.VSV for Turbo Pressure Sensor

Connector
'~t~GaSket
._
. ... V ~'-<
Gasket-----1@r:-" ' .. ~ V
H .... ..
r-~.' ',I acuum ose
.... ,
I"
~
'.
...
J:: . . .~
.
+ Gasket
.......
" 000--.:
I
~~' f ~lntakeHealer
VSVfor
EGA Valve Connector
~~lntakeHeater
:
:
,,
-.
Clamp'------e
Air H o s e - - - - - Clamp----~
"
Lead Wire ~ Inlat(e Pipe Insulator
~.GaSket
Intake Air COnnector----...;'--(,::<;
Non-reusable part
,/
,/
,,
,
ST-7
Inspection
wI EGR System
INSPECT INTAKE HEATER

Using an ohmmeter, check that there is continuity
between terminal of the intake heater and ground.
If there is no continuity, replace the intake heater.
$.
w/o EGA System
Ohmmeter
"'"
WATER TEMPERATURE SENSOR
INSPECTION
L
2.
Water Temp,;
Sensor
//J
.",,,
REMOVE WATER TEMPERATURE SENSOR

INSPECT WATER TEMPERATURE SENSOR
the terminals.
Re,i,tance:
Refer to the chart graph
If the resistance is not as specified. replace the water

temperature sensor.
3.
REINSTALL WATER TEMPERATURE SENSOR
30[
20
Acceptable
10
Ii
w
L>
Ohmmeter
0-
!"
'"w
V;
~
,
3
2
1
0.'
0.3
11.';;~
0.2
0.1
,
." ,
,
" "
TEMPERATURE "e
'"
,
60
80
(-411321 168) (104H\40H176l/212)
POl8S7
fl(1(j
(OF)
ZI~1'j
ST-8
STARTING SYSTEM - STARTER
STARTER
" __ M

ASSEMBLY
Starter Housing
.:~~
Starter Clutch
Compression Spring
~b
~I~
"
,
"
,~
Sl-,'\\
.........
<' __ '
"',
Snap Ring
Pinion Gear
t.r.-.. >. \..-~
~dl~ 8."~~9
..'
......... "
.......... "
\
1).'
;,
\ Compression Spring
Steel Ball
Oust Protector
Retrne,r@q
() \ \\
Clutch Shaft
Magnetic Switch
top C0 II at
- --""
.. -..........
'.-
__.-----
O-Ring
Lead Wire
I!l
'~
~ 1&1 - ft.
~.::
Rear Bearing
Armature
Front Beating
g---
Non-reusable part
Brush Holder
.aRing
~
End over Dust Protector
Field Frame
(Field Coil)
STARTER DISASSEMBLY
--.
1.
REMOVE FIELD FRAME WITH ARMATURE AND

LEAD WIRE FROM MAGNETIC SWITCH
(a)
Remove the nut, and disconnect lead wire from the

magnetic switch terminal.
(b)
Remove the screw, washer and the lead wire from the
terminal 50.

(e)
(d)
(e)
ST-9
Remove the 2 through bolts and spring washers.

Pull out the field frame with the armature from the
magnetic switch assembly.
Remove the felt washer from the rear bearing.
2.
REMOVE STARTER HOUSING. CLUTCH

ASSEMBLY AND GEARS
(a)
Remove the 3 screws.
"""
(b)
(2)
..J-;
(3)
(4)
Remove these parts from the magnetic switch assem-
bly:
(1) Starter housing and clutch assembly
(' )
::)
n~(5)
(2)
(3)
Return spring
Plate washer
(4)
Idler ge.r
(5)
Bearing
ST08IS
3.
REMOVE STEEL BALL

Using a magnetic finger. remove the st8el ball from
the clutch shaft hole.
4.
REMOVE BRUSH HOLDER

Remove the 2 screws and end cover from the field
frame.
(a)
."."
ST-10
(b)
(c)
5.
Using a screwdriver. hold the spring tank back and

disconnect the brush from the brush holder.
Disconnect the 4 brushes and remove the brush
holder.
REMOVE ARMATURE FROM FIELD FRAME
STARTER INSPECTION AND REPAIR
Armature Coil
1.
INSPECT COMMUTATOR FOR OPEN CIRCUIT

between the segments of the commutator.

If there ;s no continuity between any segment. replace
the armature.
Continuity
2.
INSPECT COMMUTATOR FOR GROUND

between the commutator and armature coil core.
If there is continuity, replace the armature.
No continuity
Commutator
1.
2.
(a)
(b)
3.
INSPECT COMMUTATOR FOR DIRTY AND BURNT

SURFACES
If the surface is dirty or burnt. correct it with sandpaper (No. 400) or on a lathe.
INSPECT COMMUTATOR CIRCLE RUNOUT
Place the commutator on V-blocks.
Using a dial gauge, measure the circle runout.
M.ximum eirel. runout:
0.05 mm (0.OO20 In.)
If the circle runout is greater than maximum. correct it
on a lathe.
INSPECT COMMUTATOR DIAMETER
Using vernier calipers. measure the commutator diameter.
St.nd.rd di.meter:
38.0 mm (1.417 in.)
Minimum di.meter:
35.0 mm (1.378 in.)
If the diameter is less than minimum. replace the
armature.

4.
ST-11
INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of

foreign materials. Smooth out the edge.
St.nd.rd undercut depth:
0.7 - 0.9 mm (0.028 - 0.035 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum. correct it

with a hacksaw blade.
Field Frame (Field Coil)
Continuity
I.
INSPECT FIELD COIL FOR OPEN CIRCUIT

between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
2.
No continuity
INSPECT FIELD COIL FOR GROUND

between the field coil end and field frame.

It there is continuity, repair or replace the field frame.
[ill
- +
Brushes
Brush Holder Side
INSPECT BRUSH LENGTH

Using vernier calipers. measure the brush length.
Stenderd length:
20.5 - 21.0 mm (0.807 - 0.827 in.)
Minimum length:
13.0 mm (0.512 in.)
If the length is less than minimum. replace the brush
holder and field frame.
Field Frame Side
Z\531~
ST-12
Brush Springs
STOOl'
Brush Holder
Ohmmeter
No Continuity
INSPECT BRUSH SPRING LOAD

Take the pull scale feading the instant the brush
spring separates from the brush.
Spring Inat.IIMJ IGlld:
18.8 - 35.3 N (1.S - 3.8 k_f. 4.2 - 7._ Ibf)
If the installed load is not within specification. replace
the brush springs.
DO
O:loif-..
o
INSPECT BRUSH HOLDER INSULATION

between the positive (+) and negative (-) brush hoi
ders.
If there is continuity, repair or replace the brush
holder.
STllC6
Clutch and Gears

1.
INSPECT GEAR TEETH

Check the g8ar t88th on the pinion gear. idle gear and
clutch assembly for wear or damage.
If damaged. replace the gear or clutch assembly.

If damaged. also check the drive plate ring gear for
wear or damage.
2.
INSPECT CLUTCH PINION GEAR

Hold the starter clutch and rotate the pinion gear
clockwise. and check that it turns freely. Try to rotate
the pinion gear counterclockwise and check that it
locks.
If necessary. replace the clutch assembly.
3.
IF NECESSARY. REPLACE CLUTCH ASSEMBLY

Oi....emble .tarter hou.ing end clutch embly
Push down the pinion gear and starter housing.
Using a plastic-faced hammer. tap down the stop
collar.
...,
A.
(al
(b)

Ie)
ST-13
Using a screwdriver. pry out the snap ring.
""'"
(5)
,., --..
,~
,
(d)
(3)
(!j
'
ST
f<~O
(1 )
'.-- ....--------.--; (2)
~-r-d?
(7)
(6)
Disassemble these parts:

(1) Stop collar
(2)
Pinion gear
(3)
(4)
(5)
(6)
(7)
Retainer
Compression spring
Starter housing
Starter clutch
Compression spring
(8)
Clutch shaft
B.
Assemble starter housing end clutch assembly
(a)
1st,
(1)
(2)
(3)
(b)
2nd. assemble these parts:

(1) Clutch shaft and starter shaft assembly
(2) Starter housing
(3) Compression spring
(4) Retainer
(5) Pinion gear
(6) Stop collar
(e)
(e)
Push down the pinion gear and starter housing.

Using snap ring pliers. install a new snap ring.
assemble these parts:

Clutch shah
Compression spring
Starter clutch
"..,
,~
,nl
(3)
(2)
(5) (6)
"""
ST-'4

(d)
Using pliers. compress the snap ring.
(e)
Check that the snap ring fits correctly.
(1)
Using a plastic-faced hammer. tap the clutch shaft

and install the stop collar onto the snap ring.
"'""
ST
SlD!1!>3
Bearings
1.
INSPECT BEARINGS
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks. replace the
bearing.
2.
(a)
IF NECESSARY, REPLACE BEARINGS

Using SST. remove the bearing.
SST 09286-46011
..."
Front Bearing
I
L
,H
(b)
(e)
Rear Bearing
'--
,.."
,.1
Using SST and a press, press in a new rear bearing.
SST 09820-00030
SST~
'tJ
Using a press, press in a new front bearing.
...rn
ST-15
Magnetic Switch
Terminal C
1.
PERFORM PULL-IN COiL OPEN CIRCUIT TEST

between terminals 50 and C.
Ohmmeter
If there is no continuity, replace the magnetic switch.
ContinuiTY
ST
2.
Switch Body
PERFORM HOLD -IN COIL OPEN CIRCUIT TEST

If there is no continuity, replace the magnetic switch.
Ohmmeter
Continuity
STARTER ASSEMBLY
HINT:
1.
....,-.,
Use high-temperature grease to lubricate the
bearings and gears when assembling the starter.

PLACE ARMATURE INTO FIELD FRAME
Apply greas8 to the armature bearings. and insert the
armature into the field frame.
2.
(a)
(b)
INSTALL BRUSH HOLDER

Place the brush holder on the armature.
Using a screwdriver. hold the brush spring back. and
connect the brush into the brush holder. Connect the

four brushes.
NOTICE: Check that the positive (+) lead wires are not
grounded.
(c)
3.
(a)
(b)
Install the end cover to the field frame with the 2

screws.
INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
Apply grease to the steel ball.
Insert the steel ball into the clutch shaft hole.
ST-'6

4.
Plate Washer
(a)
(b)
(c)
(e)
INSTALL STARTER HOUSING, CLUTCH

ASSEMBLY AND GEAR
Apply grease to the return spring.
Insert the return spring into the magnetic switch hole.
Install the plate washer to the magnetic switch.
Place these parts to the starter housing;
(1)
(2)
(2)
Idler gear
Bearing
. ':.
aC)\
'!l
I
(1)
...
"
Felt Washer
(d)
Assemble the starter housing and magnetic switch

assembly and install the 3 screws.
5.
INSTALL FIELD FRAME WITH ARMATURE AND

LEAD WIRE TO MAGNETIC SWITCH
Install a new felt washer to the armature.
(a)
mo.
(b)
Align the protrusion of the field frame with the cutout

of the magnetic switch.

(0)
ST-17
Install the field frame and armature assembly with the

2 through bolts.
Torque: 9.3 Nm (95 kgfem. 82 in..lb')
ST
(d)
Install the lead wire to terminal 50 with the screw and

washer.
Torque: 3.6 Nm (41 kgfem, 32ln..lbf)
(0)
Connect the lead wire to terminal C. and install the

nut.
Torque: 21.1 Nm (215 kgfem. 16 ft.lbf)
STARTER PERFORMANCE TEST
1.
(a)
NOTICE: These tests must b. performed within 3 to 5

uconds to avoid burning out the call.
DO PULL-IN TEST
Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.

Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the

2_

DO HOLD-IN TEST
With battery connected as above with the clutch
pinion gear out, disconnect the negative (-) lead from
terminal C. Check that the pinion Qear remains out.
If the clutch pinion gear returns inward. replace the
ST-18
STARTING SYSTEM - STARTER RELAY

3.
INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (-) lead from the switch
body.
Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return, replace the
4.
(a)
00 NO- LOAD PERFORMANCE TEST

Connect the battery and ammeter to the starter as
shown.
(b)
Check that the starter rotates smoothly and steadily

with the pinion gear moving out. Check that the am
meter shows the specified current.
Specified current:
12 V type:
At 11.0 V: 180 A or I...
24 V type:
At 23.0 V: 90 A or I...
STARTER RELAY
STARTER RELAY INSPECTION
1.
REMOVE STARTER RELAY
2.
A.
INSPECT STARTER RELAY

Inapect relay continuity
.....-.
wl24V Starter
wI 12 V Starter
,--,
wI 12 V St.rter:
4
(a)
Ohmmeter
oj3F.::~
(b)

Check that there is no continuity between terminals 1
and 2.
STARTING SYSTEM - VOLTAGE CONVERTER TIMER(w/ 24 V Start.,)
wi 24
(a)
(b)
Ohmmeter
00
0;.
ST-19
V Starter:

between terminals E and ST.
Check that there is no continuity between terminals B
and MG.
1
No continuity
510811
wf
Continuity
115317
s
B.
12 VStarte_(,:-_::===+_,
(a)
(b)
1
Ohmmeter
In.peet relay operation

wI 12 V Starter:
DO
O):j:.~."J
Continuity
P1)l09
115316
w /24 V Starter
wI 24 V Starter:
(a)
MG
(b)
Ohmmeter
00
0:
ST()8U
Continuity
Banery
3.
Apply battery voltage across terminals E and ST.

NOTICE: If the vehicle he' e voltege converter, do the
check u,ing. 12 V bettery.
Using an ohmmeter, check that there is continuity
between terminals B and MG.
If operation is not as specified, replace the relay.
REINSTALL STARTER RELAY
215318
VOLTAGE CONVERTER TIMER

(wi 24 V Starter)
VOLTAGE CONVERTER TIMER
INSPECTION
1.
DISCONNECT VOLTAGE CONVERTER TIMER

CONNECTOR
2.
INSPECT VOLTAGE CONVERTER TIMER
Voltage Converter Timer
Wire Harness Side
1 2
4 5
Check the connector on the wire harness side as

shown in these chart:
ST-20
STARTING SYSTEM - VOLTAGE CONVERTER RELAY(w( 24 V Starter)

Tester connection
Check for
ST
Voltage
1 - Ground
Voltage
2 -Ground
Voltage
3 -Ground
Continuity
4 - Ground
Continuity
Continuity
Condition
Specified value
Turn starter switch OFF
No voltage
Turn starter switch START
Battery voltage
Turn starter switch OFF
No voltage
Turn starter switch ON
Battery voltage
Tum starter switch OFF
No voltage
Turn starter switch START
Ballery voltage
Continuity
5-6
7 - Ground
Continuity
3.
Continuity
RECONNECT VOLTAGE CONVERTER TIMER

CONNECTOR
VOLTAGE CONVERTER RELAY

(wi 24 V Starter)
VOLTAGE CONVERTER RELAY
INSPECTION
Continuity
1.
REMOVE VOLTAGE CONVERTER RELAY
2.
INSPECT VOLTAGE CONVERTER RELAY
A.
(a)
Inspect rellY continuity

Using an ohmmeter. check that there
between terminals 8 and g.
between terminals 1 - and E.
between terminals 1 + and 2+.
Using an ohmmeter. check that there is
between terminals 1- and 2+.
If continuity is not as specified. replace
No continuity
(b)
(c)
,.
Continuity
=
o
=
o
Sl0ll81
(d)
--
is continuity
is continuity
is continuity
no continuity
the relay.
STARTING SYSTEM - 24 V HOLD WARNING RELAY(w( 24 V st.,t.'1
sT-21
B.
(a)
Inspect relay operation

Apply battery voltage across terminals e and g.
(b)

between terminals 1 - and 2 +.
No continuity Continuity
(e)
between terminals 1 + and 2+.

(d)
3.

terminals 1- and E.
REINSTALL VOLTAGE CONVERTER RELAY
Battery
510870
"""
24 V HOLD WARNING RELAY
(w/ 24 V Starter)
24 V Hold Warning Relay
--.JL J
I~::.,
Ohmmeter
Ohmmeter
00
00
No continuity
Continuity
00
o
Battery
?--"1(f)
BEOO10
1.
REMOVE 24 V HOLD WARNING RELAY
2.
A.
(a)
INSPECT 24 V HOLD WARNING RELAY
(b)
B.
(a)
(b)
Ohmmeter
Continuity
...... -.
24 V HOLD WARNING RELAY INSPECTION
3.
Inspect relay continuity

Using an ohmmeter. check that there IS continuity
Inspect reley operetion

REINSTALL 24 V HOLD WARNING RELAY
ST
sri
ST-22
STARTING SYSTEM - SERVICE SPECIFICATIONS
"
SERVICE DATA
Starter
Rated voltage and output power
No-load characteristics
BrUSh length
Current
...--
12 V 2.5 kW, 24 V 4.5 kW
12 V type
180 A or less at 11.0 V
24 V type
90 A or less al 23.0 V
'Pm
3.500 rpm or more
STO
20.5 - 21.0 mm (0.807 - 0.827 in.)
Minimum
Spring installed load
13.0 mm (0.512 in.)

18.6 - 35.3 N (1.9 - 3.6 kgf, 4.2 - 7.9 Ibl)
Commutator
Diameter
Undercut depth
Circle runout
STO
36.0 mm (1.417 in.)
Minimum
35.0 mm (1.378 in.)
STO
0.7 - 0.9 mm (0.028 - 0.035 in.)
Minimum
0.2 mm (0.008 in.)
Maximum
0.05 mm (0.0020 in.)
"0'0_'"
Part lightened
Nm
kgfcm
Itlb!
9.3
95
82 in.lbl
End cover )( Slarter housing
9.3
95
82 in.lbf
Lelld wire )[ Terminal 50
3.6
4\
32 in.lbl
lead wire x Terminal C
21.1
215
Starter housing )[ Magnetic switch
,.
CH-l
CHARGING SYSTEM
PRECAUTION
CH- 2
PREPARATION
CH- 2
ON-VEHICLE INSPECTION
CH- 3
ALTERNATOR
CH-
SERVICE SPECiFiCATIONS CH-14
CH
CH-2
CHARGING SYSTEM - PREPARATION
PRECAUTION
1.
Check that the battery cables are connected to the correct terminals.
2.
Disconnect the battery cables when the battery is given a quick charge.
3.
Do not perform tests with
4.
Never disconnect the battery while the engine is running.
--
high voltage insulation resistance tester.
--.
PREPARATION
09285 76010
09286 46011
Injection Pump Camshaft Bearing

Cone Replacer
Rotor rear bearing covar
Injection Pump Spline Shaft
Rlctifie, and frame
Puller
09820 00021
Alternator Aear ataring Puller
09820 00030
Alternator Raar Be.ring Replacer
~~
09820 63010
Alternator Pulley Silt Nut Wrench

So.
09950 60010
Replacer Set
(09951-00260)
Replacer 26
(09951-00500)
Replacer 50
~
~
..,O~
.P
0
r;p
Rotor front bearil'lll
d:J
..... .. ................................... , ,....... .............. ................... ,....
... - ....
..... , ....
------ --- --- ------- --------_._---_._- ------------_._-------------
(09952-06010)
Adapter
RECOMMENDED TOOLS
09082-00050
TOYOTA Electricel Tntar SOl.
... ----------
.....
........ ....................... ....................... ..

_
--- ....
............. -.....
--- ..
.....
CH-3
CHARGING SYSTEM - ON - VEHICLE INSPECTION
_ _a
EQUIPMENT
Ammeter(A)
Battery specific gravity gauge
Torque wrench
Vernier calipers
Rotor (Slip ring)
1.
CHECK BATTERY SPECIFIC GRAVITY AND

ELECTROLYTE LEVEL
(a)
Check the electrolyte quantity of each cell.
(b)
Check the specific gravity of each cell.
If insufficient, refill with distilled (or purified) water.

St.nderd specific gr8vitv:
At 20 C (68 F):
0
105D31L end 105D31R: 1.27 -
(bl
3.
INSPECT DRIVE BELTS
2.
(al
""-..
WRONG
1.29
Others:
1.25 - 1.27
If the gravity is less than specification. charge the
battery.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
Check that the battery terminals are not loose or
corroded.
Check the fusible link and fuses for continuity.
lal Visually check the drive belt for cracks. oiliness or

wear. Check that the belt does not touch the bottom
Clearance
(b)
of the pulley groove.

If necessary. replace the drive belts as a set.
Check the drive belt deflection by pressing on the belt
at the points indicated in the illustration with 98 N (10
kgf. 22 Ibfl of pressure.
Drive belt deflection:
New belt: 6 - 8 mm (0.24 - 0.31 in.)
Used belt: 8 - 11 mm (0.31 - 0.43 In.)
If necessary. adjust the drive belt deflection.
HINT:
'"New belt'" refers to a belt which has been used

less than 5 minutes on a running engine.
'"Used belt'" refers to a belt which has been used

on a running engine for 5 minutes or more.
After installing a new belt. run the engine for
about 5 minutes and recheck the deflection.
CH-4
CHARGING SYSTEM - ON-VEHICLE INSPECTION

4.
(a)
(b)
5.
(a)
(b)
VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
Check that the wiring is in good condition.
Check that there is no abnormal noise from the alternator while the engine is running.
INSPECT DISCHARGE WARNING LIGHT CIRCUIT
Turn the ignition switch "OW. Check that the dis
charge warning light comes on.
Start the engine. Check that the light goes off.
If the light does not operate as specified. troubleshoot
the discharge warning light circuit.
CH
Disconnect Wire
from Terminal B
6.
et---T--,
Battery
(a)
INSPECT CHARGING CIRCUIT WITHOUT LOAD

HINT: If a battery/alternator tester is available. connect the tester to the charging circuit as per the
manufacturer's instructions.
If a tester is not available. connect a voltmeter and
ammeter the charging circuit as follows:
Alternator
Voltmeter
(bl
Disconnect the wire from terminal B of the alternator and connect it to the negative (-) lead of
the ammeter.
Connect the positive (+) lead of the ammeter to

terminal B of the alternator.
Connect the positive (+ ) lead of the voltmeter to

terminal B of the alternator.
Ground the negative (-) lead of the voltmeter.

Check the charging circuit as follows:
With the engine running from idle to 2.000 rpm. check
the reading on the ammeter and voltmeter.
Standard amperege:
10Aorle
Standard voltage:
At 25C (77F): 14.0 - 15.0 V
At 115C (239F): 13.5 - 14.3 V
"""
7.
(a)
If the voltmeter reading is more than standard voltage.

replace the IC regulator.
If the voltmeter reading is less than the standard
voltage. check the Ie regulator and alternator as follows:
With terminal F grounded. start the engine and

check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard

voltage. replace the IC regulator.
If the voltmeter reading is less than standard

voltage. check the alternator.
INSPECT CHARGING CIRCUIT WITH LOAD
With the engine running at 2.000 rpm. turn on the
high beam headlights and place the heater blower
switch at "HI".
CH-5
CHARGING SYSTEM - ALTERNATOR
(bl
Check the reading on the ammeter.

Standard amperage:
12 V 80 A type: 30 A or more
12 V 100 A type: 40 A or more
It the ammeter reading is less than standard amperage, repair the alternator.
HINT: If the battery is fully charged. the indication
will sometimes be less than standard amperage.
ALTERNATOR
__

ASSEMBLY
Aotor
",-+__
Alternator
.Washer
Bearing Retainer
Front Bearing
Drive End Frame
Bearing
(Stator)
cov~r
/~
Rear Bearing
Pulley
---
Seal Plate
(/"Reclifier End Frame
"_
Rear End Cover
"
Brush Holder Cover
,lJ
\._~-6)
Ie Regulator
"Z'4""Rectifier Holder
-;...
L(?)
Rubber Insulator
",'"
_ _M
ALTERNATOR DISASSEMBLY
1.
(a)
"""
REMOVE REAR ENO COVER

Remove the nut and terminal insulator.
I!H]
CH-6
:H
(b)
Remove the 3 nuts, bolt and plate terminal.
(e)
Remove the rear end covsr.
2.
(a)
REMOVE BRUSH HOLDER AND IC REGULATOR

Remove the brush holder cover from the brush holder.
(b)
Remove the 5 screws, brush holder and Ie regulator.
(e)
Remove the seal plate from the rectifier end frame.
3.
(a)
REMOVE RECTIFIER HOLDER

Remove the 4 screws and rectifier holder.
~,
[BI~ST(A)
SST~
CH-7
(b)
Remove the 4 rubber insulators.
4.
(a)
REMOVE PULLEY
Hold SST (A) with a torque wrench. and tighten SST
(B) clockwise to the specified torque.
SST 09820-63010
Turn
Torque: 39 Nm (400 kgfcm. 29 fHbf)
(b)
Check that SST (A) is secured to the rotor shaft.
Ie)
As shown in the illustration. mount SST (C) in a vise.
(d)
To loosen the pulley nut, turn SST (A) in the direction

and install the alternator to SST (e).
NOTICE: To prevent damage to the rotor shaft, do not

loon the pulley nut more than one-half of. turn.
Z15341
(e)
(f)
(g)
Remove the alternator from SST (C).

Turn SST (B) and romovo SST (A and B).
Remove the pulley nut and pulley.
5.
REMOVE RECTIFIER END FRAME

Remove the 4 nuts.
(a)
(b)
Using SST. remove the rectifier end frame.

SST 09286-46011
CH-8
(c)
Remove the alternator washer.
6.
REMOVE ROTOR FROM DRIVE END FRAME
ALTERNATOR INSPECTION AND REPAIR'--
Rotor
OJ<llt--.
1.
INSPECT ROTOR FOR OPEN CIRCUIT

between the slip rings.
Ohmmeler
Standard r.,i,tance:
At 20C (66F): 2.9 0
If there is no continuity, replace the rotor.
CH0114
2.
INSPECT ROTOR FOR GROUND

between the slip ring and rotor.
0121I--.
If there is continuity, replace the rotor.
Ohmmeter
No Continuity
3.
(a)
(b)
INSPECT SLIP RINGS

Check that the slip rings are not rough or scored.
If rough or scored. replace the rotor.
Using vernier calipers. measure the slip ring diameter.
Standard diameter:
14.2-14.4 mm (O.559-0.567 In.)
Minimum diameter:
12.8 mm (0.504 in.)
If the diameter is less than minimum. replace the rotor.
CH9
Stator (Drive End Frame)
Ohmmeter
00
1.
Continuity
INSPECT STATOR FOR OPEN CIRCUIT

between the coil leads.

If there is no continuity, replace the drive end frame
assembly.
2.
Ohmmeter
00
No Continuity
INSPECT STATOR FOR GROUNO

between the coil lead and drive end frame.
If there is continuity, replace the drive end frame
assembly.
Brushes
INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers. measure the exposed brush
length.
Standard expo.ed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum. replace

the brush holder.
Rectifiers (Rectifier Holder)
Ohmmeter
1.
(a)
Ol~='"
(b)
.-
(e)
Ohmmeter
DO
@I
Negative (-)
Terminal
Using an ohmmeter. connect one tester probe to the

positive (+) terminal and the other to each rectifier
terminal.
Reverse the polarity of the tester probes and repeat
step (a).
Check that one shows continuity and the other shows
no continuity.
If continuity is not as specified. replace the rectifier
holder.
2.
INSPECT NEGATIVE RECTIFIER
(a)
Using an ohmmeter. connect one tester probe to each

negative (-) terminal and the other to each rectifier
terminal.
Reverse the polarity of the tester probes and repeat
step (a).
(b)
""'"
INSPECT POSITIVE RECTIFIER
CH
CH10

(c)
Check that one shows continuity and the other shows

no continuity.
If continuity is not as specified. replace the rectifier
holder.
Bearings
1.
INSPECT FRONT BEARING

Check that the bearing is not rough or worn.
CH
2.
IF NECESSARY. REPLACE FRONT BEARING
(a)
Remove the 4 screws, bearing retainer and bearing.
(b)
Using SST and a press. press out the bearing.
SST 09950-60010 (09951-00260. 09952-06010)
(e)
Using SST and a press. press in a new bearing.
SST 09950-60010 (09951-00500)

(d)
3.
Install the bearing retainer with the 4 screws.
INSPECT REAR BEARING

Check that the bearing is not rough or worn .
....
CH-ll
4.
(a)
IF NECESSARY, REPLACE REAR BEARING

Using SST. remove the bearing cover. bearing and
bearing cover.
SST 09820-00021
NOTICE: Ba careful not to damage the fan.
(b)
Place the bearing cover on the rotor.
(c)
Using SST and a press, press in a new bearing.

SST 09820 - 00030
(d)
Using SST. push in the bearing cover.

SST 09285-76010
,,,.,,
SST---:-fl;~"'-
"'""
ALTERNATOR ASSEMBLY
1.
2.
PLACE RECTIFIER END FRAME ON PULLEY

INSTALL ROTOR TO RECTIFIER END FRAME
--.
CH-12

3.
(a)
(b)
INSTALL RECTIFIER END FRAME

Place the alternator washer on the rotor.
Using a 29 mm socket wrench and press, slowly press
in the rectifier end frame.
29 mm
SOCkel-7::='f~-:'::;;!1:
Wrench
(c)
Install the 4 nuts.

Torque: 4.5 Nm (46 kgfem, 40 in.lbf)
,.,...
4.
INSTALL PULLEY
(aJ
Install the pulley to the rotor shaft by tightening the
(b)
Hold SST (A) with a torque wrench. and tighten SST
pulley nut by hand.

(8) clockwise to the specified torque.
SST 09820-6301 0
Torque: 39 Nm (400 kgfcm, 29 ftJbf)
(e) Check that SST (A) is secured to the pulley shaft.

...."
(d)
As shown in the illustration. mount SST (C) in a vise.
and install the alternator to SST (C).

(e)
To torque the pulley nut. turn SST (A) in the direction

1"08~.1PW2 ...
"""
(n
Remove the alternator from SST (C).
(9)
Turn SST (B) and remove SST (A and BI.
CH-13
5.
(a)
INSTALL RECTIFIER HOLDER

Install the 4 rubber insulators on the lead wires.
(b)
Install the rectifier holder while pushing it with the 4
""."
screws.
Torque: 2.9 Nm (30 kgfem. 28 In..lbf)
Upward
6.
INSTALL IC REGULATOR AND BRUSH HOLDER
(a)
Place the seal plate on the rectifier end frame.

Place the Ie regulator and brush holder on the rectifier
(b)
CB
(d)
end frame.
NOTICE: B. c.r.ful of the hold., intt.lI.tion direction.
Install the 5 screws.
Place the brush holder cover on the brush holder.
7.
INSTALL REAR END COVER
(e)
la)
Install the end cover and plate terminal with the 3 nuts
and bolt.
Torque:
Bolt: 3.8 Nm (38 kgfcm. 34 In.-Ibf)
80 A: ....4 Nm (45 kgfem, 39 in..lbf)
100 A: 4.5 Nm (48 kgtem, 40 in.-Ibf)
Nut
(b)
Install the terminal insulator with the nut.

Torque:
80 A: 4.1 Nm (41.5 kgfcm. 38 in..lbf)
100 A: 8.5 Nm (88 kgfcm. 58 in..lbf)
CH
CH14
CHARGING SYSTEM - SERVICE SPECIFICATIONS

8.
CH
CHECK THAT ROTOR ROTATES SMOOTHLY
_.-
SERVICE DATA
Batterv
Specific gr.vilv
II 20C (SSeF)
105D31L and I05031R
1.27 - 1.29
Others
1.25 - 1.27
12 Y 80 A.. 100 A
R,tad output
AII,rnllor
Rotor coW
Slip ring di.meter
Brush
2.90
'I.i,tlnel
,xp(ll~
length
STD
Minimum
12.8 mm (O.Sa. in.)
STD
10.5 mm (0.413 in.)
Minimum
Ie
Regulating volt.ge
Regulltor
'-4.2 mm - 1. mm (0.559 - 0.587 In.)
1.5 mm (0.059 in.)
It 25"C (nF)
14.0 - 15.0V
.t 11SC (239F)
13.5 - 14.3 V
Raetit.., Ind tr.me
)I
Drive
Part tight,ned
Nm
trim.
<.5
Alternator pulley x Rotor
Rectifier holder
It
Coil lead
Ofl
(.clitia, end fram.
Pille terminll x Rlctifi" holde,

R"f Ind covar
If
Rlcli'i" hold.r
Terminlt inlulltor x RlCtifier holder
.
."
kgf-em
,,tbf
.0 in..lbf
110
1.125
81
2.
'0
28 in..lbf
'.8
80 A
_0-.
100 A
<.,
80 A
100 A
34 inAbf
39 in.lbf
<.
40 in.-Ib'
<.1
41.5
38 in.tbf
8.5
58
58 ill..lbf

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@TOYOTA

Pub. No. RM437E

1HDFT Engine Emission Control Repair

TOYOTA MOTOR CORPORATION

1995 TOYOTA MOTOR CORPORATION

GENERAL REPAIR INSTRUCTIONS

ABBREVIATIONS USED IN THIS

STANDARD BOLT TORQUE

INTROOUCTION - HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

Timing Gear Case

INTROOUCTION - HOW TO USE THIS MANUAL

procedures are presented in a step-by-step format:

INSTALL CRANKSHAFT PULLEY

what to do and where

Set part No.

Component part No.

(b) Install the b".

INTRODUCTION - IDENTIFICATION INFORMATION

CAUTIONS, NOTICES, HINTS:

The engine serial number is stamped on the engine

INTROOUCTION - GENERAL REPAIR INSTRUCTIONS

GENERAL REPAIR INSTRUCTIONS

Use fender. seat and floor covers to keep the vehicle

During disassembly, keep parts in the appropriate

Observe the following:

order to facilitate reassembly.

the negative cable from the battery terminal.

Seal lock Adhesive

from the negative (-) terminal which is grounded

INTRODUCTION - GENERAL REPAIR INSTRUCTIONS

Use of special service tools (SSn and special service

nature of the repair. Be sure to use SST and SSM

preparation part at the front of each section in this

correct amperage rating. 00 NOT exceed the rating or

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

11. Care must be taken when jacking up and supporting

the vehicle. Be sure to lift and support the vehicle at

INTROOUCTION - GENERAL REPAIR INSTRUCTIONS

After the vehicle is jacked up. be sure to support

connector itself. not the wires.

Be careful not to drop electrical components.

13. Tag hoses before disconnecting them:

INTROOUCTION - A88REVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN THIS MANUAL

Air Control V,lve

Automatic Cold Stnt Device

Boo.t and "'tiudl Coml*'Ntion Stopper

Exhlu.t Gil Rlcireul.tion

Formed in Pl.e. Gllket

Laid Sensing Tim.r

po,itiva Cr.nke Ventil.tion

Starting Injection Control Syttem

Special Service Mllerials

Special Sel"t/iCi Tool.

Vacuum SwitChing V.IIII

INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS

STANDARD BOLT TORQUE SPECIFICATIONS