804 PDF
804 PDF
804 PDF
1HD-FT
ENGINE
REPAIR MANUAL
Jan., 1995
..
Please note that the publications below have also been pre-
pared as relevant service manuals for the components and
system in this engine.
INTRODUCTION
INDEX
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.
IN
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
1 Gasket riven otor
~J r"'""
~--
Non-reusable part
IN-3
INTROOUCTION - HOW TO USE THIS MANUAL
6_
/
INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the bolt.
SST 0921 ~54015 (90119-~' 26)
Set part No. Component part No.
Illustration:
what to do and where 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
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.
"'..
IN-5
INTROOUCTION - GENERAL REPAIR INSTRUCTIONS
7.
illustrations by the"'*. symbol.
When necessary. use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
IN-6
INTRODUCTION - GENERAL REPAIR INSTRUCTIONS
Fu", 10. When replacing fuses. be sure the new fuse has the
correct amperage rating. 00 NOT exceed the rating or
EQual Amperage Rali~
use one with a lower rating.
10 ) 10 )
IE559-t
~
.., . FUSE FUSE
~ FUSIBLE LINK FL
85517
tnSM
-R-..,.. CIRCUIT BREAKER CB
---------------
Hexagon 4- 4T ---------
Stud bolt
head bolt 5- 5T
Bolt 6- 6T
rOr'head No. 7- 7T ~ No mark
B- BT
B- 9T 4T
'0- lOT
11- ,n
0 No mark 4T
Hexagon
flange bolt
wI washer
hexagon bolt
o Nom,,' 4T
v
~ Grooved
6T
Hexagon
OJ
head bolt 2
protruding 5T
lines
Hexagon
0
flange bolt 2
protruding 6T Welded bolt
wI washer
lines
hexagon bolt
Hexagon
0
head bolt 3
~
protruding 7T
lines 4T
Hexagon
0
head bolt 4
protruding BT
lines
IN-IO INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
Specified torque
Diamete' Pitch
Class mm mm
Hexagon h.ad bot! Hexagon flange bolt
N'm kif-em ftlbf N'm kgl'em ftlbf
6 1 5 55 48 in.lbf 6 60 52 in.lbf
IN 8 , .25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
6 1 6.5 65 56 in.-lbf 7.5 75 65 in.lbf
8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
'4 1.5 91 930 67 100 1.050 76
16 1.5 140 1,400 101 - - -
6 1 8 80 69 in.lbf 9 90 78 in..lbf
8 1.25 19 195 14 21 210 '5
10 , .25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1.250 90
16 1.5 170 1,750 127 - - -
6 1 10.5 110 8 12 120 9
8 , .25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1.050 76
14 1.5 145 1,500 108 '65 1,700 123
16 1.5 230 2,300 166 - - -
ENGINE
ENGINE MECHANICAL
PREPARATION
~
:EG Repllcer Set
~
Rlpllcer 7
~
09202-70020 V,Iv, Sprine Compressor
~
{i) -', - 09213-58012 Crlnkah,ft PuM.., Holding Tool
-
~
@
.....
(90201-08131) Wlth'r
... ..-....... ......... ... _... .--..............
0 =1 09214-60010
09214 76011
C'lnhh,ft Puu,., &. G..,
R.plle...
~
Illjeetion pump drive gur oil
g.'
09222-11010 Connecting Rod Bu.hing Remoyer
...... ................. -----------------------. ,-.,- .. .......................
(O9222-05040) Bm
fJ
09223 00010 Cover &: Seel Repl,ee. C'anklh,ft timing gear
~
Replacer
~
Replacer
~ (2a
09275-54011 Plunger Stroke Menu.ing Tool
~
09330 00021 Comp.nion FI.nge Holding Tool Crenk,heft pulley
~
09950-40010 Puller B Set
~-&~f~
~: ~~~
.... ....
... , ........ ........... .............
'
~
Oil pump drive sheft gear
Crankshaft timing gear
Injection pump drive g98r bearing
..... .............. , , ......... ................. .............. ............. ................................. ,
(09952 -0401 0) Slide Aim No.1 camshaft liming pulley
~~<liil
O~ pump driv. shalt gear
Crankshaft timing gear
de Injection pump drive gear bearing
...
(09953-04010) Center Bolt 100 Oil pump drive shaft gear
~
Crankshaft timing g98r
....... ................... .............................. ....... ............. ................. ..... ........................... ........ ................. ...................... ...
(09953-04020) Center Bolt 150 No.1 camshaft timing pulla.,.
~
Oil pump drive shalt g98r
Crankshaft timing gaar
Injection pump drive gear bear,ng
... .....
, ........ . ..... ...... .............. ...... .....
"
EG-4
ENGINE - ENGINE MECHANICAL
~
Oil pump drive Illaflg'a,
Cranksh.ft timing ge,r
Injection pump drive gur be,ring
'EG
~
.
@-r- ...~
~ IJrn
'"".0
.--...ir;fii'
""""""..,, -::::--
09950-50010
(09951-05010)
Puller C Se1
~
Injection pump drive gell'
0000
Injection pump drive geer
~
Injection pump drive gear
~
(09954-05020) Claw No.2 Crankstlaft pulley
a~
(09951-07100) Handle 100 Velve guide bustling
~
09960-10010 V'riebl, Pin Wrench Set
~
(09962-01000) Variable Pin Wrench Arm Assy lrljection pump drive ge.,
~
(09963-00700) Pin 7 Injectiorl pump drive gear
~
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.
=~
~"A
..
09904-00010 E..pender Set.
~~
. --
EOUIPMENT
Caliper gauge
Cylinder gauge
Dial indicator
Dve penelrant
Heater
Micrometer
Plastigage
Soft brush
Thermometer
Torque wrench
V-block
Vernier calipers
TROUBLESHOOTING
_-0'
Diesel Engine Diagnosis
GENERAL
1. Diesel engine problems are usually caused by the engine or fuel system. The injection pump is
very rarely the cause of fuel system problems.
2. 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
ENGINE - ENGINE MECHANICAL
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 8 special test bench.
N ~ '"
.~
~
o
Symptom \ a;; ,
;;
~
~ ;;
,
~
o
z ~
,
oc
'"
Engine does not crank 2 1 3 6 4 5
~rf__---------t___+-+-f__+-+_--t-+-t___+-+___t-+-t___+-+-t__+-t___+-+_j
,,"
00
Engine cranks normally 5 2 1 6 4
r
~
High engine idle speed 3
Rough idle with warm
engine
6 7 2 5
lack of power 9 6 12 5 8 1 2
"
~
6
Excessi....e fuel
consumption
8 10 5 7
Engine overheat 7
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
ENGINE - ENGINE MECHANICAL
Suspect area
u
u '"c
0
".
0 0
~ u
E'"
0 .~
," E, "gi
~
~
.0.
"
"" .~g'" "'" "'" ;;
u
'"E,
c .2
" .
.u
-" .,;
\"
:< :I:
"" ~0
."
~ ~
0
Symptom
'" .;; ":<
~
E
~ >
0
u
~
E E
>-
~
;;
'"c
~
0
u
>'
~
"
-"
..
00
:~:~
uu - "-
E
" ~ "" " 6 " ~ '"
0
0
u
,
E
~
u:
;2
.! "u
;; " 0
::Q)
0'" u
in
~
" " u u
~
c';:
c.
o.
u",
~
~
0
U U
0
>. >.
0
<;
0 Engine does not crank 8 7
~t
o Engine cranks normally 3
o~
~
~
0
Rough idle with warm
engine
, 4 3
lack of power 7 3 4
" '0
PRE-HEATING SYSTEM
EG
No
When tne ignition switcn is turned
ON. does the indicator light?
Is tne GAUGE fuse Okay? Replace tne fuse. I
(Measure the time lighted) y"
y" No
Is the indicator light bulb Replace the bulb. I
Ok8Y?
Ye.
<D
CONTINUED ON PAGE EG-xx
EG-l0
ENGINE ENGINE MECHANICAL
0::'._..":: ~D 00_ g
'.l__ ~
.000"-_
-
J
terminal EG of the pre-heating
timer?
harness between
terminal El, EO' or
E02 of the EeU or
EG
;~ ~O2
terminal EG of the
-- E7, V" timer and body
P23602 ground.
), =]
limer (on wire harness side17
L~
No
Open circuit in wire harness Replace the ECU or
between terminal GINO of the timer.
GINO EG EeU or timer and indicator light.
P22973
No
Is the lighting lime correct? Replace tile EeU or timer. I
6.5 seconds
Ves
Is there battery voltage between No Is intake heater relay Okay? No Replace the intake
terminal G of the intake heater relay (See pre-healing system in heater relay.
and body ground for 81 seconds Starting System)
with the ignition switch ON?
y" y"
Intake Hea~ Relay
1@1'~b
When the ignition switch is turned ON, does No Replace the ECU or
terminal GREL of the ECU or timer have timer.
battery voltage fOf 81 seconds?
G ---r B
, V"
pnS8B
9 e
Connect the water temperature 0 Open circuit in wire harness
sensor connector. between terminal GREL of the ECU
or timer and terminal g of the intake
heater relay.
0 Open circuil or ground faulty in
wire harness between terminal e of
Inspect power supply the intake heater relay and body
section. ground.
ENGINE - ENGINE MECHANICAL EG-"
No Noise
Check luse.
Fuse
Check for short circuit, and repair as necessary. I
Fuse OK Blown
Washable Type:
1. REMOVE AIR FILTER
2. INSPECT AIR FILTER
Visually check that the filter element IS not ex-
cessively dirty, damaged or oily.
3. CLEAN AIR FILTER
(a) Blow dirt off in the filter element with compressed air.
EG-12
ENGINE - ENGINE MECHANICAL
dIJ Ie)
up and down more than 10 times.
Repeat rinsing in clean water until rinsing water is
"
,if
0.'<
..
~.:.;..;
~
clear.
"m~
>~
EG
..",
COMPRESSION CHECK
'GIIJ_1l
HINT; If there is lack of power, excessive oil consump-
tion 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. REMOVE CYLINDER HEAD COVER
(See steps 2 or 3 end 11 in cylinder head removal)
3. REMOVE INJECTION PIPES
(See .teps 3 and 5 in injection nozzles removal in
Fuel System)
4. REMOVE NO.1 NOZZLE LEAKAGE PIPE
(See step 4 in injection nozzles removal in
Fuel System)
5. DISCONNECT INJECTION PUMP (FUEL CUT
SOLENOID) CONNECTOR
6. 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.
(a) Remove the injection nozzle.
(See steps 6 and 7 in injection nozzles removal in
Fuel System)
(b) 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)
EG-13
ENGINE - ENGINE MECHANICAL
(b) Loosen the lock nut on the valve rocker arm. and
~~TU,"
loosen the adjusting screw.
Adjusting (e) Insert a 0.20 mm (0.008 in.) feeler gage for intake or
Screw
~~kf~~ 0.50 mm (0.020 in.) feeler gage for exhaust between
~~~)~~~-~~I;:er the adjusting screw on the valve rocker arm and the
valve bridge.
020 or Slide Arm
O:SOmm -- (d) Turn the adjusting screw on the valve rocker arm until
Feeler the feeler gauge slides with a very slight drag, and
Gauge
lock the adjusting screw with the lock nut.
(e) With the feeler gauge inserted. check that the resist-
ance of the feeler gauge remains the same when the
adjusting scre~ on the valve bridge is loosened.
Adjusting If the resistance of the feeler gauge changes. repeat
Screw from step (b).
oi!-l>,__ Valve
Bridge
P2J211
~~Q({)
(a) 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
(f) Turn the A/C switch OFF. and check that the rod end
of the idle-up actuator is not touching the idle-up
lever.
EG-21
ENGINE - ENGINE MECHANICAL
TIMING BELT
COMPONENTS FOR REMOVAL AND
..
.,,,.-
INSTALLATION
~. -_-_--~, Gasket
Vacuum
,
Hose.~:t~""':-:--t2~~~
, --:>~--'~Intake Pipe
+ Gasket ....... ~
',----' : ~.
- ~ Insulator
.:",
Intake Heater I ,
........., '
'.'~
I Gasket ......... '-
,
" Gasket . , :
,,,
,
.-_. ,
, ;.
,,, , .'
,..~
,,,
,,
,, .
,~--- .-- Vac~um Hose (wi EGA System)
No 1 Camshaft Ttming~_-------
Pulley ~-~
Plate Washer
Clamp -------'<'dl
~"..---Gasket
Vacuum Hose ~~
Clamp-----"
Nonreusable part
EG-22
ENGINE - ENGINE MECHANICAL
"'--.,
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
EG
- 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.
EG-25
ENGINE - ENGINE MECHANICAL
(b) 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 down-
we rd.
EG j
/
"''''
TIMING BELT INSTALLATION
---.,
1. INSTALL NO.1 CAMSHAFT TIMING PULLEY
lal Install the set key to the key groove of the camshaft.
Ibl Align the pulley set key with the key groove of the
timing pulley, and slide the timing pulley.
lei Temporarily install the pulley bolt.
Idl Hold the hexagon wrench head portion of the cam-
shaft with a wrench. and tighten the pulley bolt.
Torque: 98 Nm (1.000 kgfcm. 72 ftlbf)
2. INSTALL CYLINDER HEAD COVER
(See steps 10 and 18 or 19 in cylinder head
installation)
3. INSTALL NO.2 CAMSHAFT TIMING PULLEY
lal 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.
Ibl Install the No.1 flange. timing pulley and No.2 flange
with the 4 bolts.
Torque: 31 Nm (315 kgfcm. 23 f1.lbfl
4. INSTALL IDLER PULLEY
lal Using an 8 mm hexagon wrench. install the plate
Bmm washer and idler pulley with the pivot bolt.
Hexagon Torque: 34.5 Nm (350 kgfcm. 25 ftlbf)
Wrench Ib) Check that the pulley bracket moves smoothly.
\
f
"""
EG-26
ENGINE - ENGINE MECHANICAL
\/~.
(b) Alternately tighten the 2 bolts.
Torque: 13 Nm (130 kgfcm.10 ftlbfj
(c) Remove the 1.5 mm hexagon wrench from the tensi-
oner.
TIMING GEAR
COMPONENTS FOR REMOVAL AND
--.
INSTALLA TION
-,
Gasket ~~~~ ~ ~-:~:.~
"'_-_ Intake Pipe
Intake Heater ......" Insulalor
+Gasket' . . ",
,
a~: ,~
,
,
,,,
,
;,.",- ' Gasket
'.0----1 ,
.........\
_"",,:.::.,.<::-:t::7\~cuum Hose (wI EGA System)
Drive Belt
Pulley Set Key."
No.1 Camshaft 1iming _ _-,~ ---
Pulley f$?'\;:f,J
Clamp lwl EGR System)
Idler Pulley - - - - - -
,\---Timing Belt
Clamp
,
-"'''\\ ~IP-----Gasket
Vacuum HO$e-----'~
Clamp
.,
-"
Seal Washer
Non-reusable part
EG-29
ENGINE - ENGINE MECHANICAL
(
.'
x6
Crankshaft Pulley ----,''''''~~ i----'-:-Clamp
, <>::;:---+
1M Gasket
.. ,
.'
.'
.. '
Non-reusable part
EG-30
ENGINE - ENGINE MECHANICAL
~.;<-_SST
EG
B. Install bearing
Using SST and a press. press in a new bearing.
SST 09214-76011
SST
pn243
P23221
pn244
EG-34
ENGINE - ENGINE MECHANICAL
(b) Using SST and a hammer. tap in a new oil seal until its
surface is flush with the timing gear cover edge.
SST 09223-78010
(e) Apply MP grease to the oil seal lip.
(b) Using SST and a hammer. tap in a new oil seal until its
surface is flush with the timing gear cover edge.
SST 09214-76011
(c) Apply MP grease to the oil seal lip.
EG
"""
B. If timing gear cover is installed to the cylinder block:
(a) Using a knife. cut off the oil seal lip.
(b) Using a screwdriver. pry out the oil seal.
NOTICE: B. careful not to damage the injection pump
drive g8.r. Tepa the screwdriver tip.
""" __-0'
TIMING GEARS INSTALLATION
1. INSTALL CRANKSHAFT TIMING GEAR
(a) Put the timing gear with the timing mark facing for-
ward.
(bl Align the set key on the crankshaft with the key
groove of the timing gear.
(e) Using SST and a hammer. tap in the timing gear.
SST 09223-00010
- mm
-~~
lal Align the set key on the crankshaft with the key
~
groove of the drive shaft gear.
') Front Ibl Using SST and a hammer. tap in the drive shaft gear.
, \'- SST 09223-00010
SST
~ 5. INSTALL NO.2 CYLINDER BLOCK INSULATOR
6. INSTALL TIMING GEAR COVER
(a) Remove and old packing (FIPG) material and be care-
mm ful 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.
(e) 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.)
Bracket
EG
A Mm
New
O-Ring
CYLINDER HEAD
COMPONENTS FOR REMOVAL AND
INSTALLATION
--
w J EGR System
Heal Insulator
,
gis'
<il, ,
r---EGA Valve Bracket
-, >
~"
(0," ~ -.--
.~<:@-:--'",-.
~~.~~
Gasket
--, "
.--'.'
--,,
__ -I
,, ,
,,,
,
Turbocharger ---1~~
and Exhaust
Manifold
Assembly
Turbocharger
Stay
Vacuum
Vacuum--"
Hose
., ,,
" ~
Throttle Position Sensor
Non-reusable part ConnectOr
EG-39
ENGINE - ENGINE MECHANICAL
~
~T---IntakePipe
--- ~~ -
__ ~~" ~~~~~[=.:
Gasket
Intake Heater
,
,
_--I! ~ ~ -
,
'~'
~---l
~ ~
~_
Injection Pipe
,,
Turbocharger t ,
Stay If I
,
"'~Cla~p
~~~, """ ... ..., ... ~&
~:J~~~'~;~~i~:~:~~5~
I ,
,,,
,
Intake Manifold
Insulator
,,
,
,,,
'~
,,
,, .
' Clamp
,
Clamp
't
,
Accelerator
,, ,,
f
link Assembly
-,
Throttle Position Sensor
Connector (AfT)
Non-reusable part
EG-40
ENGINE - ENGINE MECHANICAL
-----t:"!~:~".::::::; ",
----_:_---_:~
,j
Cylinder Head C over
EG
12
'"
' _ --1l-. "'''-''
--Elll~0:--~:---
S
~---,
eal Washer ..,
Gasket
~::.~::~~,~~,:::.
C,m,h," B _ - Gasket
~g~==~~~5~~~~~~~~~~~~~~~~t~."..
! ,-
ocker Shaft A -- -, '
C,m,h,"
, ,y Sot BK,y _ ",mbly , ,,NO""
" ", .
P II ear,"
Q;:J
'
>--
F r ' Injection
:
,1,
'"1iQ:t!~:~:"'-' ~. NOlzleSeat
Th,"" S,ml.Cr",I, Hold"
""'9
PI."
;-,
P I ' 9 ' ----""
" _-. . :~~_-_J
S"I 0'
D-Rlng
Camshaft Oil
Seal Retainer----O'"
~~if
~~~~~~~~~~~~~~~~~---CYljnder Head
: _~~;~~;~~~~~~~~~~~.~~~
.. "- ~ "'\
\ ypa~s
(from InJectlOnHose
Pum I
Cy rmder Head Gasket P
Water B
Clip--~~
Timing Belt
Timing Belt
Cover
Seat Washer
~_'
~. \\'
_.IJ!'--=--.
Insulator
Gasket
(p~Seal Washer
Non-reusabl c part
EG41
ENGINE - ENGINE M ECHANICAL
Camshaft
Be Bring
. Cap
r--
Cylinder Head Assembly
'<l':''b
Valve Bridge
.~ Keeper
Ii :=-sprin g Retainer
0: ~ Valve Spring
,
RI e
Ol@)--------SP' nng Seat
Val U: R Oil Seal
'Ie GUide=f+U
Bushing I I '
Turbocharger and
" ' Exhaust Manifold A ssembly
~
._~\
Front Exhaust Collar
, Manifold
, m ,,0
,', "0
"'"
l!-v"ve ~ . Gasket
,
D-Ring
~~J~~J!j---TurbOCharger
III :~
" '
~ ~ :
Non-reusable
!iI !iI P2Jl89
* Preeo,' e d partpart
EG-42
ENGINE - ENGINE MECHANICAL
(e) Using snap ring pliers. remove the 2 rings from the
rear exhaust manifold.
(d) Remove all the O-ring materials from the rear ex
haust manifold grooves.
10. REMOVE REAR ENGINE HANGER
EG44
ENGINE - ENGINE MECHANICAL
EG
(c) 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.
3. REMOVE VALVES
(a) 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.
(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 - com-
pr....d air.
t
C. Clean valve guide bushings
Using a valve guide bushing brush and solvent. clean
all the guide bushings.
m:i~
P22&96 1\':007
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
.. ~--'---"
45
25"
(1) If the seating is too high on the valve face. use
25 and 45" cutters to correct the seat.
70 (Intake) (2) If the seating is too Iowan the valve face. use
6S" (Exhaust) 70" (intake) or 65 (exhaust) and 45 cutters to
"""
(d) Hand-lap the valve and valve seat with an abrasive
compound.
(e) After hand-lapping. clean the valve and valve seat.
60~~
~()O uC;;
""'"
8. INSPECT VALVE SPRINGS
Deviation
(a) 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.
~~~
(2)
~ ~Mar~
Mark 1 Mark 7 (51
{51
{51
(5)
P2Jl92
~~~ {41
. Valve Rocker Shah
,,,,,,
(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
ENGINE - ENGINE MECHANICAL
(b) Using SST and a hammer. tap in a new oil seal until its
surface is flush with the oil seal retainer edge.
SST 09223-46011
Ie) Apply MP grease to the oil seal lip.
1. INSTALL VALVES
(a) Using SST. push in a new oil seal.
SST 09201-41020
(e) Using SST. compress the valve spring and place the 2
keepers around the valve stem.
SST
SST 09202-70020 109202-00010)
.,,,,,
EG-57
ENGINE - ENGINE MECHANICAL
EG
--
ENGINE - ENGINE MECHANICAL
Turn ,,,,,,
3. INSTALL CYLINDER HEAD
A. Place cylinder head on cylinder block
la} 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.
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90 in the numerical
order shown.
(e) Retighten cylinder head bolts by an additional 90 .
(f) Check that the painted mark is now facing rearward.
(g) Connect the water bypass hose (from the injection
pump) to the cylinder head.
EG60
ENGINE - ENGINE MECHANICAL
Seal Width
2-3mm
(b)
surfaces.
Apply seal packing to the oil seal retainer as shown in
the illustration.
S' packing:
Pert No. 08826-00080 or .qulnlan'
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) 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. INSTALL PULLEYS AND TIMING BELT
(See .tep. 1 end 4 to lOin timing belt installation)
B. CHECK AND ADJUST VALVE CLEARANCE
(See steps 2 to 4 in valve cleafence inspection
and adjustment)
9. INSTALL SEMI- CIRCULAR PLUG
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi - circular plug as
shown in the illustration.
SI puking:
Part No. 08826-00080 or .quinlent
Ie) Install the semi-circular plug to the cylinder head.
CYLINDER BLOCK
COMPONENTS FOR PREPARATION AND
AFTER ASSEMBLY
--
" "," G)'.?'Ii G"kat
~
Water Inlet V'
Q.......... ~ Thermostat
"
... .........
~NO.1CYlinderBrOCk
~ Insulator
........ I l~
Alternator and Bracket ...... , I
Assembly ------
, :::::at~---,,-.Jrlll~'~~i~
.1>._";;~
Alternator
--- Oil Cooler +__ "-",-+-_W8ter Bypass
Assembly I
r Hose
,,'
, "
_~x8
Taper Screw
Plug
J.., ' -~'~. . , ( :"
.. ...... Oil Pressure Sender
"'~'-----'G. go
~ ,,
z..---ti,'1'1
t I
"':":-',
..... ......
""
, ,~'-~~~'
.- ~ .. u
1-<[\1/,,---1 .. .. :< "< .. ~ InjeclionPumpStay
x7~
~~
Q.
,
,
I
::" . ~
: : ~
.. < ~~;;- ..
... " lH Engine
, .. Mounting Bracket
Oil Pump r~--I
---+l-~~,-~
I! , .... ..:~~
Injection Pump ')J ~~
, AfT
Q-Ring _____ ~i
Flywheel
O;IP.n_",,(~~,~~'~i~
. , ,
i-x 27 Gl!ISket~
Drain Plug
Non-reusable part
* Preeeated part
EG-65
ENGINE - ENGINE MECHANICAL
Connecting Rod C a p - - - - - -
Oil N O l z \ e - - - - - -
0- . Crankshaft
Rear Oil
Seal
Check Valve ~
Crankshaft ------::~
!
Non-reusable part
EG-67
ENGINE - ENGINE MECHANICAL _ _M
, Number marked
Connecting rod
Crankshaft 1 2 3 , 2
2 3 1
3
2 3
Bearing 2 3 4 3 4 5 4 5 6
H
EXAMPLE: Connecting rod '"2 + Crankshaft H, H
:: Total number (Use bearing '"3
H
)
P211!103
1'227M
P23lJO
''''''
EG-69
ENGINE - ENGINE MECHANICAL
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.)
Mark "3" 62.026 82.032 mm (2.4420 - 2.4422 in.)
(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.
m Remove the 14 bolts (12 pointed head) and main
bearing cap. (See procedure (b) and (c) above)
EG-71
ENGINE - ENGINE MECHANICAL
, Number marked
Main bearing cap
Crankshaft , 2 3 , 2
2 3 1
3
2 3
Bearing 2 3 4 3 4 5 4 5 6
1'12170
f>1111l
PJ2772
Reference
Cylinder block main journal bore diameter:
Mlrk'l" 71.000 71.006 mm (2.7953 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.)
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) 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)
11">312
""'"
EG-73
ENGINE - ENGINE MECHANICAL
N
NO.6
4 NO.5
EG
o. ~.
ED 2 SV _ 1 Direction
diameter at positions A. Band C in the thrust and axial
Front .. GD Axial directions.
Direction Standard diamet.r:
STO
I~
'0mm Mark .,.
-A- (0.39 in.)
94.000 - 94.010 mm (3.7001 - 3.7012 in.)
- B _.
Mark -2-
-C~ l 10mm 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
""'''
2_ REMOVE PISTON RINGS
(a) Using a piston ring expander. remove the No.1. No.2
and oil rings.
(b) Remove the coil by hand.
HINT: Arrange the rings in correct order only.
Cylinder Block (b) Measure the cylinder bore diameter in the thrust di-
rections. (See step 4 in cylinder block inspection)
(c) 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.)
If the oil clearance is greater than maximum. replace
all the 6 pistons and rebore all the 6 cylinders. If
Piston necessary. replace the cylinder block.
HINT (Use new cylinder block): Use a piston with the
Mark
,..---::"...----,. 2 or 3 same number mark as the cylinder bore diameter
-....,.~ marked on the cylinder block.
Front
Mark
(Arrow)
''''''
No.1 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.)
If the clearance is greater than maximum. replace the
No.2 and Oil Ring 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.)
If the clearance is greater than maximum. replace the
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.
EG-77
ENGINE - ENGINE MECHANICAL
~=
piston pin as a set.
D. If necessary. raplace connecting rod bushing
BUShing""" (a) Using SST and a press, press out the bushing.
SST 09222-17010 (09222-05020, 09222-05040)
~2282&
fr
P228Y.>
SST
-
I
L----
Zl~
(b) Using a round file. lightly file off any roughness from
the small end of the connecting rod.
EG-79
ENGINE - ENGINE MECHANICAL
(c) Attach the bushing to SST with the ball of SST inside
~o;IHOle
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 connect-
ing rod.
-oliHOle
Oil Hole
"""
(e) Using SST and a press. press in the bushing.
SST 09222- I 701 0 (09222-05020. 09222-05030.
SST 09222-05040)
~
Bushing
SST
B--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.
--
ENGINE - ENGINE MECHANICAL
CYLINDER BORING
HINT:
Bore all the 6 cylinders to the oversized piston
outside diameter.
Replace all the piston rings with ones to match
the oversized pistons.
EG 1. KEEP OVERSIZED PISTDNS
Over.ized piston diametar:
O/S 0.50
94.345 - 94.375 mm (3.7U4 - 3.7155 in.)
Sized Mark
Front Mark 2. CALCULATE AMOUNT TO BORE CYLINDERS
(Arrow)
(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.
(b) Calculate the amount each cylinder is to be raborad as
follows:
39.06 mm 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
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 round-
n
-
EG-S1
ENGINE - ENGINE MECHANICAL
\.-_SST
Front Mark
(Protrusion)
~
\"
\'-'
~
(8) Install a new snap ring on the other side of the piston
pin hole.
HINT: Face the end gap of the oil ring in the opposite
direction of coil joint.
(0) Using a piston ring expander. install the No.1 and No.
2 piston rings with the code mark facing upward.
Code Code mark:
Mark
No.1
T1
Code No.2
Mark
2T
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.
EG
-
. . . .- $eal packing:
Part No. 08826-00080 or equivalent
0: b Install a nozzle that has been cut to a 4 - 5 mm
. . . .
0 0 0 0 0 0
(0.16 - 0.20 in.) opening .
Parts must be assembled within 5 minutes of
Seal Width 4 - 5 mm "-" application. Otherwise the material must be re-
moved and reapplied.
""" Immediately remove nozzle from the tube and
reinstall cap.
(e) Install a new cylinder block hole gasket.
(d) Place the main bearing cap on the cylinder block.
B. 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
ENGINE - ENGINE MECHANICAL
(e) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts 90 in the nu-
merical order shown above.
(9) Check that the painted mark is now at a 90 angle to
the front.
(f) Check that the crankshaft turns smoothly.
o=sr ~O
S..I 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.
HINT: Avoid applying an excessive amount to the
surface.
Parts must be assembled within 5 minutes of
application. Otherwise the material must be re
moved and reapplied.
Immediately remove nozzle from the tube and
reinstall
(c) Install the retainer with the 6 bolts.
Torque: 6.4 Nm (65 kgfcm. 57 In.. lbfl
EG88
ENGINE - ENGINE MECHANICAL
POST ASSEMBLY
--.
1. INSTALL ENGINE MOUNTING 8RACKETS
Torque: 68.6 Nm (700 kgfcm. 51 tt.lbf)
2. INSTALL TURBO OIL HOSE
3. INSTALL OIL PRESSURE SENDER GAUGE
(See oil pressure check in Lubrication System)
:EG 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:
INSTALL FLYWHEEL
(a) Install the flywheel on the crankshaft.
(b) 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
ENGINE - ENGINE MECHANICAL
SERVICE DATA
Compression at 250 rpm STo 3.432 kP. (35.0 k.,f/cm', 498 psi) or more
pressure Minimum 2.452 kPa (25.0 kgf/cm', 358 psil
Diflerence of prlluur. between .ach cylinder 490 kP. (5.0 kgf/cm", 71 psi) or Iiss
V.rve et cold Intake 0.17 - 0.23 mm (0.007 0.009 in.)
cle.rance Exhaust 0.47 - 0.53 rnm (0.019 - 0.021 in.) EG
Injection Plunger stroke Europe 1.52 - 1.58 mm (0.0598 - 0.0622 in.)
timing Austr'''. 1.37 - 1.43 mm (0.0539 - 0.0563 in.)
Idl, splIed MfT 700 50 rpm
AfT 800 50 rpm
Maximum - 4.400 100 rpm
sp. .d
V,lvilcont'd) Stem oil elr.nc. STO lnl.k, 0.025 - 0.060 mm (0.0010 - 0.002" in.)
ExheUit 0.035 - 0.070 mm (0.0014 - 0.0028 in.)
M.ximum mt.k, 0.08 mm (0.0031 in.1
Pi.ton Ind Piston ring end glp STO No.1 0.270 0.470 mm (0.0106 - 0.0185 in.)
pi.ton ring No.2 0.400 - 0.650 mm (0.0157 - 0.0256 in.)
(cont'd) O' 0.200 - 0.500 mm (0.0079 - 0.0197 in.)
Muimum No.1 0.85 mm {0.0335 in.}
No.2 0.90 mm (0.0354 in.)
O' 0.88 mm (0.0346 in.)
Connec:ting STO 0.100 - 0.200 mm (0.0039 - 0.0079 in.)
Mlximum 0.30 mm (0.0118 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 (O.COl IS - 0.0030 in.)
Mlximum 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 0.004 - 0.012 mm (0.0002 - 0.0005 in)
Maximum 0.03 mm (0.0012 in.)
Connecting rod bolt ten.ion portion diemeter STO 8.300 - 8.400 mm (0.3268 - 0.3307 in.)
Minimum 7.95 mm (0.3130 in.)
Crlnklhlft Thrust crelrlnce STO 0.040 0.240 mm (0.00'" - 0.0094 in.)
Mlllimum 0.30 mm {0.0118 in.}
Thru.t wI.her thickne.. 2.930 - 2.980 mm (0.1154 - 0.1173 in.)
Mlin journll oil clllrince 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 0.10 10m (0.0039 in.)
Main journll diameter 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 1.991 - 1.994 mm (0.0784 - 0.0785 in.)
Crlnk pin dilmeter 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-92
TORQUE SPECIFICATION
ENGINE - ENGINE MECHANICAL
--..
Pert tightened Nm kgfem fHbf
Injection pump x Timing gler c 18 185 13
Injection pump x Injection pump allY 58 700 51
Plug boll x Distributive he.d plug on injection pump 25.5 '80
Injection pipe x Injection pump 24.5 250
"
'8
No.1 camshaft timing pulley I Camlhett 98 1.coo 72
EG No.2 clmlheft timing pulley x Injection pump drive ge.r 3' 315 '3
Idler pulley x Timing gl.r cover 34.5 350 25
Timing belt len,iO"lr II Timing gill' cover '3 130 10
Injection pump drive ge" x Injection pump 98 1,000 72
Idler g r x Cylinder block 88 89. 50
Timing g.er COVlr, O~ pip. x Timing gllr CISI 19.8 '00
Vacuum pump x Timing ge.r cover 39 400
"
'9
O~ pipe x Vacuum pump, Cylinder block 18 185 13
Crank,heft pulley x Crlnksh,ft .30 4.400 317
Cylinder head x Cylinder block ,,, 68.6 700 51
Tum 90 Tum 90 Turn 90
'"'
3.' Tum 90 Tum 90 Turn 90
Camsh.ft bearing Clp x Cylinder h. .d '5 250 18
Camahelt oft I'" retainer It Cylinder Med 19.8 '00
Cylinder hlld cover It Cylinder held 8A 85
"
57 in..lbf
Rear engine hlnger It Cylinder held 39.2 400 '9
Water outlet
Intake manifold
It Cylinder head
It Cylindlr heed
19.6
19.6
'DO
'DO ,."
Intlke pipe It Inlake manifokl 19.8 '00
EGR v.lve Idapter Exhault mlnifold 40 400
"
It '8
EGR vllve bracklt It EGR v.lve dapter, Cylinder Mid (wI EGR 'Vltem) '0 '00 15
Intake pipe I,.take hl.tlr (w/o EGR IYltlm) 7.5 75 88 in.lbf
It
Main billing cap It Cylinder block 12 pointed hlad ,,, 103 1,050 78
Turn 90 Turn 90
'"'
8 pointed head 18.1 185
Turn 90'
13
Connecting rod cap It Connecting rod ,,, 38.8 375 27
Rear oil ...1retainer It Cylinder block, Mlin bI.ri"il c.p '"' Tum 90
8.'
Tum 90
85
Turn 90
57 in.lbf
E"iIine mounting bracket It Cylinder bloc:k 88.8 700 5'
Injection pump llay It Cylindlr block 89 700 51
Altarn.tor bt.ckat It Cylinder block 68.6 700 5'
Aeet and pl.1I It Cylinder block 18.1 185 13
Flywheel (MfTl. Drive pllte (AfT) II Cr.nksh.ft 127.4 1,300 9.
EG-93
ENGINE - TURBOCHARGER SYSTEM
TURBOCHARGER SYSTEM
PREPARATION
_ _K
EOUIPMENT
Dial indicator Impeller wheel
Torque wrench
EG-94
ENGINE - TURBOCHARGER SYSTEM
PRECAUTION
1. 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.
2. Avoid sudden acceleration or ,acing immediately
EG after starting 8 cold engine.
3. 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.
4. If the turbocharger is found to be defective and
must be replaced. check for the cause, and repair or
replace these items 8S necessary:
Engine oil level and quality
Conditions under which the turboch8rger was used
Oil lin Iding to the turbochargar
-
EG-95
ENGINE - TURBOCHARGER SYSTEM
TROUBLESHOOTING
HINT: Before troubleshooting the turbocharger. first check the engine itself. (Valve c1ear~c:.
engine compression. ignition timing etc.)
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
ABNORMAL NOISE
(Possible Caus.) (Check Procedure and COffeetion Methodl
1. TURBOCHARGING HEAT INSULATOR Check for loose. improperlv installed or dedormed
I- insulator mount bolts, and repair or replace as
RESONANCE
necessary.
EG 2. EXHAUST PIPE LEAKING OR I- Check for deformed exhaust pipe, loose mount
VIBRATING bolts or damaged gasket. and repair or replace 85
necessery.
TURBOCHARGER
ON - VEHICLE INSPECTION
.....-.
1. INSPECT INTAKE AIR SYSTEM
Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the tur-
bocharger outlet and cylinder head.
Clogged air cleaner .... Clean or replace element
Hoses collapsed or deformed Repair or replace
Leakage from connections Check each con-
nection and repair
Cracks in components .... Check and replace
2. INSPECT EXHAUST SYSTEM
Check for leakage or clogging between the cylinder
head and turbocharger inlet and between the turboch-
arger 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
wI EGR System 3. CHECK TURBOCHARGING PRESSURE
(a) Warm up engine.
(b) Using a 3 -way connector. connect SST (turbochar-
ger pressure gauge) to the hose between the vacuum
pipe and intake pipe.
SST 09992-00241
(c) Press in the clutch pedal. then press the accelerator
pedal down as far as it will go. Measure the turbochar-
ging pressure at maximum speed (4.400 rpm).
Standard preure:
w/o EGR System 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 assem-
bly.
If the pressure is above specification, check if the
actuator hose is disconnected or cracked. If not. re-
place the turbocharger assembly.
EG-98
--
ENGINE TUR80CHARGER SYSTEM
., ' ,
~
~~":.,,.. b .
Gasket wI EGR System
Intake Pipe Assembly.
~' ,
0,.
I' ~. ,~ ,'" <
,,
Engine Vacuum Hose
Ground 0
Strap ,
0,
Clamp
Non-reusable part
EG-99
ENGINE - TURBOCHARGER SYSTEM
TURBOCHARGER REMOVAL
--.
1. DRAIN ENGINE COOLANT
2. REMOVE INTAKE PIPE
(See step 2 or 3 in cylinder head removal in
Engine Mechanical)
3. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
Remove the 4 bolts and heat insulator. EG
4. REMOVE TURBOCHARGER HEAT INSULATOR
Remove the 2 bolts and heat insulator.
5. DISCONNECT WATER BY PASS HOSES FROM
NO.1 TURBO WATER PIPE
EG
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.
"""
EG-l0l
ENGINE - TURBOCHARGER SYSTEM
Dial Indicator
Spacer Bearing
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
ENGINE - TURBOCHARGER SYSTEM
EG
(d) Install 2 new gaskets and the union bolt of the turbo
oil pipe.
~
.) Torque: 24.5 Nm (250 kgt-em. 18 f1-lbf)
(e) Connect the turbo oil hose to the cylinder block.
0'
5. INSTALL TURBOCHARGER STAY
U Torque: 117.7 Nm (1200 kgt'em, 87 ftlb')
EG-l03
ENGINE - TURBOCHARGER SYSTEM
SERVICE SPECIFICATIONS
SERVICE DATA
Turbocharger Turbocharging pressure 38.6 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 Nm kgfcm ftlbl
No.1 turbo wllter pipe, Turbocharger he8t insuletor II: Turbocharger 7.8 80 69 in.fbl
Turbocharger x Exhaust manifold 52 530 38
Turbo oil pipe x Turbocharger 18.1 185 13
Elthaust manifold It Cylinder head 41.7 425 31
Turbo oil pipe It Cylinder block 24.5 250 18
Turbocharger stay It Turbochafgar, Cylinder block 117.7 1200 87
Turbine outlet albow x Turbochargar 52 530 38
Exhaust manifold haat insulator x Exhaust manifold 18.1 185 13
EG'04
ENGINE - FUEL SYSTEM
FUEL SYSTEM
PREPARATION
~~~~
o s-
.... -.- ...
(09237-00070) Shalt -C' Gov.mot ....... plug
ce-;?
09241-76022 Injection Pump Stend Sel
!~l~
09245-54010 Injeetion Pump Sttnd Arm
q)
09260-54012 Injection Pump Tool Sel
~e-=-
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
0 Wrench
-... ..
(09262 -54020) Regul.tor V.Iv. Wrench
elD
09268-17010 2 Spring Nonl. Tool .tt
@3 IiI 6 ,
EG'05
ENGINE - FUEL SYSTEM
~
(09952-05010) Slid, Arm Injection pump
[@ @J
(09953-05020) Center Bolt 150 Injection pump
~
(09954-05030) Ct.w No.3 Inj.Ktion pump
~
09992-00241 Turbochafllef Pressure G.ugtl
9~o
""C_CI
RECOMMENDED TOOLS
09082-00050 TOYOTA EI.ctriul Tn"r SeL
'~~-'
~-~
EQUIPMEMT
Angle gauge
Brass brush
EG Graduated cylinder
Micrometer
Steel square
TorClue wrench
Vernier calipers
Wooden stick
EG-107
ENGINE - FUEL SYSTEM
FUEL FILTER
1. DISCONNECT FUEL FILTER WARNING SWITCH--
CONNECTOR
2. DRAIN FUEL FROM FUEL FILTER
(a) Install a vinyl hose to the drain cock. and insert the
other end of the vinyl hose in a container.
(b) Loosen the drain plug, and drain the fuel.
SST
-- D. Inlten new
(a)
fuel filter
Check and clean the fuel filter installation surface.
(b) Apply fuel to the gasket of a new fuel filter.
(c) Lightly screw the fuel filter into place. and tighten it
until the gasket comes into contact with the seat.
(d) Tighten it additional 3/4 turn by hand.
o lofI--l-.
o
0.5 - 2.0 Q
10.24
port.
1.57 in.Hg) or more to the vacuum switch
~'~
If continuity is not as specified. replace the relay.
Ohmmeter
4 "....,
4 3
EG"O ENGINE - FUEL SYSTEM
INJECTION NOZZLE
COMPONENTS FOR REMOVAL AND
--.
INSTALLATION
~
Intake C---EGR Valve
Pipe ~~... Bracket
~>
Intake
Heater
\ ~_-. \
, p-----@'::---",---+Gasket
Vacuum-+-~~ .' l!.},
Hose
-:::_1
~"------Intake Pipe
Assembly
-----+ Gasket
Injection Nozzle
Gasket
,,
,
..... 1fP
...' . ' I
Throttle Position Sensor Connector
Non-reusable part (Except Australia MIT)
-
ENGINE - FUEL SYSTEM
----"'." sembly.
-
5. REMOVE INJECTION PIPES
(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.
(c) Remove the 2 nuts and 2 clamps.
EG
_-0
INJECTION NOZZLES TEST
1. 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
Good Faulty hole or around the retaining nut.
If the nozzle drips within 10 seconds. replace or clean
"'". and overhaul the nozzle assembly.
2. SPRAY PATTERN TEST
(a) The injection nozzle should shudder at a certain pum-
ping speed between 15 - 60 times (old nozzle) or 30
- 60 times (new nozzle) per minute.
(b) Check the spray pattern during shuddering.
If the spray pattern is not correct during shuddering,
the nozzle must be replaced or cleaned.
Good Faulty Faulty Faulty
EG-113
ENGINE - FUEL SYSTEM
.~-
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
No 2 Pressure Spring
. htp'i n " , " " - "I
Stralg
Nozzle Assembly
Nozzle Holder
hie
Y
Nozzle Body
TIp
I
b , NO.2 P,mu" __
-
Spring Seat ....
Retaining Nut
-
i
(
(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.
(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
--
ENGINE - FUEL SYSTEM
"""
(e) Using SST. set the SST above the nozzle. and measure
dimension A.
SST 09268-1701 0
Dimenlion L 1 = t - A
(f) Remove the SST and needle tip from the nozzle body.
tj--SST
SST 09268-17020
@-SST
Dimension L1
I l-----roimensicn A
- SST
PU31t
pune
Zl53'l1
EG-116
ENGINE - FUEL SYSTEM
(9) Place the tip packing and straight pins on the nozzle
body as shown in the illustration.
~~ Upward NOTICE: POlitlon the tip packing on top of the nozzle
S1J
"-- I LLLJ
Oowow"d
body in the direction shown In the illustration.
-SST
EG
"""
(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
(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
m Using a micrometer. measure dimension L3 of the
adjusting shim.
tF.?>i'.r~ ~
)l.8>-.~
Needle-lift = (11 + l2) - L3
Needle-lift: 0.23 - 0.28 mm (0.0091 - 0.0110 in.)
If the needle - lift dimension is not as specified.
change the adjusting shim.
Adjusting shim thickness mm (In.):
(b) 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
l,,/--SST
IT SST
EG'
SST
P23319
P2332J
-l
~mension
OO~~
"""
(dl Using a micrometer. measure dimension E and F of
Dimension E Dimension F
the NO.2 pressure spring seat.
~~; Dimension l5 = E - F
Pre-lift = L4 - L5
J,':t~~;;;:; T Dimension 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.):
(e) Pump the tester handle slowly and observe the pres-
sure gauge.
(f) 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
ENGINE - FUEL SYSTEM
- .
fi
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.
'.
Faulty Good
(9)
(h)
There should be no dripping after injection.
After checking the No.2 opening pressure, disassem-
ble the nozzle.
3. ADJUST NO.1 OPENING PRESSURE
(aJ 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 pres-
sure 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 adjust-
ing shim is not known. use a shim 1.5 mm (0.59
in.) thick instead.
(b) 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. disassem-
ble the nozzle and change the adjusting shim on the
top of the No.1 pressure spring.
EG-120
ENGINE - FUEL SYSTEM
Adjusting shim thickn mm (in.):
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
EG 2.175 (0.0856) -
HINT:
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.
(c) There should be no dripping after injection.
(See step (g) in step 2 above)
\\ :--- --
- '"""
(c)
(d)
Install the injection nozzles with the nozzle holder
clamp. washer and bolt to the cylinder head.
Torque: 25 Nm (255 kgfcm. '8 ft.lbf)
Inspect the valve clearance.
(See steps 2 to 4 in valve clearance inspection and
adjustment)
2. INSTALL NOZZLE HOLDER SEALS
Install the e new nozzle holder seals to the cylinder
head with your hand.
EG
INJECTION PUMP
COMPONENTS FOR REMOVAL AND --
INSTALLATION
No.2 Flange
liming Belt CO\ler--,\
. \ - - - Timing Belt
Seal Washer---c=,.\
Clamp --"<;l)I~
. ~-==--Gasket
Vacuum Hose
Non-reusable part
EG-123
ENGINE - FUEL SYSTEM
Injection Pipe-----------:-~;:?~
clamp--j'~-~~'?~
,,,
~-I
"'~clampr
............ : Accelerator link
.... I Assembly
, ,I ~
,r
No.3 Nozzle leakage Pipe---;,----i------::':::liidt\, :
,, ,
I ... _ - -
I r -I
I I I ,
1 I I " I
:: ~r-
"f I '
I (II,. II I I . -:-..;-'..;-_
I
Clamp
Clamp
II
II 11K'
III
~t'
L~2:~ J
1
I __
1
:I
I I ... -t ., I
I I .-U 1 I I 'J-- '
I 1 1!'t--... llt-, ,
n~--,.-l I t I -,.::-; I I I t
I :~.J'" I~ III :
q~[5\~.
Throttle Position Sensor
! Connector
(Except Australia MIT)
)#~;j ~ : .. ;
,,;:::>-
:
I
J
1
J ,
V J
SICS Vacuum
D-Ring
,-- -- Hose
w/BACS
_:::::~BACS Vacuum Hose
No.1 Cylinder Block
----~~- \f
Insulator
-~ -""'i,l~~1I --
~6Il
-- Water Bypass Hose
P13:l8<1
"''''
7. REMOVE INJECTION PUMP
(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.
."".
EG-125
ENGINE - FUEL SYSTEM
Spring seat
Dlaphragm--,
Throttle Posltlon SenIOr
Spring 5081--, (Except Australia MIT)
Adjusting
Lever ~ .10 BACS
lever Retum'---
Spring
-j......
~
Q Rubber Cap
" ,
~'" """Rod~. ;, ~
Boost Compensator
::.7SICSLeverTI',j
I "'...
t "
"
,
,'"
I
"... "I
I
~~..screw
~ ... ..
...... '" /
...~'"
:?;Jlod<- Maximum Speed
Adjusting SCrew
, ,
I
"
: Govemot~er
"",
"
1 Q.
- :: ,
Gasket
"~
I
.. :
I l ~ Bushing
<~
I .J
~~CoII"
~. ~ ... -::~.~k81/~
J F~lload
SetScrew
.J
~:il
ConnectingPIn~"''''_;'
~"'''''-1'
l ~'O)
... ...
. . . .,'I
...
L/t-~,
I" . . . . " ' ,. . . . . . '"
~~'
I
" -'
- ;- - ::
~
::;~
..._-,
: c/-
1,....--
c.. ...
I
.o-~..
~ cap
AI
-~
----."'-
1dIe_
_,",Sc,_
L_Control I'" ..., I ..., ......
<:_Inn ',I ...... I I " '.....- +Gasltet
" .....:
: " .. j'
-'f
I
I
:
'I /' <,
,
/ __
w "'... _
Fuel Inlet ' ...." Idle-Up
Hollow Screw "'"'~ Idle-Up Leve~ctuator
+ Gasket
-
EG-' 27
ENGINE - FUEL SYSTEM
Timer Shim
LH rmer Covel'
EG-128
ENGINE - FUEL SYSTEM
5 mm Hexagon Wrench
r-: :-: .
5 mm Hexagon Wrench
.",n
EG-129
ENGINE - FUEL SYSTEM
5mm
Hexagon
Wrench
EG-131
ENGINE - FUEL SYSTEM
W:618
Australia
-- (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.
FU2~2
215519
5mm
Hexagon
Wrench
EG-132
ENGINE - FUEL SYSTEM
4mm
He)lagon
Wrench
M,.
(bl Using a small screwdriver. push out the support pin
and remove the control lever.
EG133
ENGINE - FUEL SYSTEM
FU2811 ~ ""~
EG134
ENGINE - FUEL SYSTEM
A~
(3) 4 flyweights
~
(3) (2)
EG
'- """
19. REMOVE INJECTION PUMP STAY AND FUEL PIPE
BRACKET
(a) Using a 5 mm hexagon wrench. remove the 4 bolts
5mm
Hexagon and injection pump stay.
Wrench (b) Remove the bolt and fuel pipe bracket.
"""1
Shim_
Pllll86 ",m
(3)
(4)
SST
Upper plunger plate
Lower plunger plate
09260-54012 (09269-54030)
NOTICE: Do not touch the sliding lurfac of the pump
11q]
plunger with your hand.
23. REMOVE GOVERNOR LINK
Using SST. remove the 2 support bolts. gaskets and
SST governor link.
SST 09260-54012 (09269-54040)
P121'lEl
EG136
ENGINE - FUEL SYSTEM
(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,..
'EG
(1) Remove the drive gear and 2 joint rubbers from the
Joint Rubber
drive shaft assembly.
5mm
Hexagon
Wrench
EG-137
ENGINE - FUEL SYSTEM
~~c<' ( ~ assembly
(~~~ to 1\1
19)
(2) O-ring
Il} 13} (3) Shim
~ 9~"fJ..~ ~3 17116)
(4) Outer spring
(5) Inner spring
I (4) (8) (6) AH timer cover
(2)
mm (71 O-ring
(8) Piston
(9) Sub-piston
(c) Remove the nut from the LH timer cover.
(d) Using a 5 mm hexagon wrench. remove the timer
adjusting screw.
(e) Remove the O-ring from the timer adjusting ring.
Plum
~
(b) Using a piece of wire. remove the feed pump cover.
(e) Remove the feed pump rotor, 4 blades and liner.
o NOTICE:
@
Be careful not to interchange the blade positions.
B. careful not to damage the pump body.
~ r:t
28. REMOVE REGULATOR VALVE
~
Using SST. remove the regulator valve and 2 O-rings.
SST 09260-54012 (09262-54020)
SST
~
DISTRIBUTIVE HEAD
(0) Tilt the spill ring (distributive head) slightly and pull
out the plunger.
, (b) When released. the plunger should sink down smooth-
ly into the spill ring (distributive head) by its own
weight.
(e) Rotate the plunger and repeat the test at various
"",m positions.
If the plunger sticks at any position. replace the parts
as a set.
(d) Insert the governor link ball pin into the spill ring and
check that it moves smoothly without any play.
....
EG-139
ENGINE - FUEL SYSTEM
~
. ~-
~ the battery power is connected and disconnected .
3;--<;
V 1
If the solenoid valve is not operating properly. replace
it.
(f) e
Battery
",,,.
7. INSPECT PICKUP SENSOR
Using an ohmmeter. measure the resistance between
the terminals.
Riat.nc.:
860 - 970 Q
If resistance is not as specified. replace the sensor.
,
"''''
8. IF NECESSARY, REPLACE OIL SEAL
(a) Using a wrench. pry out the oil seal.
NOTICE: B. c.r.ful not to d.m.g. to th. pump body.
EG-140
ENGINE - FUEL SYSTEM
er
(b) Check that the liner and blades are facing in the
w~.o~b
correct direction. as shown.
Q (c) Check that the blades move smoothly.
(d) Align the fuel outlet holes of the cover and liner.
, 0 0
If -I (e) Install the pump cover with the 2 screws.
II ' -I
..., Torque: 3.0 Nm (31 kgfem, 27 in.lbf)
) -~,)
(f)
o@
~/. ~
~~~""'''
EG-141
ENGINE - FUEL SYSTEM
1~~
~ Drive Shaft Assembly
EG
""ro
(e) Position the key groove of the feed pump rotor
upward.
Drive Shaft (d) Install the drive shaft washer and set key on the drive
Washer shaft and insert the drive shaft assembly into the
pump housing.
Sel Key
o .. ~
"--===:.--C/ ~
(e) Install the stopper pin and clip.
l~1f
(3) Inner spring
(4) Outer spring
(5) Shim
(6) New O-ring
(6) (4)
(7) LH timer cover, timer adjusting screw and nut
assembly
EG-143
ENGINE - FUEL SYSTEM
5 mm
Hexagon
Wrench
"""
9. ADJUST PLUNGER SPRING SHIM
C61~o .
C41 -.._=.._-
5)
(al Install these parts to the distributive head:
(1) 2 plunger spring guides
0 0
[C31
@-C 21-@
-1 (2)
(3)
(4)
2 upper spring seats
2 plunger springs
Lower spring seat
J1- C11
-a (5)
(6)
(7)
Upper plunger plate
Lower plunger plate
Pump plunger
""'~
HINT: Do not assemble the plunger spring shims at
this time.
(b) Using vernier calipers. measure clearance A indicated
in the illustration.
(c) Determine the plunger spring shim size by using these
formula and chart.
New plunger spring shim thickness = 7.0 - A
A ... Measured plunger position
EG-144
ENGINE - FUEL SYSTEM
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.
",.ro
(e) Align the pin groove of the plunger with the pin of the
face camplate.
(d) Align the ball pin of the governor link with the pin hole
of the spill ring.
(e) Using SST. install the pump plunger and 2 plunger
springs.
SST 09260-54012 (09269-540301
f{~
(2) NO.2 flyweight washer
(3) Governor sleeve
~
HINT: Replace the 4 flyweights as a set.
G
~U2825
""'~
(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
5mm adjusting washer. No.1 flyweight washer and fly
(1)
HeXagOn~ weight holder assembly.
Wrench
t.-"'"<-, (e) Using a 5 mm hexagon wrench. turn the governor
""'" shaft counterclockwise.
16. CHECK FLYWEIGHT HOLDER THRUST
CLEARANCE
Using a thickness gauge. measure the thrust clear-
ance 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.) 1.45 mm (0.0571 in.l
1.65 mm (0.0650 in.l 1.85 mm (0.0728 in.)
", ..
EG-147
ENGINE - FUEL SYSTEM
1'23523
4 mm
Hexagon
Wrench
EG148
ENGINE - FUEL SYSTEM
(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.
115519
5mm
Hexagon
Wrench
(9) Install the idle speed adjusting screw and lock nut.
Torque: 6.9 Nm (70 kgfcm. 61 in..lbfl
EG-149
ENGINE - FUEL SYSTEM
""'"
23. ADJUST PLUNGER PRE - STROKE
(e) Using SST. install SST to the fuel cut solenoid installa-
tion screw section.
Air SST 09275-17010
(b) Set the dial indicator so that the tip of the dial indica-
EG
riltWf
If-- t~
~ .. ~ (P)J)
If dimension B is not within the specification. replace
the distributor head.
mo,
I f--t-{1l
FU3034
FU27JS
81200
FU2843
ZI'io'l17
EG-152
ENGINE - FUEL SYSTEM
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
Torque: 8.35 Nm (85 kgfcm. 74 in.lbf)
"""
(e) Connect an air hose to the fuel inlet pipe and place the
injection pump into diesel fuel.
49 kPa - 490 kPa (d) Apply 49 kPa (0.5 kgf/cm'. 7 psi) of pressure and
confirm that there are no leaks.
(e) 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
~,
..- _ .
DN12SD12 (NIPPONOENSO)
Test nozzle opening pressure:
14.220 - 15.200 kPa
(145 - 155 kgf/cm', 2,062 - 2.205 psi)
(b) Check the accuracy of the tachometer.
Allowable error:
40 rpm
(c) Install the angle gauge stand.
(d) Mount the injection pump body on the pump tester.
HINT: Place a mark on the key groove portion of the
coupling.
NOTICE:To prevent vibration or dislocation of the injec-
tion 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
ENGINE - FUEL SYSTEM
""'"
(i) Using a 5 mm hexagon wrench. remove the 2 bolts
Timer and RH timer cover.
Measuring
Device OJ Install the inner pressure gauge with the timer meas-
uring device.
Part No. 95095-10231 and 95095-10480
Air Bleed (NIPPONOENSO)
Screw
HINT: Bleed the air by the air bleed screw.
(k) Connect SST (turbocharger pressure gauge) to the
boost compensator.
""" SST 09992-00241
NOlzle
"""
EG-156
ENGINE - FUEL SYSTEM
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.
'l1528'l
EG-' 57
ENGINE - FUEL SYSTEM
f -s-
(r) Measure the injection volume.
Pump No. of mtlBluring Each injection volume
\~_l m:Q;-~
'Pm stroke. cc (cu in.)
~II_-
14.92 16.52
1.080 200
(0.91 - LOll
IT' FU1716
(5) Race the injection pump for 5 minutes at 1.200 rpm.
NOTICE: Check that there i, no tuelle.keg. or abnormal
HINT:
30 Seconds Measure the volume of each injection cylinder
with a measuring cylinder.
Before measuring the injection volume. first hold
the cylinder tilted for at least 30 seconds to
discard all the fuel.
2. PRE-SET FULL LOAD INJECTION VOLUME
(a) Set the adjusting lever to maximum position.
fU0636 FU2709 lOOl12 (b) Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hg) of vacuum
to the SICS actuator.
(e) w/o BACS:
Apply 79 kPa (0.81 kgfjcm', 11.5 psi) of pressure to
the boost compensator.
(d) wi BACS:
Apply 121.9 kPa (1.24 kgfjcm 2 , 17.7 psi) of pressure
to the boost compensator.
(e) Measure the injection volume.
Pump No. of menuring Each injection yolume
,pm strokes cc Icu in.)
14.92 16.52
1,080 200
(0.91 - 1.01)
3. w/o BACS:
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.)
4. PRE - SET MAXIMUM SPEED
5 mm Hexagon
Wrench (a) Set the adjusting lever to maximum position.
fU2981 FU0242
zml19 (bl Apply 67.2 kPa (503.7 mmHg. 19.83 in.Hg) of vacuum
to the SICS actuator.
(e) w/o BACS:
Apply 79 kPa (0.81 kgf/cm'. 11.5 psi) of pressure to
the boost compensator.
(d) wi BACS:
Apply 121.9 kPa (1.24 kgf/cm',17.7 psi) of pressure
to the boost compensator.
(e) Measure the injection volume.
Pump No. of measuring Eeeh injection yolume
.troke. ce leu in.)
"""
2.200 200 4.0-6.0 (0.24 0.37)
Maximum Speed Adjusting Screw
(f) Remove the lock plate.
(g) Adjust the injection volume with the maximum speed
adjusting screw.
FU0244 flJ024S
6. ADJUST TIMER
(a) Set the timer measuring device at zero.
(b) Measure the timer piston stroke at the below listed
rpm.
Ilem Pump.pm Piston strokes mm lin.)
1.080 0.63 - 1.6310.025 - 0.064)
1.440 3,24 - 4,2410. 128 - 0.167)
w/o BACS
1,800 5.85 - 8.8510.230 - 0.2701
2.000 7.7 - 8.7 (0.303 - 0.3431
~,.
1,080 0.22 - 1.22 (0.009 - 0.0481
1.440 2.83 - 3.83 (0." 1 - O. 1511
wI BACS
1.800 5.44 - 6.44 (0.214 - 0.2541
2.000 7.7 - 8.7 (0.303 - 0.343)
- --<~:::::'f-- Wrench
Hel(agon (c) Using a 5 mm hexagon wrench. adjust by turning the
timer adjusting screw.
EG-160
ENGINE - FUEL SYSTEM
,/\
Long Spring-+I
,
~
e ,,
~
c ,, , , ,
, ,, ,
Short Spring
~
;;:
"
EG Pump rpm
FU3102
"p"
If tendency is not as specified. select and replace the
~!
~ ~'OO"
Innef spring.
Time' spring fr.e length:
'P';"' 34.4 mm (1.35 in.)
~~ 34.0 mm (1.34 in.)
@O 33.6 mm (1.32 in.)
~"
HINT: The timer stroke wllJ increase with a long spring
and decrease with a short spring.
" PI2'>I'l
~
="
Remove the E- ring and following parts from the
It,,)
r S l e e v e Plug sleeve plug:
(1) Stop ring
(2) Bearing and 2 bearing retainers
@--m
@-----E-Ring
EG-163
ENGINE - FUEL SYSTEM
w/o BACS:
5mm
Hexagon
---fr=~ Pump No. of melluring Each injection volume
.pm strokll cc (cu in.)
Wrench
~~'\:::::;_
d-
Timer
Slide Pin 8.02 - 9.22
720 200
(0.49 - 0.58)
w/o BACS:
Pump No. of m...uring Each injection volume
,pm strokes cc (cu in.)
12.70 14.30
720 200
(0.17 - 0.87)
IL
'0' -np~u=m=p~,=p=m:-----'--
e~-f-
a
Apply 41.2 kPa (0.42 kgf/cm 2 , 6.0 psi) of pressure to
the boost compensator.
(d) Measure the injection volume.
wi BACS:
Pump No. of mfIBiuriog beh injection volume
'Pm strokls ee leu in.)
E d
, 720 200
8.02 - 9.22
-0 '--l'b,,-/ 10.49 - 0.56)
>,
.9 '-- _
w/o BACS:
~ Boost Pressure-
'2 fal "'<11"" lultlM<I ,,,,,.;1_
~.~
Pump No. of mllsuring rleh injection volume
II>J Adl",'lu~ _ ..........".,
"'1'_ """'_
(cl ........'c""'''.. ''''!1~
'pm strokes ee leu in.)
-~
(dl""'''''_c_ _ 8.80 10.00
720
.....
11011
1.1 c........."''''
AdI
_OCOfr"llOC'_"""
", 200
(0.5.4 - 0.611
EG-165
ENGINE - FUEL SYSTEM
"""
(i) Using a 5 mm hexagon wrench. adjust the load sens-
5mm ing timer by turning the governor shaft. and do the
Hexagon
Wrench 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
Pump No. of mesuring Injection volume of each cylinder Timer piston stroke
Item cc leu in.) mmlin.1
'pm strokes
Measured value at step If) minus 1.56 2.56
w/BACS ',440 200 3.8 (0.231 1.0 (0.06) (0.061 - 0.1011
Me8Sured value a1 step 10 minus '.29 2.29
w/o BACS ',440 200 3.810.231 1.0 (0.061 (0.051 - 0.090)
wlo BACS:
Pump rpm Timer pillon Itrokl mm (in.)
1M. 1.45 - 2.45 (0.057 0.096J
EG
AOO"
Europe
Full position 400
200
7.86 - 10.6610.48 - 0.65) -
Minus 12 - 22 0
350 q 0.70 1.10 (0.04 - 0.07) 0.51O.03} Adjust
Australia Full position 400
200
7.86 - 10.66 (0.48 - 0.65) -
MIT Minus 12 ,," 350 q .. 0.70 - 1.10 (0.04 - 0.07) 0.510.03) Adjust
Australia Full position 400 7.86 - 10.66 10.48 - 0.65}
200
AIT Minus 12 _ 22 0 400 q_0.70 - 1.10(0.04 - 0.07) 0.5 (0.03) Adjust
"""
Idle Speed (b) Adjust injection volume by turning the idle speed
Adjusting adjusting screw.
~~~~~~~2screw
i -----~i-----
2S-C (n-F) 1.9 - 2.1 (O.07S 0.083)
a; 20(079)
,
I
,
I
~ : :,
~ 0 25
~ (32) (77)
i= Fuel Temperature CrF)
EG-169
ENGINE - FUEL SYSTEM
EG
"."
EG
ON - VEHICLE INSPECTION
INSPECT SICS
(a) With the engine stopped after it is warmed Up. check
tha the SiCS lever and SICS adjusting screw are in
contact with each other.
(b) After restarting the engine. check that the SICS lever
and SICS adjusting screw are apart from each other.
EG-173
ENGINE - FUEL SYSTEM
_-0
wf EGR System SICS COMPONENTS INSPECTION
1. REMOVE SICS VSV
SICS VSV
SICS VSV
e
Battery
SERVICE SPECIFICATIONS
SERVICE DATA
_.-
FUll h.,ter Rilt1ne. .t 20C (BSeF) O.S 2.0 0
Inj.etion NOln. type DLLA 1"Spe39
noul Noul. opening pNl"ur. 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
Ndle-lift 0.23 - 0.28 mm (0.0091 - 0.0119 in.)
Adjusting ,him thickn... 1.900 mm (0,07.8 in.) 1.925 mm (0.0758 in.)
1.950 mm (0.0788 in., 1.975 mm (0.0778 in.)
2.000 mm (0.0787 in.,
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... 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.)
No.1 opening pr...ure .dju.ting .him thickn... 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 in.,
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.,
EG-175
ENGINE - FUEL SYSTEM
_."
TORQUE SPECIFICATIONS
Parl tightened Nm kgfcm flolbf
Fuel filter l( Fual filtar bracket 18 185 13
Fuel hose clamp l( Fuel filter bracket
Nozzle holder body x Nozzle holder retaining nut
12
30
120
300
22
Injection nozzle x Cylinder heed 25 255 18
Injection pipe x Injection nozzle, Injection pump 24.5 250 25
Injection pipa clamp I( Intake manifold, Injection pipe clamp 6.4 65 56 in.lbf
No.3 nozzle leakage pipe I( Intake manifold 19.6 200 14
No.1 nozzle leakage pipe
No.1 nonle leakage pipe x Cylinder head
Accelerator link assembly
I( Injection nozzla
I( intake manifold
I.
18
19.6
176
1B6
200
13
14
14
Delivery valve holder I( Distributive head 5B 600 43
Fuel inlat hollow screw I( Injection pump body 37 375 27
Regulator valve I( Injection pump body B.B BO 78 in.lbl
Feed pump cover I( Injection pump body 3.0 31 27 in.lbf
EG176
ENGINE - FUEL SYSTEM
8.35 85
..
Time' eovlr,lnjletiol"l pump atly, Th,rmo WI. x InjKtion pump body 74 in.-Ibf
Tim" adjusting "rew II Tim.r cover
Govemor link IUpport x Ini-ction pump body ,.
'4.2 "5
, ,.
11
7.35
225
800
75
15.S
.5
65 inAbt
a.phr.gm cover x Governor cove, 7.35 75 85 inAb'
LIver control spring x Governor COYlr
FUll c!Jt lo"noid Distributive hd
LI.d wire )( FUI' cut solenoid
11.3
22
1.7
115
225
17
,.
15 in.lbf
C.p II Injeclion pump
SICS .ctu.tor br.ckl! II Governor cov.r
11
9.3
115
95
82 inAbt
SICS 'Clultor II SICS .clullor br.ckel 9.35 95 83 in.lbl
SICS .dju,ting .cr.w II SICS .ctuetor br.ck.t .8 7. 81 inAbf
Idl. up I.v.r II Inj.clion pump body Short bolt 8.35 .5 7-4 in.lbt
COOLING SYSTEM
PREPARATION
."0-'"
SST (SPECIAL SERVICE TOOLS)
--
09230-00010 R.dillor Service Tool Set
~OO
. '.P
00
.'''''_<10
EQUIPMENT
Heater
Thermometer
Torque wrench
COOLANT
Item Capacity Clnsificetion
Engine coolant Ethylene glycol bas'
wi Front lind fe., heaters MIT 12.0 liters (12.7 US qts. 10.7 Imp. qts)
AIT 11.8 liters (12.5 US qls, 10.4 Imp. qts)
wi Front heater MIT 11.1 liter. (11.7 US qls, 9.8 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. 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
-EG 2.
(a)
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) 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.
(c) Reinstall the radiator cap.
COOLANT REPLACEMENT
1. DRAIN ENGINE COOLANT
_..
(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.
(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.
Ora i n --..e::";:~"'J
Plug Drain Plug
WATER PUMP
COMPONENTS FOR REMOVAL AND
--.
INSTALLAnON
F.n---;=~::\l
Idler Pulley _
Clip---~
Clamp-----'..,Jl\
,
d)'-----Gssket
Vacuum Hose -\\
Seat Washer
Non-reusable parI
EG-1Bl
ENGINE - COOLING SYSTEM
Alternator
Adjusting
aoc
---=--
Turbo
Water-L~
Pipe
,,
,, ,5 '
,,, ~J
,
NO.2 Cylinder ~
a,oo' '",""0' lP '--aJ!--...
" '"'r-- Water Bypass Hose
Non-reusable part
_ _ 11
Adjusting
-'
, ..
Water Bypass Hose
Waler Pipe
8.
(a)
REMOVE WATER PUMP
Remove the 3 bolts and alternator adjusting bar.
SO' u
(b) Remove the 2 nuts, and disconnect the turbo water
pipe from the wate, pump.
(c) Disconnect the turbo water pipe from the water
bypass hose.
(d) Remoye the 5 bolts, water pump and gasket.
--
ENGINE - COOLING SYSTEM
THERMOSTAT
COMPONENTS FOR REMOVAL AND
INSTALLATION
'I \
,G
":-------ThermOsIBt
,"'-----+ Gasket
,
,
/---"'<---Water
,,
Inlet
,, ,
''til
o
'"
,,
,
Non-reusable part
THERMOSTAT REMOVAL
--.
HINT: Removal of the thermostat would have an ad-
verse effect. causing a lowering of cooling efficiency.
Do not remove the thermostat. even if the engine
tends to overheat.
1. DRAIN ENGINE COOLANT
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve
opening temperature.
EG
'"""
(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-
stat.
(d) Check that the valve spring is tight when the thermo-
stat is fully closed.
c:::;::;=>---i..
~
~ -
Valve Lift If not closed. replace the thermostat.
THERMOSTAT INSTALLATION
--.
1. PLACE THERMOSTAT IN CYLINDER SLOCK
(a) Install a new gasket to the thermostat.
(b) Ins1all the thermostat with the jiggle valve upward.
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
EG 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,
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 meas-
ure 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.:
Radiator Cap 59 kP. (0.8 kgf/cm l , 8.5 pII)
COOOH HINT: Use the tester's maximum reading as the open-
ing pressure.
If the opening pressure is less than minimum. replace
the radiator cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator and engine with coolant, and attach a
radiator cap tester to the water filler.
(b) Warm up the engine.
(c) 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.
4. REINSTALL RADIATOR CAP
EG-187
ENGINE - COOLING SYSTEM
. ' .. _M
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
~~--AadiatorCap
,
~~--UpperTank
Support---------
l----Tank Plate
~---+. D-Ring
Cushion -~----f,~,,-
f---Core
~~~~~~~- D-Ring I
"'",
~~If---Support
Tank Plate
Q-Ring _
""'''
RADIATOR DISASSEMBLY
1. REMOVE CUSHIONS
2. REMOVE SUPPORTS
3. REMOVE DRAIN PLUG
4. REMOVE TANK PLATE
(a) 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
ENGINE - COOLING SYSTEM
RADIATOR ASSEMBLY --
,. INSTALL OIL COOLER TO LOWER TANK
(a) Install 2 new 0 - rings to the oil cooler.
(b) Install the oil cooler to the lower tank.
(e) Install the 2 plate washers. 2 spring washers and 2
nuts.
Torque: 10 Nm (lOa kgt-em. 7 ftlbf)
(d) Install the 2 pipes.
Torque: 15 Nm (150 kgfem. " ftlbf)
HINT: Face the pipes in the direction shown in the
~&v;iiCoili=":P:":l:'==~
illustration.
2. CHECK CORE PLATE FOR DAMAGE
HINT:
If the sides of the core plate groove are de
formed. reassembly of the tank will be impossi-
ble_ Therefore. first correct any deformation with
pliers.
COON. Water leakage will result if the bottom of the core
plate groove is damaged or dented. Therefore.
/~
-'~
@~
o Normal X Twisted
3. INSTALL TANK
Install a new 0 - ring and the tank.
HINT:
-.-J Clean the tank and core plate.
~
Take out any twists.
~O-Ring
-
../ X Twisted
COOl! ,
~~B'"
(a) Set the punch of SST to -LOW,
SST 09230-00010
Punch -f~__
~~ :LJE .
-
1S haft
Guide BLock
- am"
(b) Stake the claws of the tank plates with SST In the
numerical order shown in the illustration.
_ _..:;3_ _ 3.. __-,-4_ _
5 6
Tank Plate NOTICE: If the bottom of the cor. plate i. staked with the
Punch SST on the guide block stopper. it may result in water
leakage.
Tank
o
SST SST
Stopper
Guide Block
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.)
Zl!631
""'''
(e) 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 appear-
ance of an air leak when the radiator is submerged in
water. Therefore. before performing the water leak
Core Plate test, first swirl the radiator around in the water until all
Tank Plate D-Ring
air bubbles disappear.
6. PAINT TANK PLATE
HINT: If the water leak test checks out okay. allow the
radiator to dry completely and then paint the tank
plate.
9. INSTALL SUPPORTS
Torque: 12.7 Nm (130 kgfcm. 9 ft.lbfl
SERVICE SPECIFICATIONS
SERVICE DATA
--..
TheNTIOIllt v.t.... opening temperltUf, 7.. - 78C (185 - 172"F)
V,tv, lift at 90C (19.F) 10 mm (0.39 in.) or more
R.d~tor elp R"Mf nlvi Ope1ling pre.lur. OTO 7. - 103 kP. (0.75 - 1.05 kot/cm", 10.7 14.9 psi)
Minimum 59 kP, (0.8 kgf/em', 8.5 ~i)
EG
TORQUE SPECIFICATIONS
--..
Part tighllnld Nm kgl-em Itlbf
Drain plug x Oil cooler cover 29.4 300 22
W.ter pump l( Cylinder block 12 mm hd 19.6 2DD
40D
"
14 mm he.d 39.2 2.
6.'
F,n II Fluid coupling
Fluid coupling II WeIer pump pulley 19.6 "
200
571nAbf
"
Watlr inlllll Cyli"der block 19.6 200
Wltlr inl.t II Altetnator brach! 19.8 200
"
O~ coo~r II Lower tank lD 100
"
7
O~ coo'-r pipe II Oil cooler 15 15D 11
Support II; Tlnk on IlIdi.ltOl'" 12.7 13D
EG-192
ENGINE - LUBRICATION SYSTEM
LUBRICATION SYSTEM
PREPARATION
~
:EG
tfW
RECOMMENDED TOOLS
09200-00010 Engin. Adjull Kit.
---
~~~
~ W<:a.
EQUIPMENT
., .....
Oil pressure gauge
Torque wrench
LUBRICANT
Item Capacity CI."itie.tion
Engine oil API grad. CD or better
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'
TDll'I\ATUlE
~ EG
Ilf.roAE ,.EXT 01. c:w.NGE Recommended viscosity:
"= R.f., to Illustration
Oil Pressure Gauge 2. 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.
3. REMOVE OIL PRESSURE SENDER GAUGE
4. INSTALL OIL PRESSURE GAUGE
5. WARM UP ENGINE
Allow the engine to warm up to normal operating
temperature.
6. 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)
7. REMOVE OIL PRESSURE GAUGE
EG
o
0- Rm 9 *-,-(j- _' - -
,,
, -1.>lI
,
,,
0;1 Pu";p 0';V81) ' ' ' ' -
Shaft Gear
-',
- :~=<:'~,~
,,
, ,,..--
,
,,,
',- 1 Cover
Crankshaft Front Oil Seal
--t';~c~'a~m:p~-+
l Gasket
Vacuum Pump-----::--:1
El--- ,-61~~::::~!J-----'OirPipe
,, ,-
Q)---' Gasket
-'
,,
I
,-
,-
,,
I
,
L' '
Non-reusable pan
EG-195
ENGINE - LUBRICATION SYSTEM
OIL PUMP
COMPONENTS FOR REMOVAL AND
INSTALLATION
\~~~~~~~~--~>-'-"c,- -+ Gasket
vacuumHose}~;:::::~~~~~,
.GaSk~; ", ~ ,,""""- ~- -r.'" " - - - -
~lntakePipe
-,
--,
Intake Heater '" " , ' , .
Gaskel' , '-, ,:, Insutalor
,,
, ,
~a:
------
,
,,,
,,
,
F.n---::::jr5'~
,,."",-1nr
Drive 8elt
Pulley Set Key
No.1 Camshaft liming ~ __ --------
Pulley f$.1t.~
Idler P u l l e y ' - - - - - -
\----Timing Belt
--
,
Clamp -"'" ~Il'----- Gasket
Hose-------'\\
Vacuum
,,
-,-
Clamp -'-
Seal Washer
Non-reusable part
EG-197
ENGINE - LUBRICATION SYSTEM
GaSket---;-r--:-:--"~~~;r- --'0
Water Outlet , '. ----"---- ---
Oil Pump
(Timing Gear Case)
4'
" \U.1Hfi \ ~_F
, ~~;~~~~~~m~uu
~.r .~.~.
,
I If---Oil Pan
~.Gasket
6--- '" ..
~DrainPlug
Non-reusable parI
*. Precoated part
~J1..
.G"k"
~--
Non-reusable part
EG'99
ENGINE - LUBRICATION SYSTEM
"',,,
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.
5 mm Hexagon Wrench
moO'
EG-202
ENGINE - LUBRICATION SYSTEM
OIL COOLER
COMPONENTS FOR REMOVAL AND
--.
INSTALLATION
Intake
Pipe
Vacuum ,
~ ~
. ' .__-
~P'.
,
r.:. ~EGR Valve Bracket
""0;"
> '-~.
~--'
G as kat
Hose , ,
-::.-.
Gasket Intake Pipe Assembly
::-o...:::-,~r.--~
Intake Heate r
Gasket ~
,,
No.2 Flange
Timing Belt Cover---"'\ \---liming Belt
)J)--=--Gasket
Vacuum Hose
Non-reusable part
EG-204
ENGINE - LUBRICATION SYSTEM
,
_. _;--_ _ Injection Pipe
Clamp--+;---,
,,
,
,,
.' .-,
,r .. , --- ....
.'
.. , t-
,,
~
-- =
):;;;~~;:-Accelerator
Oil Cooler Cover 0- ,,
,,
,., link
Assembly
~
,
.'
,,,
,, ,,,
,
" ,.....~-+:-+1 Clamp
,, ,,
?z Throttle Position
Sensor Connector
,
,,, - Except
( Australia MIT
)
," ...:""'ll
, ""IL_Oil Dipstick and
: Guide
'~'-,
J,
: f1
~.ORing
.-~--- 1 .J : I
---;.: .~.
........... ::'l', I~ :j '........ r0 I QilFilter
r'fl-~
''. 'I II ..... I
:
1 ('
.. ~I ..~I...... r"'1-"'~'
I" ~ib::: _....to:?i
__ Check Valve
.
/_.;'.... I I ....... I ' ~ .... ~. Gasket
(.<1>-.. -,
~::l~,
NO.1 Cylinder Block ,,-
!: ~~.GaSket
Insulator
,,
~
" R,",fV.,.,
,
Injection Pump-------I",---~:_J'j
,, .
Oil c:o::::~~/'
Cover Assembly
~~~erature
Sensor
D-Ring c9lcGl
lG :>_:'--- Water Bypass Hose
(from Injection Pump)
Non-reusable part
EG-205
ENGINE - LUBRICATION SYSTEM
OIL NOZZLE
COMPONENTS FOR REMOVAL AND
--.
INSTALLATION
OitNozzle ~
Check Valve' ----a
~,~O;IP.n
,
~. _ _ Gasket
Non-reusable part
6--x 27 9""" Drain Plug
.",,,
OIL NOZZLES REMOVAL
....-.
1. REMOVE OIL PAN
(See steps 1 and 4 in oil pump removal)
2. REMOVE CHECK VALVE AND OIL NOZZLES
Remove the 6 check valves and 6 oil nozzles.
""0-0'
OIL NOZZLES INSTALLATION
1. INSTALL OIL NOZZLES AND CHECK VALVES
(a) Align the pin of the oil nozzle with the pin hole of the
cylinder block.
(b) Install the oil nozzle with the check valve. Install the 6
oil nozzles and 6 check valves.
Torque: 27 Nm (275 kgfcm. 20 ft.lbf)
2. INSTALL OIL PAN
(See steps 5. 7. 9 and 10 in oil pump installation)
TORQUE SPECIFICATIONS
Pari tightened Nm kgf-cm Itlbf
Drain plug x Oil pan 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 19.6 200
Injection pump x Timing g88r case 18
"
Oil pan x Main beering cap, Timing geaf case. Reef oil s8al retainer 9.8
18'
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
Relief valve x Oil cooler cover 39 .00
"
29
Check velve x Oil cooler cover 27 275 20
Weter temperature sensor x Oil cooler cover 19.6 200
Oil nozzle x Cylinder block 27 275
"
20
EG-210
ENGINE LUBRICATION SYSTEM
-MEMO-
'EG
ST.'
STARTING SYSTEM
PREPARATION ................................... 5T - 2
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
SST (SPECIAL SERVICE TOOLS)
09286-46011 Injection Pump Spline Sh.ft
~
'. Pul~r
09820-00030 Alternator R.., Be.ri"'l! R.pI.c., ArlTMllur. ' " ' H.ring
5T
~
RECOMMENDED TOOLS
09082-00050 TOYOTA Eleel"",1 Tnt,r Set.
EOUIPMENT
.._-.
Dial indicator Comm",Utor
Magnetic finger
Sandpaper Comrnutltor
TOrl:tue wrench
V block
PRE-HEATING SYSTEM
ON-VEHICLE INSPECTION
--.
HINT: Refer to Diesel Electrical System Diagnosis for
inspection procedures.
(See troubleshooting in Engine Mechanical)
1. INSPECT LIGHTING TIME OF INTAKE HEATER
INDICATOR LIGHT
Turn the ignition switch ON", measure the lighting
time. ST
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 pre-
heating 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
Grl
10
PreHeating Timer \ "
~
---
E 120 Cl
F After
~
c
:E Glow
lime
90 "
:1
~ 4 light 60 3
II~:~~
::l
l' 2 '- "- U9hti"IQ 30 -
~
Time '"
!C.
= = ::l 0
20 0 20 40 60 80
0
(4) (32) (58) (1041 (140) (176)
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 pas-
senger seat.
ST-4
STARTING SYSTEM - PRE-HEATING SYSTEM
" K , r"11l.. II
.- .,
1/ '" ." / l- r-' / V
'" " /
,~,
1/ Ie sp,
1/ / / '"
~~
n"'" mn2Il
~- Intake
I-'cf-Heater
1. REMOVE INTAKE HEATER RELAY
1 Relay
No Continuity Continuity
Continuity
." ..
ST-6
STARTING SYSTEM - PRE - HEATING SYSTEM
ST
w/o EGR~.t.m
~,
-'-
~ ~ .. ~"
" ~ :::::t'
,~-:TA. -..._1 b
Gasket Intake Heater
Lead Wire
f r~ 'P'~
Intake Heater
Engine
Ground
Strap
Vacuum Hose
Intake Pipe
'-ba Gasket
. ,
'.
Clamp
,
.. ,
wI EGR Syatem ..... ~EVRV Connector "
Intake Pipe Assembly 1t . .~~TUrbo Pressure SensOr Connector
~, ~'- ,
l "tl... '," ~ " .-
", ....,.. .. VSV for Turbo Pressure Sensor
~. Connector
, .. .... '~t~GaSket
. ... V ~'-<
" 000--.:
Gasket-----1@r:-" ' .. ~ V H .... ..
._
r-~.' ',I acuum ose I , .... ,
I" ~ '. ...
J:: . . .~
. + Gasket .......
~~' f ~lntakeHealer ,/
VSVfor ~ : ~~lntakeHeater "
EGA Valve Connector : -. Lead Wire ~ Inlat(e Pipe Insulator
; ~.GaSket [ ,/
,, ,,
Intake Air COnnector----...;'--(,::<; ,
Clamp'------e
Air H o s e - - - - - -
Clamp----~
Non-reusable part
ST-7
STARTING SYSTEM - PRE-HEATING SYSTEM
$.
w/o EGA System
Ohmmeter
"'"
WATER TEMPERATURE SENSOR
INSPECTION
L REMOVE WATER TEMPERATURE SENSOR
2. INSPECT WATER TEMPERATURE SENSOR
Using an ohmmeter. measure the resistance between
Water Temp,;
Sensor the terminals.
//J 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 3
L> 2
Z
Ohmmeter !" 1
'"w 0.'
= V;
~
0.3
0- 0.2 11.';;~
0.1
." ,
, , , , , , ,
POl8S7
" " 60 80
'"
(-411321 168) (104H\40H176l/212)
fl(1(j TEMPERATURE "e (OF)
ZI~1'j
ST-8
STARTING SYSTEM - STARTER
STARTER " __ M
Starter Housing 5
top C0 II at
Starter Clutch .:~~
~
I
Compression Spring () \ \\ Retrne,r@q
Clutch Shaft \ ~b I
1).' Snap Ring
~I~
<' __ '
"
,'\\ .........
......... "
Steel Ball
~dl~ 8."~~9 ..' - --""
,~
,
,
"
Sl-- Oust Protector
.......... "
........ __.-----
.. -..-
'.-
Lead Wire O-Ring
I!l
Rear Bearing
~ 1&1 - ft.
'~ ~ Armature
~.:: Front Beating
g---
Field Frame
~ Brush Holder (Field Coil)
~ .aRing ~
End over Dust Protector
Non-reusable part
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.
ST-9
STARTING SYSTEM - STARTER
"""
(b) Remove these parts from the magnetic switch assem-
bly:
(2) (1) Starter housing and clutch assembly
..J-; (' )
(2)
(3)
Return spring
Plate washer
(3) (4) ::) (4) Idler ge.r
ST08IS
."."
ST-10
STARTING SYSTEM - STARTER
No continuity
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt. correct it with sandpa-
per (No. 400) or on a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) 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.
3. INSPECT COMMUTATOR DIAMETER
Using vernier calipers. measure the commutator diam-
eter.
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.
ST-11
STARTING SYSTEM - STARTER
[ill
- +
Z\531~
ST-12
STARTING SYSTEM - STARTER
Brush Springs
t 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
STOOl' the brush springs.
...,
3. IF NECESSARY. REPLACE CLUTCH ASSEMBLY
A. Oi....emble .tarter hou.ing end clutch embly
(al Push down the pinion gear and starter housing.
(b) Using a plastic-faced hammer. tap down the stop
collar.
ST-13
STARTING SYSTEM - STARTER
""'" ST
(5) (3) (d) Disassemble these parts:
,~
(!j (1) Stop collar
,., --..
,
'
f<~O
(1 )
(2)
(3)
Pinion gear
Retainer
(4) Compression spring
'.-- ....--------.--; (2)
(5) Starter housing
~-r-d?
(6) Starter clutch
(7) Compression spring
(7) (6) (8) Clutch shaft
"..,
(b) 2nd. assemble these parts:
(1) Clutch shaft and starter shaft assembly
,~
,nl
(2) Starter housing
(3) Compression spring
(4) Retainer
(5) (6)
(5) Pinion gear
(3) (6) Stop collar
(2)
- (e)
(e)
Push down the pinion gear and starter housing.
Using snap ring pliers. install a new snap ring.
"""
ST-'4 STARTING SYSTEM - STARTER
ST "'""
(1) Using a plastic-faced hammer. tap the clutch shaft
and install the stop collar onto the snap ring.
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.
..."
Front Bearing Rear Bearing (b) Using a press, press in a new front bearing.
I (e) Using SST and a press, press in a new rear bearing.
I SST 09820-00030
L
,H
'--
SST~
)
~ ,.." ,.1
~ 'tJ ...rn
ST-15
STARTING SYSTEM - STARTER
Magnetic Switch
Terminal C
1. PERFORM PULL-IN COiL OPEN CIRCUIT TEST
Using an ohmmeter. check that there is continuity
Ohmmeter between terminals 50 and C.
If there is no continuity, replace the magnetic switch.
ContinuiTY
ST
2. PERFORM HOLD -IN COIL OPEN CIRCUIT TEST
Switch Body
Using an ohmmeter. check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
Ohmmeter
Continuity
....,-.,
STARTER ASSEMBLY
HINT: Use high-temperature grease to lubricate the
bearings and gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME
Apply greas8 to the armature bearings. and insert the
armature into the field frame.
(c) Install the end cover to the field frame with the 2
screws.
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.
ST-'6 STARTING SYSTEM - STARTER
(2) . ':.
aC)\
'!l I
(1)
" ...
(d) Assemble the starter housing and magnetic switch
assembly and install the 3 screws.
mo.
(b) Align the protrusion of the field frame with the cutout
of the magnetic switch.
ST-17
STARTING SYSTEM - STARTER
(0) 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)
wl24V Starter
wi 24 V Starter:
(a) Using an ohmmeter. check that there is continuity
between terminals E and ST.
(b) Check that there is no continuity between terminals B
Ohmmeter and MG.
00 If continuity is not as specified. replace the relay.
1
0;.
510811 No continuity Continuity 115317
s
B. In.peet relay operation
wf 12 VStarte_(,:-_::===+_, wI 12 V Starter:
(a) Apply battery voltage across terminals 3 and 4.
4 (b) Using an ohmmeter. check that there is continuity
1 between terminals 1 and 2.
Ohmmeter If operation is not as specified. replace the relay.
DO
O):j:.~."J
Continuity
P1)l09 115316
w /24 V Starter B
wI 24 V Starter:
MG (a) Apply battery voltage across terminals E and ST.
NOTICE: If the vehicle he' e voltege converter, do the
check u,ing. 12 V bettery.
Ohmmeter (b) Using an ohmmeter, check that there is continuity
00 between terminals B and MG.
e @ If operation is not as specified, replace the relay.
0: Banery 3. REINSTALL STARTER RELAY
ST()8U Continuity 215318
1 2
4 5
ST-20 STARTING SYSTEM - VOLTAGE CONVERTER RELAY(w( 24 V Starter)
Continuity
,. (d) Using an ohmmeter. check that there is
between terminals 1- and 2+.
no continuity
Battery
510870
"""
24 V Hold Warning Relay 24 V HOLD WARNING RELAY
--.JL J (w/ 24 V Starter) ...... -.
I~::., 24 V HOLD WARNING RELAY INSPECTION
1. REMOVE 24 V HOLD WARNING RELAY
Ohmmeter
B. Inspect reley operetion
00 (a) Apply battery voltage across terminals 1 and 3.
(b) Using an ohmmeter. check that there is continuity
o between terminals 2 and 4.
If continuity is not as specified. replace the relay.
Continuity Battery 3. REINSTALL 24 V HOLD WARNING RELAY
?--"1(f)
BEOO10
ST-22
STARTING SYSTEM - SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
" ...--
Starter Rated voltage and output power 12 V 2.5 kW, 24 V 4.5 kW
No-load characteristics Current 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
BrUSh length STO 20.5 - 21.0 mm (0.807 - 0.827 in.)
"0'0_'"
TORQUE SPECIFICATIONS
Part lightened Nm kgfcm Itlb!
Starter housing )[ Magnetic switch 9.3 95 82 in.lbl
End cover )( Slarter housing 9.3 95 82 in.lbf
Lelld wire )[ Terminal 50
lead wire x Terminal C
3.6
21.1
4\
215 ,.
32 in.lbl
CH-l
CHARGING SYSTEM
PRECAUTION CH- 2
PREPARATION CH- 2
ON-VEHICLE INSPECTION CH- 3
ALTERNATOR CH- 5
SERVICE SPECiFiCATIONS CH-14
CH-2
CHARGING SYSTEM - PREPARATION
PRECAUTION
1.
2.
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
--
3. Do not perform tests with 8 high voltage insulation resistance tester.
4. Never disconnect the battery while the engine is running.
PREPARATION
SST (SPECIAL SERVICE TOOLS)
--.
09285 76010 Injection Pump Camshaft Bearing Rotor rear bearing covar
~
Cone Replacer
CH
09286 46011 Injection Pump Spline Shaft Rlctifie, and frame
~
Puller
~
09820 00030 Alternator Raar Be.ring Replacer
~
09820 63010 Alternator Pulley Silt Nut Wrench
~~ So.
~ ..,O~ .P
..... .. ................................... , ,....... .............. ................... ,.... .....
(09951-00260) Replacer 26
(09951-00500) Replacer 50
r;p d:J
RECOMMENDED TOOLS
09082-00050 TOYOTA Electricel Tntar SOl.
CH-3
CHARGING SYSTEM - ON - VEHICLE INSPECTION _ _a
EQUIPMENT
Ammeter(A)
Torque wrench
ON - VEHICLE INSPECTION
1. CHECK BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
(b) Check the specific gravity of each cell.
St.nderd specific gr8vitv:
0
At 20 C (68 F):
105D31L end 105D31R: 1.27 - 1.29
Others: 1.25 - 1.27
If the gravity is less than specification. charge the
battery.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(al Check that the battery terminals are not loose or
corroded.
(bl Check the fusible link and fuses for continuity.
""-..
3. INSPECT DRIVE BELTS
WRONG
lal Visually check the drive belt for cracks. oiliness or
wear. Check that the belt does not touch the bottom
of the pulley groove.
If necessary. replace the drive belts as a set.
Clearance (b) 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
ALTERNATOR __ m I!H]
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
Aotor
Bearing Retainer ",-+__
.-
Alternator
Washer
Front Bearing
Seal Plate
-;...
"Z'4""Rectifier Holder
L(?) Rubber Insulator
",'"
_ _M
ALTERNATOR DISASSEMBLY
1. REMOVE REAR ENO COVER
(a) Remove the nut and terminal insulator.
"""
CH-6
CHARGING SYSTEM - ALTERNATOR
~,
(e) Remove the seal plate from the rectifier end frame.
4. REMOVE PULLEY
[BI~ST(A) (a) Hold SST (A) with a torque wrench. and tighten SST
c
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.
No Continuity
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.
Ol~='"
(a) Using an ohmmeter. connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(b) Reverse the polarity of the tester probes and repeat
step (a).
.- (e) Check that one shows continuity and the other shows
no continuity.
If continuity is not as specified. replace the rectifier
Ohmmeter
holder.
DO Negative (-) 2. INSPECT NEGATIVE RECTIFIER
""'"
CH10
CHARGING SYSTEM - ALTERNATOR
(c) Check that one shows continuity and the other shows
no continuity.
If continuity is not as specified. replace the rectifier
holder.
Bearings
....
CH-ll
CHARGING SYSTEM - ALTERNATOR
,,,.,,
(b) Place the bearing cover on the rotor.
SST---:-fl;~"'-
"'""
ALTERNATOR ASSEMBLY
--.
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO RECTIFIER END FRAME
CH-12
CHARGING SYSTEM - ALTERNATOR
,.,...
4. INSTALL PULLEY
(aJ Install the pulley to the rotor shaft by tightening the
pulley nut by hand.
(b) Hold SST (A) with a torque wrench. and tighten SST
(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.
...."
1"08~.1PW2 ...
"""
CH-13
CHARGING SYSTEM - ALTERNATOR
""."
(b) Install the rectifier holder while pushing it with the 4 CH
screws.
Torque: 2.9 Nm (30 kgfem. 28 In..lbf)
t end frame.
NOTICE: B. c.r.ful of the hold., intt.lI.tion direction.
CB (e)
(d)
Install the 5 screws.
Place the brush holder cover on the brush holder.
CH SERVICE SPECIFICATIONS
SERVICE DATA
_.-
Batterv Specific gr.vilv
II 20C (SSeF) 105D31L and I05031R 1.27 - 1.29
Others 1.25 - 1.27
AII,rnllor R,tad output 12 Y 80 A.. 100 A
Rotor coW 'I.i,tlnel 2.90
Slip ring di.meter STD '-4.2 mm - 1. mm (0.559 - 0.587 In.)
Minimum 12.8 mm (O.Sa. in.)
Brush ,xp(ll~ length STD 10.5 mm (0.413 in.)
Minimum 1.5 mm (0.059 in.)
Ie Regulltor Regulating volt.ge It 25"C (nF) 14.0 - 15.0V
.t 11SC (239F) 13.5 - 14.3 V
TORQUE SPECIFICATIONS
_0-.
Raetit.., Ind tr.me
Alternator pulley x Rotor
)I Drive
Part tight,ned
~ trim.
Nm
<.5
110
.
kgf-em
1.125
,,tbf
.0 in..lbf
81
."
Rectifier holder It Coil lead Ofl (.clitia, end fram. 2. '0 28 in..lbf
Pille terminll x Rlctifi" holde, '.8 34 inAbf
R"f Ind covar If Rlcli'i" hold.r 80 A U 39 in.lbf
100 A <., <. 40 in.-Ib'
Terminlt inlulltor x RlCtifier holder 80 A <.1 41.5 38 in.tbf
100 A 8.5 58 58 ill..lbf