Sect 0 General 1kd Engine Ce302 PDF

1KD_RM.
book 1 ページ２０１３年９月２７日　金曜日　午後１２時４７分
FOREWORD
This repair manual explains the repair points of the 1KD model engine
equipped on the Toyota Industrial Vehicles.
Please use these manuals for providing quick, correct servicing of this
engine.
This manual deals with the above models as of October 2013. Please under-
stand that disagreement can take place between the descriptions in the man-
ual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
1KD_RM.book 2 ページ２０１３年９月２７日　金曜日　午後１２時４７分
SECTION INDEX
NAME SECTION
GENERAL 0
TROUBLESHOOTING 1
ENGINE OVERHAUL 2
FUEL SYSTEM 3
COOLING SYSTEM 4
STRTING SYSTEM 5
LUBRICATION SYSTEM 6
CHARGING SYSTEM 7
APPENDIX 8
9
10
0-1
GENERAL
SPECIFICATIONS .......................................................... 0-2 1

ENGINE EXTERIOR VIEW .......................................... 0-3 0
ENGINE SECTIONAL VIEW ........................................ 0-4 1
HOW TO READ THIS MANUAL ................................. 0-6
2
EXPLANATION METHOD............................................... 0-6
3
TERMINOLOGY .............................................................. 0-7
ABBREVIATIONS ........................................................... 0-7
4
OPERATION PRECAUTIONS ..................................... 0-9 5
SPECIAL PRECAUTIONS .............................................. 0-9 6
GENERAL PRECAUTIONS ............................................ 0-9 7
INSPECTION OF ELECTRIC PARTS ........................... 0-11
8
SIMULATION OF DEFECT PHENOMENA ............ 0-16
9
STANDARD BOLT AND
NUT TIGHTENING TORQUE ................................. 0-18 10
BOLT STRENGTH CLASS IDENTIFICATION METHOD 11
AND TIGHTENING TORQUE..................................... 0-18
12
PRECOAT BOLTS (BOLTS WITH SEAL LOCK
AGENT COATING ON THREADS) ....................... 0-21 13
SI UNITS......................................................................... 0-22 14
HANDLING THE FIPG (LIQUID GASKET) ............ 0-23
0-2
SPECIFICATIONS
Engine model 1KD

Type Diesel
Cycle 4
Number of cylinder and arrangement In-line 4 cylinders, vertical

Ignition order 1-3-4-2
Starting method Pinion shift
Fuel supply system Common rail
Combustion chamber type Direct injection
Direct acting DOHC4 valve

Valve mechanism
Belt and gear drive
Intake and exhaust system Crossflow

Electronically-controlled variable nozzle
Turbo charging system
turbo
Bore x stroke mm (in.) 96.0 x 113 (3.78 x 4.06)
Total displacement cm3 (cu in) 2982 (181.97)
Compression ratio 16.0

Compression pressure MPa/rpm 2.6/250
Maximum output kW (PS)/rpm 55 (75)/2200
Maximum torque N m/rpm 300/1200 to 1500
No-load static maximum speed rpm 2350, 2600
Idling speed rpm 720 to 780
Compression ring 2
Number of piston rings
Oil ring 1
Cylinder liner type No liner
Open BTDC 3°
Intake valve opening & closing timing
Close ABDC 28°
Open BBDC 48°

Exhaust valve opening & closing timing
Close ATDC 0°
Ignition system Compression ignition
Oil pump type Cycloid gear
Oil filter type Paper filter type

No filter change 6.6
Engine oil amount L Filter change 7.0
Total capacity 7.8

0-3
ENGINE EXTERIOR VIEW

0-4
ENGINE SECTIONAL VIEW

0-5
0-6
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
• The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with an illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by
explanation of cautions and notes summarized as "key point operations".
Example of description in pattern B
Disassembly, inspection and reassembly

 Non-reusable parts T = N m
Parts to be replaced with new ones at disassembly/installation Tightening torque unit
• Step numbers are sometimes

2 4 partially omitted in illustrations.
• When a part requiring tightening
 torque instruction is not indicated
in the illustration, the part name is
described in the illustration frame.
1
T = 274.59 to 370.69 (2800 to 3780) [202.58 to 273.48]
Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Crank pulley
2 Timing gear cover
3 Idle gear No.1 [Point 1]
4 Oil pump assembly [Point 2]
Point operation
[Point 1] Explanation of operation point with illustration
Inspection:Measure the backlash.
Standard: 0.05 mm (0.0020 in.) Operation covered on the following page
Disassembly:Install the rotor in the position shown
in the illustration.
Abbreviation used for point operations
Removal Reassembly
Installation Adjustment
Disassembly Inspection
0-7
2. How to read components figures (Example)

The components figure uses the illustration in the parts catalog
3201
for the vehicle model. Please see the catalog for checking the
part name. Parts catalog FIG number
3. Matters omitted from this manual
This manual omits descriptions of the following jobs, but perform
them in actual operation:
(1) Cleaning and washing of removed parts as required
(2) Visual inspection (partially described)
TERMINOLOGY
WARNING: Important information and operation procedures, failure to observe which may cause accidents.
Caution: Important information and operation procedures, failure to observe which may cause accidents.
Note: Important information, failure to observe which may cause accidents, or information on
operation procedures that requires special attention.
Standard: The permissible range in inspection or adjustment
Limit: The maximum or minimum value of the criterion in inspection or adjustment
ABBREVIATIONS
Abbreviation Original term Meaning
ABDC After Bottom Dead Center After the bottom dead center position of the piston in the cylinder.
An assembly is composed of two or more individual parts or
ASSY Assembly
subassembly parts that are put together.
ATDC After Top Dead Center After the top dead center position of the piston in the cylinder.
Before the bottom dead center position of the piston in the
BBDC Before Bottom Dead Center
cylinder.
BTDC Before Top Dead Center Before the top dead center position of the piston in the cylinder.
DTC Diagnostic Trouble Code Diagnostic trouble code
ECD Electronically Controlled Diesel Electronically controlled diesel
ECU Electronic Control Unit Electronic control unit
EDU Electronic Driver Unit Electronic driver unit
EGR Exhaust Gas Recirculation Exhaust gas recirculation system
EX Exhaust Indicates the exhaust system.
FB Feed Back Feed back
FCM Fuel Control Module Fuel control module
FIPG Formed In Place Gasket Formed in place gasket
FR Front Front side
IG Ignition Ignition
IN Intake Indicates the intake system.
LH Left Hand Left side
LWR Lower Lower side
M/T Manual Transmission Indicates a manual transmission.
For items that have worn over a long time, or where the fitting
has loosened due to repeated removal and reassembly, by
O/S Over Size replacing the one side (fitting side) with an item that has a larger
size, the other side can be reused. Sizes larger than this stan-
dard are indicated with O/S.
RH Right Hand Right side
RR Rear Rear side
0-8
Abbreviation Original term Meaning

SST Special Service Tool Indicates special tools.
Indicates that the standard size is the size of the parts that were
STD Standard
used for assembly at the manufacturer.
Two or more individual parts that are welded, cast or caulked
SUB/ASSY Sub Assembly
together.
T= Torque Tightening torque
T/C Torque Converter Indicates an automatic transmission.
TDC Top Dead Center Top dead center
In the same way as O/S, by replacing the one side (fitted side)
U/S Under Size with an item that has a smaller hole, the other side can be
reused. Sizes smaller than this standard are indicated with U/S.
The item following is attached. (Example: w/washer = with a
W/ With/
washer)
0-9
OPERATION PRECAUTIONS
SPECIAL PRECAUTIONS
1. Disassembly and reassembly operations for the engine assembly must be carried out while the engine is set on
the engine stand. Never perform the operations on a work bench or the floor, since doing so is very dangerous.
2. Always wear gloves when holding or moving the cylinder head assembly or cylinder block: never use bare
hands.
GENERAL PRECAUTIONS
1. For safe operation
(1) Correctly wear protection tools (cap, safety glasses, gloves, safety shoes, etc.).
(2) Do not touch the radiator, muffler, exhaust pipe and other engine related parts immediately after stopping
the engine to prevent scalding.
(3) Do not bring clothes, tools and others close to rotating parts during engine operation.
(4) Always turn the ignition switch OFF and remove the ignition key unless engine operation is necessary.
2. Preparation for disassembly
(1) Prepare general tools, SST, measuring tools, greases, and non-reusable parts.
(2) When disassembling a complicated assembly, put punch or matching marks at places not affecting the
function to facilitate reassembly operations.
0-10
3. Keeping out foreign matter

If foreign matter such as dust, sand or metal pieces enter the engine, it could cause a malfunction.
(1) Fully clean off any sand or mud from the outside of the engine.
(2) Use plastic covers to protect the disassembled parts from dust.
4. Prevention of part damage
If there is damage to rotating parts or the connection surface of parts, it could cause oil leaks or seizures.
(1) Do not use a screwdriver when disassembling the connection surface of parts. Disassemble by striking the
parts gently with a plastic hammer.
(2) When securing parts in a vise, do not secure the parts directly. Use aluminum plates between the parts and
the vise.
5. Washing the parts
(1) Wash the parts thoroughly before reassembly, dry with compressed air, and coat with the specified oil.
(2) Parts that must not be washed with alkaline solutions:
Aluminum parts, rubber parts (O-rings, etc.)
(3) Parts that must not be washed with cleaning oil (kerosene, white gasoline, etc.):
Rubber parts (O-rings, etc.)
6. Removal and reassembly of fuel system parts
(1) Work area for removing and reassembling fuel system parts
(a) Perform the work in an area with good ventilation where there is no machinery that cause sparks, such as
welders, grinders, drills, electric motors or stoves.
(b) Do not work in or around a work pit where there is a danger of ignited fuel flowing in.
(2) Removal and reassembly of fuel system parts
(a) Prepare a fire extinguisher before starting to work.
(b) To prevent static electricity, attach a ground wire to areas such as the fuel changer, vehicle and fuel tank,
and pour water over the parts, but not so much that it will cause you to slip.
(c) Do not use electric equipment such as power pumps and working lamps, because they could cause
sparks or high temperatures.
(d) Do not use tools such as iron hammers, because they could cause sparks during work.
(e) Dispose of cloths that are saturated with fuel separately.
7. Reassembly position and direction

(1) Reassemble the parts in the position and direction they were in before disassembly.
(2) Install correct parts according to the correct procedure and observing the determined standards (tightening
torques, adjustment values, etc.). (Reassemble at the median of the ranges for tightening torques and
adjustment values.)
(3) Always use genuine parts for replacement of existing parts.
(4) Always use new oil seals, O-rings, gaskets, cotter pins, etc.
(5) Coat the seal packing on the gaskets depending on where they will be used, coat the specified oil or the
grease on the specified places on the sliding parts, and coat the MP grease on the oil seal lips before
reassembly.
0-11
8. Tightening by extension tool attached torque wrench

(1) For the case a torque wrench is used after extending the
total length by combining with SST or another tool, the
L1 L2
actual tightening torque becomes excessive when the
reading on the torque wrench is at the specified torque.
(2) This manual shows the specified torque only. To use a
SST or extension tool, calculate the reading of torque
wrench using the following formula.
(3) Formula: T' = T x L2 / (L1 + L2)
T' Reading of torque wrench [N m]
L1 L2 T Specified tightening torque [N m]
L1 SST or tool length [in]
L2 Torque wrench length [in]
9. Handling the hose clamps

(1) Before removing the hose, check the insertion depth of the hose and the clamp positions to make sure that
reassembly is performed correctly.
(2) Replace deformed or dented clamps with new ones.
(3) When reusing the hose, install by aligning the clamps to the clamp marks on the hose.
(4) With plate spring clamps, after installation apply pressure in the direction it is to be tightened.
10. Adjustment and checking work
Adjust to the service standard values by using gauges and testers.
11. Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If oil, fuel, coolant, oil filters, batteries or other harmful substances are directly discharged or scrapped without
permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids etc.
and treat them properly by requesting disposal by specialized companies.
Further, always recover or wipe up any waste fluid that is spilt.
12. Protection of function parts
Before connecting the battery terminal after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure to connect the controller connectors or incomplete connection may damage the elements inside the
controllers.
INSPECTION OF ELECTRIC PARTS

1. Always disconnect the battery plug before performing electric part inspections or maintenance.
2. Electric parts resistance measurement condition
Unless otherwise specified, the resistance of electric parts should be measured at an ambient temperature of 20 °C.
The resistance value is out of the specified range when measured at a high ambient temperature immediately
after using a truck, therefore measure the resistance after the engine is cooled sufficiently.
0-12
3. Handling the connectors

(1) To disconnect a connector with lock, push the connector
(2) Release the lock to the fitted side to ease the tab of the lock and then
release the lock.
(2) Hold the connector, not the harness, to disconnect the
connector.
(3) Before connecting the connector, check it for deformation,
damage or looseness of the terminal.
(1) Push to the fitted (4) Insert the connector with lock securely until it clicks.
side (5) To inspect the connector using a tester, it should be
performed at the back (harness side) using a mini test
lead.
Caution:
• Since the waterproof connector cannot be inspected at the
back, a sub harness needs to be connected.
• Do not damage the terminal by carelessly moving a tester
probe after inserting it.
4. Connector inspection
(1) With the connector connected, hold the connector

Looseness of swaged area housing and check for insertion and locking conditions.
(Fitting condition)
(2) With the connector disconnected, pull the wire harness
lightly. (Check for terminal disconnection, condition of
Core breakage swaged area and core breakage)
Caution:
Terminal
Always use a gold plated male terminal to test a gold plated
deformation
female terminal.
Pull lightly (3) Visually check the connector for a presence of rust, metal
chip or water, and bend of the terminal. (Check for
corrosion, intrusion of foreign matter and terminal
deformation)
(4) Check the terminal contact pressure by inserting a male
terminal prepared for inspection into the female terminal
to check the fitting and sliding conditions.
Male terminal for

inspection
0-13
5. Repairing the connector terminal
(1) If the contact area is contaminated, clean it using an air

gun or cloth. Never polish the contact area with a
sandpaper. Doing so causes the plating on the surface to
come off.
(2) Replace the female terminal if the contact pressure is
abnormal. At this time, use a gold plated female terminal
when the male terminal to be connected on the part is
plated with gold.
Likewise, use a tin plated female terminal (silver) when
the male terminal to be connected on the part is plated
with tin.
(3) When no abnormality is found in the contact area, clean it
using an air gun and then coat it with connector grease.
(This can prevent oxidation and wear of the contact.)
6. Connector grease
(1) The connectors in the areas prone to be exposed to water

are filled with grease to prevent corrosion of terminals.
(2) When the connector grease is insufficient or the terminal
is repaired, add the connector grease to the female
terminal by hand.
Caution:
• Keep dirt away.
• Do not use tools such as screwdriver to add the connector
grease.
(3) It is no problem that the grease is attached to the O-ring
or rubber plug of the waterproof connector; however, the
attachment of grease on the other rubber parts (including
a wire harness grommet) should be avoided to prevent
deterioration or discoloration. Wipe grease off these parts
promptly if attached.
7. Handling the wire harness
(1) Before removing the harness, check the route and clamp
positions to make sure that reassembly is performed
correctly.
(2) Do not twist, pull or make the harness sag unnecessarily.
(3) Do not bring the harness into contact with hot, rotating,
sliding or vibrating parts or sharp edges (panel end, screw
end, etc.).
(4) Do not squeeze the harness in installing parts.
(5) Do not break the sheath of the harness. If it is broken,
replace it with new one or repair it securely using vinyl
tape or the like.
0-14
8. Be very careful when handling electric parts.

(1) Do not subject electric parts such as computers or relays
to impacts.
(2) Do not subject electric parts to high temperatures or
humidity.
(3) Do not touch the connector terminals, because
deformation or static electricity could cause a malfunction.
9. Use a circuit tester that suits the measurement object and objective.
Analog type: This type is convenient for observing movement during operation and the operating condition. The
measured values are used as a reference or as a guideline.
Digital type: A fairly accurate reading is possible. However, it may be difficult to observe variation or movement.
(1) Difference between results of measurement with analog and digital types
The results of measurements using the analog type and the digital type may be different.
See the instruction manual when using a circuit tester.
The information below describes the precautions required when there are polarity differences between
analog and digital circuit testers.
Forward Reverse (a) Analog circuit tester

Black Red Red Black
Example of measurement result
tester tester tester tester Tester range: kΩ range
rod rod rod rod Forward: Continuity 11 kΩ
Reverse: No continuity ∞
(b) Digital circuit tester

Forward Reverse Example of measurement result
Red Black Black Red Tester range: 2 MΩ range
tester tester tester tester Forward: Continuity 2 MΩ
rod rod rod rod Reverse: No continuity 1
0-15
(2) Differences in results of measurement with circuit testers
The circuit tester power supply voltage depends on the

tester type. 1.5 V, 3.0 V or 6.0 V is used.
(mA)
6 The resistance of a semiconductor such as a diode
varies with the circuit tester power supply voltage.
5 The diode characteristics are shown in the figure.
The resistance values of the same semiconductor
Forward 4
Germanium measured with two types of circuit testers having different
current
diode power supply voltages are different.
3
Silicon
diode This manual describes the results of measurement with a
2
circuit tester whose power supply voltage is 3.0 V.
1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)
(3) Differences in results of measurement by measurement range
In the analog type circuit tester, changing the

Resistor Meter measurement range switches over the internal circuit to
vary the circuit resistance.
Even when the same diode is measured, the
0Ω measurement result varies with the measurement range.
Current Variable resistance
flow
Resistor
Range: x 10 (SW1)
Resistor
Range: x 1 (SW2)
Voltage: 1.5 V
Red Black
0-16
SIMULATION OF DEFECT PHENOMENA

• Troubleshooting is difficult when defect phenomena are not recognized. In this case, it is necessary to conduct a
thorough analysis on a defect and replicate the condition and environment where the defect occurred. Performing
troubleshooting without checking the defect phenomena may cause oversight of important points in repair work or
result in a deadlock.
• For example, a defect that occurred while the engine is cool cannot be identified while the engine is hot. Likewise,
a defect that resulted from the vibration during truck operation cannot be identified while the truck is stopped.
• Vibration, heat or intrusion of water (humidity) is a cause of defect which cannot be replicated easily. The
replication methods of defect phenomena described here are effective in that external factors exert an influence
on a truck while it is stopped.
Note:
In replicating defect phenomena, the area or location of defect needs to be found as well as checking the
defect phenomena. To do this, find the circuit that may include a defect according to the defect phenomena
and connect a tester to it before testing. After that, try the defect replication method and check the circuit for
abnormality and also defect phenomena. To narrow the causes of defect phenomena, refer to the list of
defect phenomena of each system. To replicate the diagnosis code output, the method based on the
detection condition/time of the diagnosis code is required.
1. Vibration method: For defects that may be caused by vibration
Vibrate lightly
(1) Parts and sensors
Cause vibration on the suspected part by tapping it lightly by hand
to see if the defect occurs.
Note:
Note that applying a strong impact on relays may cause the
point to open.
(2) Connector
Shake the connector up and down, or right and left lightly.
(3) Wire harness
Shake the wire harness up and down, or right and left lightly to see
if the defect occurs.
Note:
Shake lightly Pay special attention to the root of the connector, fulcrum of
vibration and penetrated area of the body.
Shake lightly
2. Cooling/heating method: For defects that may occur in a

cooled or heated state
(1) Heat or cool the suspected part using a hair dryer or
Defect
coolant to see if the defect occurs.
Co
Caution:
ola
nt
• Do not heat the part to 60 °C or above (too hot to touch).

• Do not open the cover of ECU or other parts to heat/cool the
electric part directly.
0-17
3. Watering method: For defects that may occur in rainy or high temperature conditions
(1) Pour water on a truck to see if the defect occurs.
Caution:
• Do not pour water directly on the engine room. Spray water onto the front surface of radiator to change
the temperature and humidity indirectly.
• Do not pour water directly on the electric parts.
4. Others: For defects that may be caused by excessive electric load
(1) Increase the electric load by operating the electric parts such as headlamp to see if the defect occurs.
0-18
STANDARD BOLT AND NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Determine the tightening torques of the standard seat hexagon head bolts, welded bolts and stud bolts by
identifying the strength class in the table below, and checking the torque in the tightening torque table.
2. Determine the tightening torque of hexagon flange bolts by identifying the strength class, and checking the
torque in the tightening torque table.
3. Determine the tightening torque of nuts by applying the method in item 1 above to the connecting bolt.
BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING

TORQUE
Identification by bolt shape
Type Shape and strength class Strength class
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon bolt (standard

bearing surface) Two embossed lines 5T
Three embossed lines 7T
Four embossed lines 8T
Welded bolt 4T
No mark 4T
Stud bolt
About 2 mm (0.08 in.) groove(s) on one/both

6T
edge(s)
0-19
Identification by part number

Type Example of part number Shape
Length (mm) Diameter

Hexagon bolt
Diameter (mm)
Strength class Length
Length (mm) Diameter

Stud bolt
Diameter (mm)
Strength class Length
Tightening torque table

Diameter Pitch Standard tightening torque
Strength class
mm (in.) mm (in.) Nm
6 (0.23) 1.0 (0.039) 5.4
8 (0.31) 1.25 (0.049) 13
10 (0.39) 1.25 (0.049) 25
4T
12 (0.47) 1.25 (0.049) 47
14 (0.55) 1.5 (0.059) 75
16 (0.63) 1.5 (0.059) 113
6 (0.23) 1.0 (0.039) 6.5
8 (0.31) 1.25 (0.049) 16
10 (0.39) 1.25 (0.049) 32
5T
12 (0.47) 1.25 (0.049) 59
14 (0.55) 1.5 (0.059) 91
16 (0.63) 1.5 (0.059) 137
6 (0.23) 1.0 (0.039) 7.8
8 (0.31) 1.25 (0.049) 19
10 (0.39) 1.25 (0.049) 39
6T
12 (0.47) 1.25 (0.049) 72
14 (0.55) 1.5 (0.059) 108
16 (0.63) 1.5 (0.059) 172
6 (0.23) 1.0 (0.039) 11
8 (0.31) 1.25 (0.049) 25
10 (0.39) 1.25 (0.049) 52
7T
12 (0.47) 1.25 (0.049) 95
14 (0.55) 1.5 (0.059) 147
16 (0.63) 1.5 (0.059) 226
6 (0.23) 1.0 (0.039) 12
8 (0.31) 1.25 (0.049) 29
10 (0.39) 1.25 (0.049) 61
8T
12 (0.47) 1.25 (0.049) 108
14 (0.55) 1.5 (0.059) 172
16 (0.63) 1.5 (0.059) 265
0-20
Identification by bolt shape (Hexagon flange bolt)

Strength class 4.8T 6.8T 8.8T 10.9T 11.9T
No mark
Hexagon flange bolt
— —
No mark
Tightening torque table (Hexagon flange bolt)

Diameter Pitch Standard tightening torque
Strength class
mm (in.) mm (in.) Nm
6 (0.23) 1.0 (0.039) 5.5
8 (0.31) 1.25 (0.049) 13
10 (0.39) 1.25 (0.049) 27
4.8T
12 (0.47) 1.25 (0.049) 50
14 (0.55) 1.5 (0.059) 78
16 (0.63) 1.5 (0.059) 120
6 (0.23) 1.0 (0.039) 7.5
8 (0.31) 1.25 (0.049) 19
10 (0.39) 1.25 (0.049) 39
6.8T
12 (0.47) 1.25 (0.049) 71
14 (0.55) 1.5 (0.059) 110
16 (0.63) 1.5 (0.059) 170
6 (0.23) 1.0 (0.039) 12
8 (0.31) 1.25 (0.049) 29
10 (0.39) 1.25 (0.049) 61
8.8T
12 (0.47) 1.25 (0.049) 110
14 (0.55) 1.5 (0.059) 175
16 (0.63) 1.5 (0.059) 270
6 (0.23) 1.0 (0.039) 15.5
8 (0.31) 1.25 (0.049) 38
10 (0.39) 1.25 (0.049) 80
10.9T
12 (0.47) 1.25 (0.049) 145
14 (0.55) 1.5 (0.059) 230
16 (0.63) 1.5 (0.059) 360
6 (0.23) 1.0 (0.039) 17.5
8 (0.31) 1.25 (0.049) 42
10 (0.39) 1.25 (0.049) 89
11.9T
12 (0.47) 1.25 (0.049) 160
14 (0.55) 1.5 (0.059) 260
16 (0.63) 1.5 (0.059) 400
0-21
PRECOAT BOLTS
(BOLTS WITH SEAL LOCK AGENT COATING ON THREADS)
1. Do not use precoat bolts in any of the following cases:
(1) When a precoat bolt is removed.
(2) When a precoat bolt is moved as a result of tightening
torque check, etc. (Loosened or tightened.)
Note:
Check the torque with the lower limit of the tightening torque.
If it moves, retighten it according to the following procedure:
2. Reusing of precoat bolts
Seal lock agent (1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing
the bolt with new one.)
(2) Dry it well with compressed air.
(3) Apply the specified seal lock agent to the bolt threaded
portion.
0-22
SI UNITS
What are SI units?

The SI unit system has been introduced for this manual. SI units unify the various unit systems that were previously
used in different countries. It is an international unit system established to ensure the smooth exchange of
technology.
New units arising from SI unit introduction
Item New unit Previous unit Conversion value *1 (1 [Previous unit] = X [SI unit])
Force*2 N (Newton) kgf 1 kgf = 9.80665 N
Torque*2
N·m kgf·cm 1kgf·cm = 0.0980665 N·m
(Moment)
Pressure *2 Pa (Pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
Pressure *2 Pa (Pascal) mmHg 1 mmHg = 0.133322 kPa
Rotation speed r/min rpm 1 rpm = 1 r/min
Spring constant*2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume L cc 1 cc = 1 mL
Power W PS 1 PS = 0.735499 kW
Heat quantity W·h cal 1 kcal = 1.16279 W·h
Fuel consumption
g/W·h g/PS·h 1g/PS·h = 1.3596 g/kW·h
ratio
Reference:
*1: X is the value of 1 unit of the previous unit converted into the SI unit. This value can be used as the conversion
factor for the previous unit and SI unit.
*2: The [kg] kilogram unit expressing mass is used instead of the [kgf] kilogram force unit expressing "force" that was
previously used.
Conversion between previous units and SI units
Conversion formula
SI unit value = conversion factor x previous unit value Conversion factor: The figure corresponding to X in the
Previous unit value = SI unit value / conversion factor conversion value field in the table above
Caution:
Make sure that the unit of the previous or SI unit value used in the calculation is the same as the unit in the
conversion value field in the table above. For example, when converting 100 W into the previous PS unit,
convert it into 0.1 kW before dividing it with the conversion factor of 0.735499.
0-23
HANDLING THE FIPG (LIQUID GASKET)

Use 1280B made by THREEBOND or seal packing black for the FIPG.
The part number is set as 08826-76001-71.
Example of coating location
Coating method and parts reassembly procedure
Caution:
When removing the gasket, make sure that shreds from the
gasket do not enter the engine.
1. Clean the connection surface of parts and their connecting
parts with a cloth to eliminate any oil, moisture or dirt.
2. Coat the part to be reassembled with FIPG. The parts that
require coating are described in the key point operations in
each section.
3. Do not coat excessively or insufficiently, and be sure to overlap
FIPG
the beginning and end of the coat.
4. Do not move the parts after they are reassembled.
5. Reassemble within 3 minutes of coating the parts.
6. Do not charge coolant, supply oil or start the engine for 2 hours
after the reassembly.

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1KD_RM.

book 1 ページ ２０１３年９月２７日 金曜日 午後１２時４７分

SPECIFICATIONS .......................................................... 0-2 1

Engine model 1KD

Number of cylinder and arrangement In-line 4 cylinders, vertical

Starting method Pinion shift

Fuel supply system Common rail

Combustion chamber type Direct injection

Direct acting DOHC4 valve

Intake and exhaust system Crossflow

Bore x stroke mm (in.) 96.0 x 113 (3.78 x 4.06)

Total displacement cm3 (cu in) 2982 (181.97)

Compression ratio 16.0

Maximum output kW (PS)/rpm 55 (75)/2200

Maximum torque N m/rpm 300/1200 to 1500

No-load static maximum speed rpm 2350, 2600

Idling speed rpm 720 to 780

Cylinder liner type No liner

Open BBDC 48°

Ignition system Compression ignition

Oil pump type Cycloid gear

Oil filter type Paper filter type

Engine oil amount L Filter change 7.0

Total capacity 7.8

ENGINE EXTERIOR VIEW

ENGINE SECTIONAL VIEW

HOW TO READ THIS MANUAL

Disassembly, inspection and reassembly

Parts to be replaced with new ones at disassembly/installation Tightening torque unit

• Step numbers are sometimes

T = 274.59 to 370.69 (2800 to 3780) [202.58 to 273.48]

Disassembly and reassembly procedure

2. How to read components figures (Example)

Abbreviation Original term Meaning

3. Keeping out foreign matter

7. Reassembly position and direction

8. Tightening by extension tool attached torque wrench

9. Handling the hose clamps

INSPECTION OF ELECTRIC PARTS

3. Handling the connectors

(1) With the connector connected, hold the connector

Male terminal for

5. Repairing the connector terminal

(1) If the contact area is contaminated, clean it using an air

(1) The connectors in the areas prone to be exposed to water

7. Handling the wire harness

8. Be very careful when handling electric parts.

Forward Reverse (a) Analog circuit tester

(b) Digital circuit tester

(2) Differences in results of measurement with circuit testers

The circuit tester power supply voltage depends on the

(3) Differences in results of measurement by measurement range

In the analog type circuit tester, changing the

SIMULATION OF DEFECT PHENOMENA

2. Cooling/heating method: For defects that may occur in a

• Do not heat the part to 60 °C or above (too hot to touch).

STANDARD BOLT AND NUT TIGHTENING TORQUE

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING

Hexagon bolt (standard

book 1 ページ２０１３年９月２７日　金曜日　午後１２時４７分