Toyota 1HD-FT, Repair Manual

Page 1: ... TOYOTA 1HD FT ENGINE REPAIR MANUAL Jan 1995 Pub No RM437E ...

Page 2: ...T engine equipped in the TQYOTA LAND CRUISER Applicable models HDJ80 series Please note that the publications below have also been pre pared as relevant service manuals for the components and system in this engine Manual Name Pub No 0 1HD FT Engine Emission Control Repair ERM111E Manual All information in this manual is based on the latest product in formation at the time of publication However sp...

Page 3: ...INTRODUCTION ENGINE STARTING SYSTEM CHARGING SYSTEM ...

Page 4: ...IN 1 INTRODUCTION HOW TO USE THIS MANUAL IN 2 IDENTIFICATION INFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 5 ABBREVIATIONS USED IN THIS MANUAL IN 8 STANDARD BOLT TORQUE SPECIFICATIONS IN 9 ...

Page 5: ...n 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 purpo...

Page 6: ...o do task b Install the b Torque 30 N m 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 mini...

Page 7: ...d HINTS are separated from the text but do not appear in bold They provide additional information to help you perform the repair efficiently SI UNIT The UNITS given in this manual are primarily expressed according to the 51 UNIT lnternational System of Unit and alternately expressed in the metric system and in the English System Example Torque 30 N m 310 kgf cm 22 ft lbf The engine serial number i...

Page 8: ...attery post with the nut loose and tighten the nut after installa tion Do not use a hammer to tap the terminal onto the post f Be sure the cover for the positive terminal is properly in place Check hose and wiring connectors to make sure that they are secure and correct Non reusable parts a Always replace cotter pins gaskets 0 rings and oil seals etc with new ones b Non reusable parts are indicate...

Page 9: ...erage Rali 10 10 10 When replacing fuses be sure the new fuse has the correct amperage rating 00 NOT exceed the rating or use one with a lower rating illustration Symbol Abbreviation IE559 t 8 5517 tnSM FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE FUSIBLE LINK R CIRCUIT BREAKER FUSE M fUSE H FUSE FL CB 11 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the v...

Page 10: ...team cleaning an engine protect the dis tributor air filter and VCV from water f Never use an impact wrench to remove or install temperature switches or temperature sensors g When checking continuity at the wire connector insert the tester probe carefully to prevent termi nals from bending h When using a vacuum gauge never force the hose onto a connector that is too large Use a step down adapter i...

Page 11: ...Control Unit EGR Exhlu t Gil Rlcireul tion FIPG Formed in Pl e Gllket LHO Left Hand Driv LST Laid Sensing Tim r MP Multipurpou MfT Menu l Tran minion OHC Ova He d Camahaft O S Oversized PCS POWI Control SY5tlm PCV po itiva Cr nke Ventil tion PS POWI St ring RHO Right Hand Drive SICS Starting Injection Control Syttem SSM Special Service Mllerials SST Special Sel t iCi Tool STO Stand rd SW Switch TO...

Page 12: ...olt 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 oNom flange bolt wI washer 4T Grooved hexagon bolt v 6T Hexagon OJ head bolt 2 protruding 5T lines Hexagon 0 flange bolt 2 wI washer protruding 6T Welded bolt hexagon bolt lines Hexagon 0 head bolt 3 protruding 7T lines 4T Hexagon 0 head bolt 4 protruding BT lines ...

Page 13: ...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 8 1 25 29 300 22 33 330 24 8T 10 1 25 6...

Page 14: ...G 89 TURBOCHARGER SYSTEM EG 93 PREPARATION EG 93 PRECAUTION EG 94 TROUBLESHOOTING EG 95 TURBOCHARGER EG 97 SERVICE SPECiFiCATIONS EG 103 FUEL SySTEM EG I04 PREPARATION EG l04 FUEL FILTER EG l07 FUEL HEATER SYSTEM EG l08 INJECTION NOZZLE EG ll0 INJECTION PUMP EG 122 STARTING INJECTION CONTROL SYSTEM SICS EG 172 SERVICE SPECiFiCATIONS EG 174 COOLING SYSTEM EG 117 PREPARATION EG l77 COOLANT CHECK EG ...

Page 15: ...m Oil Seal Repl e 09202 70020 V Iv Sprine Compressor _ 09202 00010 Attlchmll ll i 09213 58012 Crlnkah ft PuM Holding Tool _ 90201 08131 Wlth r _ 91111 50845 Bolt 09214 60010 C lnhh ft Puu G Cranktt ft pulley 0 1 R plle 09214 76011 erlnkshaft Pull Repllcer In ection pump driv S1 r baaring Illjeetion pump drive gur oil g e 3EJ 09222 11010 Connecting Rod Bu hing Remoyer El Repl eef _ _ _ B 09222 0502...

Page 16: ...nklh ft front oil 811 09330 00021 Comp nion FI nge Holding Tool Crenk heft pulley 09950 40010 Puller B Set f 09951 04010 Hang r 150 No 1 camshaft timing pulley Oil pump drive sheft gear Crankshaft timing gear Injection pump drive g98r bearing 09952 0401 0 Slide Aim No 1 camshaft liming pulley O pump driv shalt gear Crankshaft timing gear de liil Injection pump drive gear bearing 09953 04010 Center...

Page 17: ... Arm Assy No 1 cllmahalt timing pulley Oil pump drive Ih ft gear Crankshalt timing gear Injection pump drivll gear bearing No umshaft timing pulley Oil pump drive Illaflg a Cranksh ft timing ge r Injection pump drive gur be ring C nklhaft pulley Injection pump drive gell Cr nksh ft pulley Injection pump drive geer Crtnkshaft pulley Injection pump drive gear Crankstlllft pulley Crankstlaft pulley I...

Page 18: ...Heugon Wrenc h Set 09200 00010 Engine Adj tt Kit A 09904 00010 E pender Set EOUIPMENT Caliper gauge Connecting rod aligner Cylinder gauge Dial indicator Dve penelrant Engine tune up tester Heater Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Vel pring Steel square V I pring ...

Page 19: ...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 filte...

Page 20: ...s normally o c rf__ t___ f__ _ t t___ ___t t___ t__ t___ _j 00 2 3 2 Engine cranks slowly Engine cranks normally r Bo E I il I I t _j I t I t I I 0 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 Engine suddenly SlOPS 2 4 1 3 Engine does not shut off with key 2 6 Excessive exhaust smoke Excessi e fuel consumption 4 3 8 10 2 5 7 Engine overheat 7 Low oil ...

Page 21: ... u u 6 0 u u U U U u Engine does not crank 8 7 0 t o Engine cranks normally 3 o t Engine cranks slowly 4 5 Q 0 Engine cranks normally 0_ 0 c High engine speed 2 Rough idle with warm 4 3 0 engine lack of power 7 0 3 4 Engine suddenly stops Engine does not shut off with key Excessive exhaust smoke Excessive fuel 4 6 9 2 3 consumption 0 Engine overheat 5 2 3 6 4 1 8 9 low oil pressure 3 2 4 5 High oi...

Page 22: ...en the ignition switch is turned ON Check the fusible link for intake heater I does pre heat side of Ihe intake heater have battery vollage for 81 seconds Fusible Link OK Ves Connect the water temperature sensor connector II Inspect control section II I I OK I 2 Inspect control section HINT Perform this inspection with the intake heater lead wire properly connected Disconnect tne water temperature...

Page 23: ...cator light P22973 No I Is the lighting lime correct Replace tile EeU or timer 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 do...

Page 24: ...oid I and check for noise Noise No Noise IReplace luel CUI solenoid valve AIR FILTER INSPECTION AND CLEANING Paper Filter 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 Clean the filter element with compressed air First blow from the inside thoroughly Then blow off the outside of the filter element 4...

Page 25: ... 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 NO...

Page 26: ...der through the injection nozzle hole and repeat steps b through d for the cylinder with low compression If adding oil helps the compression chances are that the piston rings and or cylinder bore are worn or damaged If pressure stays low a valve may be sticking or seating improperly or there may be leakage past the gasket g Remove the SST SST 09992 00400 09992 00024 09992 00160 h Reinstall the inj...

Page 27: ...s indicated in the illustration Using a feeler gauge measure the clearance be tween the adjusting screw on the valve rocker arm and the valve bridge Record the out of specification valve clear ance measurements Velve cleerence Cold Inteke 0 17 0 23 mm 0 007 0 009 in Exheu t 0 47 0 53 mm 0 019 0 021 in b Turn the crankshaft pulley 1 revolution 360 and align the mark as above See procedure step 2 c ...

Page 28: ...ned If the resistance of the feeler gauge changes repeat from step b f Tighten the adjusting screw on the valve bridge and lock the adjusting screw with the lock nut when the resistance of the feeler gauge begins to get stronger NOTICE Hold the valve bridge with a wranch and lock the adjusting crew with the lock nut Do not apply torque to the valve bridge __t P2J211 Adjusting Screw t _valve T Rock...

Page 29: ...erclockwise approx 20 b Put a metal plate thickness of 9 0 10 0 mm 0 354 0 394 in between the cold starting lever and thermo wax plunger 4 INSPECT AND ADJUST INJECTION TIMING a Slowly rotate the crankshaft pulley counterclockwise and set the dial indicator at 0 mm 0 in when the dial indicator reaches the minimum value b Turn the crankshaft to the left and right and check that the dial indicator sh...

Page 30: ...p the pump flange away from the engine g Tighten these nuts and bolts e 2 nuts holding injection pump to timing gear case Torque 18 N m 185 kgf cm 13 ft lbf e 2 bolts holding injection pump to injection pump stay Torque 69 N m JOO kgf cm 51 ft lbfl h Recheck the plunger stroke 5 REMOVE METAL PLATE 6 REMOVE SST AND DIAL INDICATOR a Remove the SST and dial indicator SST 09275 54011 b Install a new g...

Page 31: ...d Reconnect the accelerator linkage After adjustment adjust the accelerator linkage PU314 puno 4 CHECK AND ADJUST MAXIMUM SPEED a wI Throttle Position Sensor Depress the accelerator pedal all the way Then check that the adjusting lever does not move when you try to push it to the maximum speed side If not adjust the accelerator linkage b wlo Throttle Position Sensor Ckeck that the adjusting lever ...

Page 32: ...right position e Check the idle up speed P idle up speed 650 750 rpm d Loosen the 2 nuts and adjust the idle up setting speed by sliding the idle up actuator body Lock the idle up actuator with the 2 nuts e Return the steering wheel to the straight ahead posi tion Then turn the steering wheel from the straight ahead position to full left or full right position and recheck the idle up speed f Retur...

Page 33: ...CHOMETER Idle Up Adjusting Screw Singl Diephngm Type A T 3 ADJUST AIC IDLE UP SPEED a Start the engine b Turn the Ale switch ON and set these position Blower switch to HI Air intake control lever to RECIRCULATED AIR Air flow control lever to FACE Temperature control lever to COOL c Check the idle up speed Ale idle up speed 175 850 rpm d Loosen the lock nut and adjust the idle up setting speed by t...

Page 34: ...lve Bracket 1 f _ _ Gasket Intake Pipe Insulator Gasket wI EGR System Clamp No 2 Flange Timing Belt Cover Seal Washer Clamp dl Vacuum Hose Intake Pipe Vacuum Hose t t2 Gasket Intake Heater I I Gasket Plate Washer Idler Pulley Timing Belt Tens oner _ NO 2 Camshaft Timing lP _ __1 __ _ ___ Pulley No Flange No 1 Camshaft Ttming _ Pulley w o EGR System Non reusable part ...

Page 35: ...he No 1 and No 2 camshaft timing pulleys with the BOC marks NOTICE If the timing belt i disengaged h8Ylng the erank h ft pulley at the wrong angle can cau the pilton h d and valve head 10 coma Into contact with each other when you remove the camshaft timing pulley tep 8 causing damage 0 alway et the crankshaft pulley at the correct angle 3 REMOVE TIMING BELT HINT When re using timing belt Draw a d...

Page 36: ... 1 CAMSHAFT TIMING PULLEY a Slightly turn the camshaft timing pulley counterclock wise and hold the hexagon wrench head portion of the camshaft with a wrench and remove the bolt and timing pulley b Using SST remove the timing pulley SST 09950 40010 09951 04010 09952 04010 09953 04020 09954 04010 09955 040601 c Remove the set key TIMING BELT COMPONENTS INSPECTION 1 INSPECT TIMING BELT NOTICE Do not...

Page 37: ...mage on only one side of the belt check the belt guide and the alignment of each pulley e If there is noticeable wear on the belt teeth check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth If necessary replace the timing belt 2 INSPECT IDLER PULLEY a Visually check the seal portion of the idler pulley for oil leakage If leakage is...

Page 38: ...nd 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 N m 1 000 kgf cm 72 ft lbf 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 ...

Page 39: ... to keep the setting position of the push rod c Release the press 5 SET NO 1 CYLINDER TO BOC COMPRESSION a Check that the timing mark of the No 2 camshaft timing pulley is aligned with the BOC mark NOTICE Do not turn the crankshaft pulley The valve heads will hit against the piston top b Align the timing mark of the No 1 camshaft timing pulley with the BOC mark 1 5mm Hexagon Wrench 1 5 mm Hexagon ...

Page 40: ... retainer and timing gear cover as shown in the illustration S I JNIcking Pert No 08826 00080 or equivelent 0 Install the insulator to the timing gear cover d Install the gasket to the timing belt cover el Install the timing belt cover with the 3 seal washers 3 bolts and 3 clips f Install the vacuum hose to the 2 clamps on the timing belt cover ...

Page 41: ... IP Gasket _ t 7 cuum Hose wI EGA System Intake Pipe Assembly n EGAValveBracket 1 0 _ _ W s Gasket _ i _ _ Intake Pipe Insulalor wI EGR System a Clamp Vacuum HO e Clamp 0 1 Idler Pulley Drive Belt Pulley Set Key No 1 Camshaft 1iming __ Pulley f f J Vacuum Hose 1 Gasket Intake Heater Gasket Intake Pipe w o EGR System Non reusable part ...

Page 42: ... Crankshaft Pulley Crankshaft Front Oil Seal I Crankshaft Timing Gear _ 0 p m OdV W Q q r i Thrust Plale c J I I _ _ I _ _ I _ _ i V I __ I I I I I njection Pump Drive 1 Gear Oil Seal Injection Pump Drive Gear Bearing 0 R nJ No 2 Cylinder Block Insulator Injection Pump Drive Gear Non reusable part ...

Page 43: ...pulley step 8 in timing belt removal causing damage 3 REMOVE TIMING BELT AND PULLEYS See steps 1 to 7 timing belt removal 4 REMOVE CAMSHAFT OiL SEAL RETAINER See step 14 in cylinder head remoYal 5 REMOVE CRANKSHAFT PULLEY a Remove the pulley bolt and plate washer NOTICE Do not turn the crankshaft pulley The valve heed will hit ageins the piston top b Using SST remove the crankshaft pulley SST 0995...

Page 44: ...learance Standard thrust clearance 0 05 0 15 mm 0 0020 0 0059 in Maximum thrust clearance 0 30 mrn 0 0118 in If the thrust clearance is greater than maximum ra place the thrust plate If necessary replace the idler gear and or idler gear shaft 12 REMOVE IDLER GEAR a Remove the 2 bolts and thrust plata b Using SST turn the injection pump drive gear clock wise or counterclockwise and remove the idler...

Page 45: ... the inside diameter of the idler gear Idler gear inside diamet r 45 000 45 025 mm 1 7717 1 7726 in b Using a micrometer measure the diameter of the idler gear shaft Idler g8 shaft diamat r 44 950 44 975 mm 1 7697 1 7707 in c Subtract the idler gear shaft diameter measurement from the idler g8ar inside diameter measurement Standard oil cle ranca 0 025 0 075 mm 0 0010 0 0030 in Maximum oil cle ranc...

Page 46: ...earing SST 09950 40010 09951 04010 09952 04010 09953 04020 09954 04010 09955 040401 B Install bearing Using SST and a press press in a new bearing SST 09214 76011 4 CHECK BACKLASH OF TIMING GEARS a Install the gears b Using a dial indicator measure the backlash Standard g88r backlash 0 05 0 15 mm 0 0020 0 0059 in Maximum gear backlash 0 30 mm D O 18 in If the gear backlash is greater than maximum ...

Page 47: ...010 e Apply MP grease to the oil seal lip B If timing ge r cover i in talled to the cylinder block a Using SST remove the oil seal SST 09308 10010 09950 50010 09953 050101 b Apply MP grease to a new oil seal lip Ie Using SST and a hammer tap in the oil seal until its surface is flush with the timing gear cover edge SST 09223 78010 INJECTION PUMP DRIVE GEAR OIL SEAL REPLACEMENT HINT There are 2 met...

Page 48: ...r tap in a new oil seal until its surface is flush with the timing gear cover edge SST 09214 76011 __ 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 2 INSTALL INJECTION PUMP DRIVE GEAR ...

Page 49: ...R GEAR a Align the bolt holes of the idler gear shaft and cylinder block and install the idler gear shaft b Using SST turn the injection pump drive gear clock wise or counterclockwise and align timing marks 3 and 4 of the idler gear with timing mark 3 of the crankshaft timing gear and timing mark 4 of the injection pump drive gear respectively and mesh the gears SST 09960 10010 09962 01000 09963 0...

Page 50: ...e valve h d will hit againlt the pitton top B INSTALL VACUUM PUMP a Install a new O ring to the vacuum pump b Install the vacuum pump with the 2 nuts Torque 39 N m 400 kgf cm 29 ft lbf 9 INSTALL OIL PIPE Install the oil pipe with the bolt 2 union bolts and 4 new gaskets Torque Bolt 1S 6 N m 200 ksf cm 14 ft lbf Union bolt 18 N m 185 kgf cm 13 ft lbf 10 INSTALL CAMSHAFT OIL SEAL RETAINER See Itep 6...

Page 51: ... FOR REMOVAL AND INSTALLATION w JEGR System Heal Insulator Throttle Position Sensor ConnectOr gr EGA Valve Bracket il is Gasket Vacuum C Hose QJ Gasket __ I Turbocharger Stay Turbocharger 1 and Exhaust Manifold Assembly 0 Non reusable part Clamp Vacuum Hose ...

Page 52: ... 5 I Intake Manifold Insulator Accelerator link Assembly T IntakePipe __ Gasket Intake Heater 1 1 y Vacuum Hose Gasket rGJ Turbochargar and E haust Manifold Assembly IntakePipe Insulator fiiblf Gasket _ I Turbocharger _ t Stay If I t Clamp Throttle Position Sensor Connector AfT Non reusable part ...

Page 53: ...t Timing Belt Cover Seat Washer _ IJ Gasket _ Insulator p Seal Washer Clip Camshaft Oil Seal Retainer O Cylinder Head C t over S _ 12 1l eal Washer Gasket _ _ _ C m h B _ Elll 0 Gasket ocker Shaft A C m h B _ mbly P II ear g 5 t F r Injection y Sot K y NO 1 9 Q J Th S ml Cr I Hold PI P I 9 0 S I 1iQ t D Rlng _ _ _J NOlzleSeat if EG Non reusablc part ...

Page 54: ...ead Assembly P2Jl89 J J j TurbOCharger III iI iI Turbocharger and Exhaust Manifold Assembly Rear ExhBust Manifold Front Exhaust Collar Manifold _ m 0 0 r ti c a Ring C RI09 O l j 1 R 09 _ Gasket D Ring Water Tsemperature ansar l v ve r Valve Bridge b l Keeper Ii spring Retainer 0 Valve Spring Ol SP RI e nng Seat Val U R Oil Seal Ie GUide f U Bushing I I Non reusable Preeo d part e part ...

Page 55: ...he intake pipe assembly 2 gaskets and intake pipe insulator bl w o EGR System Disconnect these vacuum hose 2 vacuum hoses from injection pump Vacuum hose from 2 clamps on timing belt cover 3 w o EGR System REMOVE INTAKE PIPE AND INTAKE HEATER a Disconnect the vacuum hose from the vacuum pipe on the intake manifold b Remove the bolt and disconnect the ground cable from the cylinder head c Remove th...

Page 56: ...R ANO EXHAUST MANIFOLOS ASSEMBLY See steps 3 to 5 7 and 8 in turbocharger removal in Turbocharger System 6 REMOVE EXHAUST MANIFOLDS FROM TURBOCHARGER See step 10 in turbocharger removal in Turbocharger System 9 SEPARATE EXHAUST MANIFOLDS a Separate the front and rear exhaust manifolds b Remove the collar e Using snap ring pliers remove the 2 rings from the rear exhaust manifold d Remove all the O ...

Page 57: ...s A bl Uniformly loosen and remove the 14 other bolts in several passes in the sequence shown e Remove the 7 bearing caps 12 rocker arms 6 holder clamps rocker shaft assembly and 7 upper camshaft bearings Keep the bearing caps rocker arms and n02zle holder clamps installed with the rocker shaft Keep the bearings inserted with the bearing cap d Remove the camshaft thrust plate and 7 lower cam shaft...

Page 58: ... REMOVE VALVE BRIDGE HINT Arrange the valve bridge in correct order 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 c Using needle nose pliers remove the oil seal CYLINDER HEAD COMPONENTS...

Page 59: ...ng a gasket scraper remove all the gasket material from the cylinder block contact surface NOTICE Ba careful not to scratch the cylinder block contact lurface B CI n intake and exhaust ports Using a wire brush remove all the carbon from the intake and exhaust ports NOTICE Ba careful not to scratch the valve contact lurt8ca C Clean valve guide bushings Using a valve guide bushing brush and solvent ...

Page 60: ...96 1 007 Thread Eod B Inspect for cracks Using a dye penetrant check the intake ports exhaust ports and surface contacting the cylinder block If cracked replace the cylinder head C Inspect cylinder head bolts Using vernier calipers measure the minimum outer diameter of the compressed thread at the measuring point Standard outer diameter 10 800 11 000 mm 0 4252 0 4331 in Minimum outer diameter 10 5...

Page 61: ...meter measurement from the guide bushing inside diameter measurement Standard oil cl rance Intake 0 025 0 060 mm 0 0010 0 0024 In Exhaust 0 035 0 070 mm 0 0014 0 0028 in Meximum oil cl rance lntak 0 08 mm 0 003 in Exhaust 0 10 mm 0 0039 In If the clearance is greater than maximum replace the valve and cylinder head M01 1 6 INSPECT AND GRIND VALVES a Check the valve face for wear If the valve face ...

Page 62: ... 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b Check the valve seating position Apply a light coat of prussian blue or white lead to the valve face lightly press the valve against the seat Do not rotate valve e Check the valve face and seat for the following If blue appears 3600 around the valve face the valve is concentric If not replace the valve If bl...

Page 63: ...aust and 45 cutters to correct the seat Hand lap the valve and valve seat with an abrasive compound After hand lapping clean the valve and valve seat Deviation 8 INSPECT VALVE SPRINGS 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 b Using vernier calipers measure the free length of...

Page 64: ... ROCKER ARM AND SHAFT a Check that each rocker arm turns smoothly If movement is felt disassemble and check b Remove the bolt and disassemble the parts HINT Arrange the disassembled parts in correct order No 1 l NO 7 121 Others 3 Mar 51 51 31 u 51 5 Intake 4 Exhaust 5 41 Valve Rocker Arm 21 2 Valve Rocker Shah Mark 7 Nozzle Holder Mark 1 Camshaft Bearing Cap P2Jl92 41 e Using a caliper gauge measu...

Page 65: ...the illustration See step b above 10 A a b B INSPECT CAMSHAFTS AND BEARINGS Inspect cam haft for runout Place the camshaft on V blocks Using a dial indicator measure the circle runout at the center journal Maximum circle runout 0 10 mm 0 0039 in 1 If the circle runout is greater than maximum replace the camshaft Inspect cam lobes Using a micrometer measure the cam lobe height Standard cam lobe hei...

Page 66: ...lace the bearing caps and cylinder head as a set E Inspect camshaft journal oil clearance a Clean the bearing caps and camshaft journals b Place the camshaft on the cylinder head e Lay a strip of Plastigage across each of the camshaft journals d Remove the 7 bearing caps from the valve rocker shaft See item E above e Install the 7 bearing caps with the 14 bolts Uniformly tighten the bolts in sever...

Page 67: ... F Inspect c mlh ft thrust cleer nce a Install the camshaft Se8 procedure in item E above b Using a dial indicator measure the thrust clearance while moving the camshaft back and forth Standard thrust cl renc 0 100 0 200 mm 0 0039 0 0079 in Mnimum thru t cle rance 0 30 mm 0 01 8 In If the thrust clearance is greater than maximum re place the camshaft If necessary replace the bearing caps and cylin...

Page 68: ... B to replace the oil seal which are as follows REPLACE CAMSHAFT OIL SEAL A If camshaft oil 8al retainer is removed from cylinder head a Using a screwdriver tap out the oil seal 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 B If camshaft oil s881 retainer is installed to cylinder heed...

Page 69: ...y clean all parts to be assembled Before installing the parts apply new engine oil to all sliding and rotating surfaces Replace all gaskets and oil seals with new ones 1 INSTALL VALVES a Using SST push in a new oil seal SST 09201 41020 b Install these parts 1 Valve 2 Spring seat 3 Valve spring 4 Spring retainer SST e Using SST compress the valve spring and place the 2 keepers around the valve stem...

Page 70: ... valve stem tip to assure a proper fit 2 INSTALL VALVE BRIDGES a Install the valve bridge b Check that the valve bridge rotates smoothly 3 INSTALL WATER TEMPERATURE SENDER GAUGE a Apply seal packing to 2 or 3 threads S I packing Part No 08826 00100 or equivalent b Install the sender gauge EG ...

Page 71: ...s f For the piston protrusion value of each cylinder use the average of the 2 measurements of each cylinder Protrusion P 0 175 0 425 mm 0 0069 0 0167 in When removing piston and connecting rod assembly If the protrusion is not as specified remove the piston and connecting rod assembly and reinstall it See cylinder block disassembly and assembly B Select new cylinder head gasket HINT There are 5 ty...

Page 72: ...s broken or deformed replace it al Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts bl Install and uniformly tighten the 26 cylinder head bolts in several passes in the sequence shown Torque 88 8 N m 700 kgf cm 51 ft lbf HINT Each bolt length is indicated in the illustration Bolt length A 121 5 mm 4 783 in B 133 5 mm 5 256 in If anyone of the cylinder ...

Page 73: ...o the bearing caps d Install the 7 bearing caps 12 rocker arms 6 holder clamps and rocker shaft assembly e Install and uniformly tighten the 14 bearing cap bolts in several passes in the sequence shown Torque 25 N m 250 kgf cm 18 ft lbf f Install the 7 others bolts Torque 25 N m 250 kgf cm 18 ft lbf 5 INSTALL INJECTiON NOZZLES See steps 1 2 end 4 in injection nozzles install tion in Fuel System 6 ...

Page 74: ... both sealing surfaces b 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 r...

Page 75: ...he intake manifold b Connect the wate bypass hose to the water outlet e Install the water outlet with the 2 nuts Torque 19 8 N m 200 kgt em ft lbf 16 INSTALL INTAKE MANIFOLD a Install 2 new gaskets and the intake manifold with the 8 seal washers and 8 nuts Uniformly tighten the nuts in several passes Torque 19 8 N m 200 kgf em 14 ft lbt b wi EGR System Connect the 3 vacuum hoses to the injection p...

Page 76: ...s in several passes Torque 20 N m 200 kgf cm 15 ft lbf i Install the vacuum hose to the 3 clamps on the timing belt cover and fuel return hose Ul Connect the 3 vacuum hoses to the vacuum pipe on the intake manifold 19 w o EGR Sy tem INSTALL INTAKE PIPE AND INTAKE HEATER a Place the intake pipe insulator on the cylinder head b Install a new gasket the intake heater and a new gasket to the intake ma...

Page 77: ..._____ i Oil Pressure Sender t I G go z ti u 1 1 InjeclionPumpStay lH Engine Mounting Bracket I J G Ii G kat Water Inlet V Q Thermostat NO 1CYlinderBrOCk Insulator I l I at Jrlll i 1 _ Oil Cooler __ Assembly I O IP n_ i i x 27 Gl ISket Drain Plug 1 1 1 x7 Q I Oil Pump r I Injection Pump l Q Ring Alternator Non reusable part Preeeated part Alternator and Bracket Assembly Taper Screw Plug J ...

Page 78: ...AND WATER PUMP See water pump removal in Cooling System 9 REMOVE WATER INLET AND THERMOSTAT See thermo tat removal in Cooling System 10 REMOVE ALTERNATOR AND BRACKET ASSEMBLY 1 REMOVE INJECTION PUMP See injection pump removal in Fuel System 12 REMOVE NO 1 CYLINDER BLOCK INSULATOR 13 REMOVE INJECTION PUMP STAY 14 REMOVE OIL PAN OIL PUMP TIMING GEAR CASE AND OIL STRAINER See oil pump removal in Lubr...

Page 79: ... Oil Seal Retainer Connecting Rod i No 1 Piston Ain g 1Gi No 2 Piston Ring Oil Ring o l Coil t3o Snap Ring Pislon 1 Snap Ring 1 l Connecting Rod Bushing Connecting Rod Bearin9l __ Connecting Rod Cap Oil NOlz e Check Valve Crankshaft Cylinder Block O H o e G e k e t Ij I j M n Be n C p P Non reusable part ...

Page 80: ...st clearance while moving the connecting rod back and forth Standard thrust cle rance 0 100 0 200 mm 0 0039 0 0079 in Maximum thrust clearance 0 30 mm 0 0118 in If the thrust clearance is greater than maximum re place the connecting rod assembly If necessary re place the crankshaft 3 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Check the matchmarks on the connecting rod and cap to ensure c...

Page 81: ...S 0 50 0 037 0 077 mm 0 0015 0 0030 in Maximum oil cl ranc8 0 10 mm 0 0039 in If the oil clearance is greater than maximum replace the bearings If necessary grind or replace the crank shaft HINT If using a standard bearing replace it with one having the same number If the number of the bearing cannot be determined select the correct bearing by adding together the numbers imprinted on the crank sha...

Page 82: ...OVE PISTON AND CONNECTING ROD ASSEMBLIES a Using a ridge reamer remove all the carbon from the top of the cylinder b Push the piston connecting rod assembly and upper bearing through the top of the cylinder block HINT Keep the bearings connecting rod and cap to gether Arrange the piston and connecting rod assembl ies in correct order 5 CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator measu...

Page 83: ... the upper bearings inserted with the cylin der block Arrange the thrust washers in correct order e Clean each main journal and bearing t Check each main journal and bearing for pitting and scratches If the journal or bearing is damaged replace the bear ings If necessary grind or replace the crankshaft g Place the crankshaft on the cylinder block h Lay a strip of Plastigage across each journal i I...

Page 84: ... same number as the total There are 5 sizes of standard bearings marked 2 3 4 5 and 6 accordingly Number marked Main bearing cap 2 3 Crankshaft 2 3 2 3 1 2 3 Bearing 2 3 4 3 4 5 4 5 6 EXAMPLE Main bearing cap 2 Crankshaft Total number Use bearing 3 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 ...

Page 85: ...he gasket material from the top surface of the cylinder block B Clean cylinder block Using a soft brush and solvent thoroughly clean the cylinder block 2 INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge mea sure the surfaces contacting the cylinder head gasket for warpage Maximum warpage 0 20 mm 0 0079 In If warpage is greater than maximum replace...

Page 86: ...0 94 010 mm 3 7001 3 7012 in Mark 2 94 010 94 020 mm 3 7012 3 7016 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 5 REMOVE CYLINDER RIDGE If the wear is less than 0 2 mm 0 008 in using a ridge reamer grind the top of the cylinde...

Page 87: ...emove the No 1 No 2 and oil rings b Remove the coil by hand HINT Arrange the rings in correct order only 3 DISCONNECT CONNECTING ROD FROM PISTON a Using a small screwdriver pry off the snap ring from the piston b Gradually heat the piston to approx SDoe 176 F c Using a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod HINT The piston and pin are a matc...

Page 88: ...row 39 06mm 2 INSPECT PISTON AND PISTON RING A In pect pilton diameter and oil clearance HINT There are 3 sizes of the standard piston diams ter marked 1 2 and 3 accordingly The mark is stamped on the piston top a Using a micrometer measure the piston diameter at right angles to the piston pin center line 39 06 mm 1 5378 in from the piston head Piston diameter STD Mark O 93 845 93 855 mm 3 6947 3 ...

Page 89: ...nspect 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 cl rance 0 20 mm 0 0079 in If the clearance is greater than maximum replace the piston No 2 and Oil Rings Using a feeler gauge measure the clearan...

Page 90: ...piston ring rebore all the 6 cylinders or replace the cylinder block 3 INSPECT PISTON PIN FIT At so e 1176 F you should be able to push the piston pin into the piston pin hole with your thumb 4 INSPECT CONNECTING ROD A Inspect connecting rod alignment Using a rod aligner and feeler gauge check the con nacting rod alignment e Check for bend M8ximum bend 0 03 mm 0 0012 in per 100 mm 3 94 in If bend ...

Page 91: ...020 mm 1 2995 1 3000 in b Using micrometer measure the piston pin diameter PI ton pin diameter 33 000 33 012 mm 1 2992 1 2997 In e Subtract the piston pin diameter measurement from the bushing inside diameter measurement St nd rd oil cl r nce 0 004 0 012 mm 0 0002 0 0005 in M ximum oil cl r nce 0 03 mm 0 0012 in If the oil clearance is greater than maximum replace the bushing If necessary replace ...

Page 92: ...n pin fit at normal room temperature Coat the piston pin with engine oil and push it into the connecting rod ns oil and push it into the connecting rod with your thumb Oil Hole e SST Bushing SST B SST l 12M2 1 l28l5l f Using SST and a press press in the bushing SST 09222 I 701 0 09222 05020 09222 05030 09222 05040 Using a pin hole grinder hone the bushing to obtain the standard specified clearance...

Page 93: ...155 in 2 CALCULATE AMOUNT TO BORE CYLINDERS 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 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 C...

Page 94: ...m 2 6179 2 6183 in Crank pin diameter STD 58 982 59 000 mm 12 3221 2 3228 in U S 0 25 58 745 68 756 mm 2 3128 2 3132 in U S 0 50 58 495 58 505 mm 2 3029 2 3033 in If the diameter is not as specified check the oil clear ance See steps 6 and 9 in cylinder block assembly If necessary grind or replace the crankshaft b Check each main journal and crank pin for taper and out of round as shown Mexlmum te...

Page 95: ...al retainer edge SST 09223 56010 c Apply MP grease to the oil seal lip B If r r oil eal reteiner i in telled to cylinder block a Using a knife cut off the oil seal lip b Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crank h ft Tepe the screwdriver tip 1 ASSEMBLE PISTON AND CONNECTING ROO a Install a new snap ring on one side of the piston pin hole Ie Apply MP grease ...

Page 96: ...ngine oil d Align the front marks of the piston and connecting rod and push in the piston pin with your thumb 8 Install a new snap ring on the other side of the piston pin hole 2 INSTALL PISTON RINGS a Install the coil by hand b Install a piston ring expander install the oil ring HINT Face the end gap of the oil ring in the opposite direction of coil joint ...

Page 97: ... connecting rod and con necting rod cap CYLINDER BLOCK ASSEMBLY HINT Thoroughly clean all parts to be assembled Before installing the parts apply new engine oil to all sliding and rotating surfaces Replace all gaskets O rings and oil seals with new parts 1 INSTALL OIL NOZZLES AND CHECK VALVES See step 1 in oil nozzles installation in Lubrication System 2 INSTALL MAIN BEARINGS HINT Upper bearings h...

Page 98: ...remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the cylinder block as shown in the illustration eal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 4 5 mm 0 16 0 20 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be re moved and reapplied Immediately remove...

Page 99: ... 9 Check that the painted mark is now at a 90 angle to the front f Check that the crankshaft turns smoothly C Install main bearing cap bolts 6 pointed head Install the 15 main bearing bolts Torque 18 N m 185 kgf cm 13 ft lbf 6 CHECK CRANKSHAFT THRUST CLEARANCE See step 5 in cylinder block disassembly 7 INSTALL PISTON AND CONNECTING ROO ASSEM8L1ES Using a piston ring compressor push the correctly n...

Page 100: ...othly 9 CHECK CONNECTING ROD THRUST CLEARANCE See step 2 in cylinder block disl IISsembly 10 INSTALL REAR OIL SEAL RETAINER a Remove any old packing FIPG material and be care ful not to drop any oil on the contact surfaces of the retainer and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPGl material from the gasket surfaces and sealing groove Thoroughly clean ...

Page 101: ...R AND BRACKET ASSEMBLY Torque 68 6 N m 700 kgf cm 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 PULL...

Page 102: ... 0118 in Idl r ga r inside d meter 45 000 45 025 mm 1 7717 1 7726 in Idler g r sheft diemeter 44 950 44 975 mm 1 7697 1 7107 in l Idler g r oil elelrlnee STO 0 025 0 075 mm 0 0010 0 0030 in MllCimum 0 20 mm 0 0079 in l Geer bleklesh STO 0 05 0 15 mm 0 0020 0 0059 in Mlximum 0 30 mm 0 0118 in l Cylinder head W rp ge MllCimum 0 20 mm 0 079 in l V lv sellt R f eing lingle Intlk 25 45 70 Exhlust 25 45...

Page 103: ... 1018 1 1023 in Circll runout M limum 0 10 mm 0 0039 in CIIm 10M hlight Sf0 Int kI 48 498 48 598 mm 1 9094 1 9133 n Ex h usl 50 734 50 834 mm 1 9974 2 0013 n MiNmum Int kI 47 998 mm 1 8897 in Ex h usl 50 234 mm 1 9777 in M n fold WIrPlgl MIl imum 0 40 ITWTl 0 0157 in Cylinder block Cylinder hlad urf ce w rPlg MIl imum 0 20 mm 0 0079 in Cylinder bore di meter STO STO Mertc 1 94 000 94 010 mm 3 7001...

Page 104: ...008 33 020 mm 12 995 1 3000 inJ 33 000 33 012 mm 1 2992 1 2997 in 0 004 0 012 mm 0 0002 0 0005 in 0 03 mm 0 0012 in 8 300 8 400 mm 0 3268 0 3307 in 7 95 mm 0 3130 in Thru t wI her thickne Mlin journll oil clllrince STO STO U S 0 25 U S 0 50 Mlllimum 0 040 0 240 mm 0 00 0 0094 in 0 30 mm 0 0118 in 2 930 2 980 mm 0 1154 0 1173 in 0 036 0 054 mm 0 0014 0 0021 in 0 037 0 077 mm 0 0015 0 0030 in 0 10 1...

Page 105: ...0 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 It Cylinder head 19 6 DO Intake manifold It Cylindlr heed 19 6 DO Intlke pipe It Inlake manifokl 19 8 00 EGR v lve Idapter It Exhault mlnifold 40 400 8 EGR vllve brackl...

Page 106: ...ENGINE TURBOCHARGER SYSTEM TURBOCHARGER SYSTEM PREPARATION SST SPECIAL SERVICE TOOLS EG 93 _ _K 09992 00241 Turboeharger Preuure Gauge EOUIPMENT Dial indicator Torque wrench Impeller wheel ...

Page 107: ...assembly Do not drop it or bang it aga inst anything or grasp it by easily deformed parts such as the actuator or rod when moving it 6 Before removing the turbocharger plug the intaka and exhaust ports and oil inlet to prevent entry of dirt or other foreign material 7 If replacing the turbocharger check for accumula tion of sludge particles in the oil pipes and if neces sary replace the oil pipes ...

Page 108: ...SYSTEM 5 LEAK IN EXHAUST SYSTEM lCheck Procedure end Correction Method Check inlake air system and repair or replace parts as necessary See page EG 97 Check intake air system and repair or replace parts as necessary ISee page EG 97 Check exhaust system and repair or replace parts as necessary See page EG 97 Check exhaust system and repair or replace parts as necessary See page EG 971 6 ERRATIC TUR...

Page 109: ...EL CONSUMPTION EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST Possible Cause Check Procedure and Correction Method FAULTY TURBOCHARGER OIL SEAL I Check for oil leakage in exhaust system Remove the turbine elbow from he turbocharger and check for excessive carbon deposits on the turbine wheel Excessive carbon deposits indicate e faulty turbocharger Check for oil leakage in intake air system Check for a...

Page 110: ...nents Repair or replace Foreign material in passages Remove Leakage from components Repair or replace Cracks in components Check and replace 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 ...

Page 111: ... Hose Turbo Oil Pipe wI EGR System Intake Pipe Assembly Clamp b Gasket 0 I Engine Vacuum Hose Ground 0 Strap 0 w o EGR System Exhaust Manifold Turbine Outlet r Elobow Gasket No 1 T UrbowaterPiPe i rd Gasket Ga Sket I Li il G i J 1 r 1 1 Gasket i V Turbo Heat Insulator Non reusable part ...

Page 112: ...RGER HEAT INSULATOR Remove the 2 bolts and heat insulator 5 DISCONNECT WATER BY PASS HOSES FROM NO 1 TURBO WATER PIPE B REMOVE TURBINE OUTLET ELBOW Remove the 4 nuts turbine outlet elbow and gasket 7 REMOVE TURBOCHARGER STAY Remove the 3 bolts and turbocharger stay 8 REMOVE TURBOCHARGER AND EXHAUST MANIFOLDS ASSEMBLY a Disconnect the turbo oil hose from the cylinder block b Remove the union bolt a...

Page 113: ...GER FROM EXHAUST MANIFOLDS Remove the 4 nuts turbocharger and gasket 1 REMOVE NO 1 TURBO WATER PIPE Remove the 2 nuts No 1 turbo water pipe and gasket TURBOCHARGER INSPECTION 1 INSPECT IMPELLER WHEEL ROTATION Grasp the edge of the turbine wheel and turn it Check that the impeller wheel turns smoothly If the impeller wheel does not turn or jf it turns with a heavy drag replace the turbocharger asse...

Page 114: ...he turbine shaft Maximum oil clearance 0 1a mm 0 0071 in or I If the radial play is not as specified replace the turbo charger assembly EG Dial Indicator Spacer Bearing SST_ G Valve Closed 4 INSPECT ACTUATOR OPERATION a Disconnect the actuator hose b Using SST turbocharger pressure gauge 88 96 kpa 0 90 0 98 kgf em 12 8 13 9 psi of pres sure to the actuator and check that the rod moves If the rod d...

Page 115: ...URBO OIL PIPE Install a new gasket and the oil pipe with the 2 nuts Torque 18 1 N m 185 kg cm 13 t lb 4 INSTALL TURBOCHARGER AND EXHAUST MANIFOLDS ASSEMBLY a Install 2 new gasket to the cylinder head b Install the turbocharger and exhaust manifolds as sembly with the 12 nuts Torque 7 N m 425 kgf cm 31 ft lb d e 0 5 U Install 2 new gaskets and the union bolt of the turbo oil pipe Torque 24 5 N m 25...

Page 116: ...GINE OIL LEVEL 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 N m kgf cm ft lbl No 1 turbo wllter pipe Turbocharger he8t insuletor II Turbocharger 7 8 80 69 in fbl Turbocharger...

Page 117: ...halt C Gov mot plug ce l 09241 76022 Injection Pump Stend Sel q 09245 54010 Injeetion Pump Sttnd Arm e 09260 54012 Injection Pump Tool Sel Qi5i S l1l 09262 54010 Oi tributor H d P11Jl1 Wrench ID 09269 54020 Socket 14 mm aD 09269 54030 Tweeze 09269 54040 Governor LIve SYppor1 Bolt 0 Wrench 09262 54020 Regul tor V Iv Wrench elD 3 Ii 09268 17010 2 Spring Nonl Tool tt 6 I ...

Page 118: ...r DlJ O CoO 09951 05010 H ng r 150 Injec tion pump 09952 05010 Slid Arm Injection pump J 09953 05020 Center Bolt 150 Injection pump 09954 05030 Ct w No 3 Inj Ktion pump 9 o 09992 00241 Turbochafllef Pressure G ugtl EG RECOMMENDED TOOLS C_CI 09082 00050 TOYOTA EI ctriul Tn r SeL 09200 000I0 Engine Adjust Kit q 6Y 09258 00030 Hose Plug Set Plug lor fuel hose f ...

Page 119: ...w EG Angle gauge Brass brush Diel indicator with magnetic base Graduated cylinder Injection nozzle tester Injection pump tester Inner pressure gauge Micrometer Steel square Timer measuring device TorClue wrench Vernier calipers Wooden stick ...

Page 120: ...ghtly screw the fuel filter into place and tighten it until the gasket comes into contact with the seat Tighten it additional 3 4 turn by hand B Remove fuel filter werning switch from fuel filter Using pliers remove the warning switch and 0 ring NOTICE B car ful not to dam g the werning switch Inltell fuel filter wlrning switch to new fuel filter Install a new 0 ring to the warning switch Apply fu...

Page 121: ... 260 40 mmHg 10 24 1 57 in Hg or more to the vacuum switch port b Using an ohmmeter measure the resistance between terminal 1 and and the switch body R lat nee At 20 C SS F 0 5 2 0 0 If the resistance is not as specified replace the fuel heater and vacuum switch assembly 3 INSPECT VACUUM SWITCH A In pect witch continuity Using an ohmmeter check that there is no continuity between terminal 1 and th...

Page 122: ...0 1 b Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 4 Ohmmeter DO f0 Continuity 4 3 3 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as specified replace the relay 4 REINSTALL FUEL HEATER RELAY ...

Page 123: ...EMOVAL AND INSTALLATION Injection Nozzle C EGR Valve Bracket _ p Gasket l _1 Intake Pipe Assembly Gasket wI EGR System Intake Heater Gasket Intake Pipe Vacuum Hose w o EGR System Non reusable part 1fP I Throttle Position Sensor Connector Except Australia MIT ...

Page 124: ...ntake manifold b Remove the 4 nuts and 2 clamps from the intake manifold c Remove the 2 nuts and 2 clamps REMOVE NO NOZZLE LEAKAGE PIPE Disconnect the fuel return hose from the No 1 nOlzle leakage pipe Remove the nut holding the No 1 oule leakage pipe to the cylinder head Remove the 6 hollow bolts 7 gaskets and No 1 nOlzle leakage pipe 3 REMOVE ACCELERATOR LINK ASSEMBLY a w o Australia MIT Disconn...

Page 125: ...n nozzles in correct order INJECTION NOZZLES TEST _ 0 Good Good Faulty Faulty Faulty Faulty 1 LEAKAGE TEST While maintaining pressure at about 981 1 961 kPa 10 20 kgf cm2 142 284 psi below No 1 open ing pressure adjust by tester handle check that there is not dripping for 10 seconds from the injection hole or around the retaining nut If the nozzle drips within 10 seconds replace or clean and overh...

Page 126: ... Nozzle Body Y Nozzle Holder Retaining Nut _ INJECTION NOZZLE DISASSEMBLY DISASSEMBLE INJECTION NOZZLES a Remove the nOlzle holder retaining nut NOTICE When disassembling the nozzl b careful not to drop the inner parts b Disassemble the injection nOlzle INJECTION NOZZLES CLEANING AND INSPECTION I NOZZLE CLEANING a To wash the nozzles use a wooden stick and brass brush Wash them in clean diesel fue...

Page 127: ...se conditions are present replace the nozzle assembly One third of its lenglh About 60 degrees 2 INSPECT NOZZLE ASSEMBLY a Wash the nozzle in clean diesel fuel HINT Do not touch the nozzle mating surfaces with your fingers b Tilt the nozzle body about 60 degrees and pull the needle out about one third of its length el When released the needle should stick down into the body vent smoothly by its ow...

Page 128: ... indicator scale to 0 mm 0 in on top of the SST or the surface plate SST 09266 17010 INJECTION NOZZLES ASSEMBLY AND ADJUSTMENT T 3 0mm SST unll SST A lIFT Dimension t e Using a micrometer measure dimension t of the SST A SST A 09266 17020 d Using SST place the nOlzle assembly and SST A on the SST BI as shown in the illustration SST A 09268 17020 8 09266 17010 1 __V SST IBI tj SST SST e Using SST s...

Page 129: ... L2 SST 09268 1701 0 P13320 P2un PZJ330 DiJensi on l2 SST Dimension L3 tF i r l 8 m Using a micrometer measure dimension L3 of the adjusting shim Needle lift 11 l2 L3 Needle lift 0 23 0 28 mm 0 0091 0 0110 in If the needle lift dimension is not as specified change the adjusting shim Adjusting shim thickness mm In 1 900 0 0748 1 925 0 0758 1 950 0 0768 1 975 0 0778 2 000 0 0787 Upward CI IJ Downwar...

Page 130: ...crometer measure dimension 0 of the tip packing Dimension L4 0 C dl Using a micrometer measure dimension E and F of the NO 2 pressure spring seat Dimension l5 E F Pre lift L4 L5 Pre lift 0 085 0 105 mm 0 00335 0 00413 in If the pre lift dimension is not as specified change the adjusting No 2 pressure spring seat Adjusting spring 8 t thickness mm In 3 09 0 1217 3 12 0 1228 3 15 O 1240 3 18 0 1252 3...

Page 131: ... socket wrench torque the retain ing nut Torque 30 N m 300 kgf cm 22 ft lbfl NOTICE O r torquing could caul the nozzl deforma tion and the ne dle adhesion or other defects e Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut CAUTION Do not piece your finger over the nozzle Injec tion hole d Pump the tester handle a few times as fast as possible to dis...

Page 132: ...lder 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 hole...

Page 133: ...ALL INJECTION PIPES a Place the 2 intake manifold insulators on the intake manifold b Attach the 6 injection pipes to the injection nozzle and injection pump c Tighten the 6 union nuts to the injection pump Torque 24 5 N m 250 kgf cm 25 ft lbf 1 INSTALL INJECTION NOZZLES a Install a new a ring to the injection nOlzle bl Place 6 new nozzle seats into the injection nOlzle holes of the cylinder head ...

Page 134: ...t 1I the gaskat A ao that it connecting part ia between the pipe a hown in the illustration b Using SST apply the SST to the fuel return side of the No 1 nozzle leakage pipe and maintain 49 kPa O 5 kgf cm2 7 1 psi of pressure for 10 seconds to check that there are no leaks SST 09992 00241 c Connect the fuel return hose to the No 1 nozzle leak age pipe 5 INSTALL ACCELERATOR LINK ASSEMBLY a Install ...

Page 135: ...EMOVAL AND INSTALLATION w o EGR System wi EGR System Intake Pipe Gask e t 7C Intake Heater Gasket No 2 Flange liming Belt CO ler Seal Washer c Clamp l I Vacuum Hose Non reusable part EGRValve Brackel 0 if _ _ __ Gasket Intake Pipe Assembly Timing Belt Gasket ...

Page 136: ...ection Pump a Ring Clamp No 1 Cylinder Block Insulator l D Ring I clampr Accelerator link I Assembly Inlake Manifold Insulator t t 1 rea I r No 3 Nozzle leakage Pipe i liidt I _ I r I I I I 1 I I I I I I I f I I II I _ I I I I I 1 r Clamp I I 11K t 1 L 2 I __ J I I t I 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 j J I 1 J V J Injection Pipe clamp j Non reusable part ...

Page 137: ...ES See steps 1 3 end 5 in injection nozzle removal 5 DISCONNECT WATER BYPASS HOSES FROM THERMO WAX 6 DiSCONNECT HOSES Disconnect these hoses from the injection pump 1 SICS vacuum hose 2 Boost compensator hose 3 wi BACS SACS vacuum hose 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 hi...

Page 138: ...g SST remove the injection pump SST 09950 40010 09957 040101 09950 50010 09951 05010 09952 05010 09953 05020 09954 050301 NOTICE Tighten the 2 bolts more than 8 mm 0 31 in at SST ao that it I balanced Do not hold or carry the injection pump by the adjusting leyer Do not put the injection pump at an angle more than 450 from the horizontal 9 Remove the No 1 cylinder block insulator h Remove the O ri...

Page 139: ... I GuJe dl1 SICSAdJuS lngSCrew IY i Gasl el I Gasket I l Bushing il 1 CoII I Q J J J I F lload Govemot er k81 SetScrew ConnectingPIn _ I 1 _ I c 1 o 1dIe_ l O L t c AI _ Sc _ I I cap L_Control I I _Inn I I I Gasltet O Rlng O Rlng Q v I j 8Sner Control Lever Washer I Gasket I No 2 SICS Lever ca SupportPjn GISkOlll Gasket Europe I Adjusting 1 r seat Lever AU tr II t mg R80ulalor Sho oamperSpring Val...

Page 140: ...ENGINE FUEL SYSTEM Timer Shim Timer Adjusting 5aew LH rmer Covel EG 27 Roller and Washar ...

Page 141: ...ER a Remove the idle up lever link from the adjusting lever b Using a 5 mm hexagon wrench remove the 3 bolts and idle up lever 5 mm Hexagon Wrench 8 REMOVE THERMO WAX a Using a 5 mm hexagon wrench temporality install the bolt AI b Using a screwdriver turn the cold starting lever coun ld4 A 1erclockwise 0 Using a 5 rnm hexagon wrench remove the bolt B Melal Plate r 5 mm Hexagon Wrench n d Put a met...

Page 142: ... bracket assembly B REMOVE SICS ACTUATOR a Remove the SICS adjusting screw b Remove the clip Ie Disconnect the wire harness d Remove the nuts and SICS actuator e Remove the lock plate f Remove the maximum speed adjusting screw g Using a 5 mm hexagon wrench remove the 3 bolts and SICS actuator bracket 9 REMOVE NO 1 SICS LEVER Remove the nut and NO 1 SICS lever 10 REMOVE CAP Remove the cap and gaske...

Page 143: ...r a Remove the fuel cut solenoid O ring spring valve strainer and wave washer 12 REMOVE PICKUP SENSOR a Remove the pickup sensor and O ring b Disconnect the sensor lead wires from the connector 13 REMOVE ADJUSTING LEVER a Place the matchmarks on adjusting lever and shaft b Remove the nut adjusting lever and return spring 14 REMOVE GOVERNOR COVER a Remove the idle speed adjusting screw b Using a 5 ...

Page 144: ...e governor link and remove the governor cover and gasket 215519 W 618 Europe FU2 2 Australia 15 REMOVE GOVERNOR ADJUSTING LEVER SHAFT FROM GOVERNOR COVER a Remove the adjusting lever shaft assembly from the governor cover b Disassemble these parts 1 O ring 2 Washer 16 DiSASSEMBLE BOOST COMPENSATOR A Remove lever control spring Remove the bolt gasket and lever control spring 5mm Hexagon Wrench B Re...

Page 145: ...r shim 4mm He lagon Wrench b Remove the nut and disassemble these parts 1 2 spring seats 2 Diaphragm Q t 2 3 Push od 1 1 3 C Remove guide bushing D Remove control lever a Using a 4 mm hexagon wrench remove the 2 bolts and gaskets M bl Using a small screwdriver push out the support pin and remove the control lever ...

Page 146: ...e the rubber cap and overflow screw b wi BACS Remove the overflow screw and gasket G Remove full load set screw 17 CHECK FLYWEIGHT HOLDER THRUST CLEARANCE See step 16 in injection pump assembly Thrust cl rance 0 15 0 35 mm 0 0059 0 0138 in 18 REMOVE GOVERNOR SHAFT AND FLYWEIGHT HOLDER a Remove the governor shaft lock nut by turning it clockwise NOTICE The governor shaft and lock nut have LH thread...

Page 147: ... bolts and injection pump stay b Remove the bolt and fuel pipe bracket 20 REMOVE DISTRIBUTIVE HEAD PLUG Using SST remove the distributive head plug and D ring SST 09260 54012 09262 54010 5mm Hexagon Wrench 21 REMOVE DISTRIBUTIVE HEAD a Using a 5 mm hexagon wrench remove the 4 bolts and wire clip b Remove the distributive head and these parts 1 2 lever support springs 2 2 plunger spring guides 3 2 ...

Page 148: ... 54030 11q NOTICE Do not touch the sliding lurfac of the pump 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 111 0 2 3 4l l 1 Shim_ Pllll86 24 REMOVE FACE CAMPLATE AND COUPLING Remove the face camplat8 and coupling 25 REMOVE ROLLER RING AND DRIVE SHAFT a Remove the timer clip and stopper pin b Push the s...

Page 149: ... 03937 0 05512 in If the protrusion is not as specified replace the cou pling spring NOTICE Do not remove the coupling spring unlit neees y If you remove the coupling spring replace it with new one e Remove the drive shaft governor drive gear 2 joint rubbers assembly set key and drive shaft washer Joint Rubber Drive Shaft Assemblv 1 Remove the drive gear and 2 joint rubbers from the drive shaft as...

Page 150: ...emove the timer adjusting screw e Remove the O ring from the timer adjusting ring i i o r t SST Plum 27 REMOVE FUEL FEED PUMP a Remove the 2 screws b Using a piece of wire remove the feed pump cover e Remove the feed pump rotor 4 blades and liner NOTICE Be careful not to interchange the blade positions B careful not to damage the pump body 28 REMOVE REGULATOR VALVE Using SST remove the regulator v...

Page 151: ...t 10 the It 1bill when doing en oyer haul 3 INSPECT PLUNGER SPRINGS FOR DEVIATION Using a steel square check the deviation of the plung er springs M ximum devi tion 2 0 mm 0 079 in If deviation is greater than maXimum replace the springs INSPECT PUMP PLUNGER SPILL RING AND DISTRIBUTIVE HEAD Tilt the spill ring distributive head slightly and pull out the plunger When released the plunger should sin...

Page 152: ... 0 0008 In If the variation is greater than specification replace the roller ring and roller as a set 6 INSPECT FUEL CUT SOLENOID a Connect the solenoid valve body and terminal to the battery terminals b You should f881 the click from the solenoid valve when the battery power is connected and disconnected If the solenoid valve is not operating properly replace it 7 INSPECT PICKUP SENSOR Using an o...

Page 153: ...7 ft lbf 2 INSTALL REGULATOR VALVE a Install 2 new 0 rings to the regulator valve b Using SST install the regulator valve SST 09260 54012 09262 540201 Torque 8 8 N m 90 kgf cm 78 in lb 3 INSTALL FUEL FEED PUMP a Install the liner rotor and 4 blades b Check that the liner and blades are facing in the correct direction as shown c Check that the blades move smoothly d Align the fuel outlet holes of t...

Page 154: ...ro EG e Position the key groove of the feed pump rotor upward Drive Shaft Washer Sel Key d Install the drive shaft washer and set key on the drive shaft and insert the drive shaft assembly into the pump housing 8 Check that the drive shaft turns without catching 5 INSTALL TIMER PISTON a Apply grease to the timer piston b Install the sub piston into the timer piston el Insert the timer piston into ...

Page 155: ...Carefully install the slide pin into the sub piston e Install the stopper pin and clip 7 INSTALL TIMER SPRING a Install a new a ring to the timer adjusting screw b Using a 5 mm hexagon wrench install the timer ad justing screw to the LH timer cover and temporarily install the nut l 1f 6 4 e Install these parts 1 NewO ring 2 RH timer cover 3 Inner spring 4 Outer spring 5 Shim 6 New O ring 7 LH time...

Page 156: ...spring seats 3 2 plunger springs 4 Lower spring seat 5 Upper plunger plate 6 Lower plunger plate 7 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 b Using a 5 ...

Page 157: ...n use a 1 2 mm 0 047 in shim Select 2 shims which have the same thickness 10 INSTALL COUPLING Install the coupling ro 11 INSTALL FACE CAMPLATE a Face the drive shaft with the key groove facing upward b Install the camplate with the camplate pin facing the governor cover side 12 INSTALL GOVERNOR LINK a Using SST install the governor link with 2 new gas kets and the 2 support bolts Torqu 14 N m 1 0 ...

Page 158: ...SST install the pump plunger and 2 plunger springs SST 09260 54012 09269 540301 14 INSTALL DISTRIBUTIVE HEAD a Apply grease to these parts and install them to the distributive head 1 2 plunger spring guides 2 2 new selected plunger spring shims 3 2 upper spring seats 4 2 lever support springs 5 New 0 ring fU0210 FU021l mlD7 b Install the distributive head NOTICE Be careful not to damage the pump p...

Page 159: ...agon 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 0...

Page 160: ...rubber cap facing the arrow downward B Install No 2 SICS lever a Assemble these parts to the No 2 SICS lever 1 Washer 2 New a ring b Install the No 2 SICS lever washer and 0 ring as sembly to the governor cover C Install control lever a Insert the connecting pin into the governor cover b Using a small screwdriver install the control lever with the support pin 4 mm Hexagon Wrench c Using a 4 mm hex...

Page 161: ...haft to the governor link and twist the shaft lightly_ cl Australia Install the speed control spring to the adjusting shaft d Australia Install a new gasket to the groove of the governor cover e Australia Install the damper spring and spring seat and connect the speed control spring to the spring seat 115519 fl Using a 5 mm hexagon wrench install the governor cover with the 4 bolts Torque 8 3 N m ...

Page 162: ... oil diesel fuel to the top surface of the plunger and when 49 kpa 0 1 kgf cm2 1 4 psi of air is applied to SST bubbles appear on the upper surface of the plunger f Slowly rotate the drive shaft in the pump rotation direction clockwise and read the dial indicator when the bubbles on the top of the plunger disappear Pre stroke 0 48 0 52 mm 0 0189 0 0205 in If the pre stroke is not as specified repl...

Page 163: ...BLE BOOST COMPENSATOR A Inltell guide bushing Install and adjust the guide bushing to the dimension A as shown in the illustration Dimension Euro 17 3 17 4 mm 0 881 0 885 in Austr li 18 9 19 0 mm 0 744 0 748 In B Inltell boost compen tor diaphragm a Adjust boost compensator shim Place the shim on the guide bushing Using vernier calipers measure the dimension B as shown in the illustration Dim nsio...

Page 164: ...while pushing on the dia phragm assembly dimension X with vernier cal ipers as shown Dimension X wI SACS 8 8 9 0 mm 0 346 0 354 in w o SACS 8 5 8 7 mm 0 335 0 343 in HINT Measure at the center of the hole Place match marks on the diaphragm assembly and governor cover Shim Remove the diaphragm assembly 5 2 5 d Insert 1 5 2 5 cc 0 09 0 15 cu in of engine oil into the bushing hole Matchmarks FU2843 4...

Page 165: ... a Install a new O ring on the fuel cut solenoid b Install the wave washer strainer valve spring and fuel cut solenoid Torque 22 N m 225 kgf cm 16 ft lbf Ie Install the lead wire to the fuel cut solenoid with the nut Torque 1 7 N m 17 kgf cm 15 inAbf d Install the dust cover to the fuel cut solenoid e Install the wire harness to the wire clip f Install the lead wire connector to the bracket 28 INS...

Page 166: ... screwdriver turn the cold starting lever coun terclockwise approx 200 b Put a metal plate thickness of 5 0 8 0 mm 0 20 0 31 in between the cold starting lever and thermo wax plunger c Install a new O ring to the pump body d Using a 5 mm hexagon wrench temporality install the thermo wax with the 2 bolts e Using a screwdriver turn the cold starting lever coun terclockwise f Using a 5 mm hexagon wre...

Page 167: ...90 kPa d e 35 INJECTION PUMP ADJUSTMENT _ 1 PRE TEST CHECK AND PREPARATION a The specifications for t8St nOlzle and nOlzle holders are as follows Test noule 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...

Page 168: ...ing a 5 mm hexagon wrench remove the 2 bolts and RH timer cover Install the inner pressure gauge with the timer meas uring device Part No 95095 10231 and 95095 10480 NIPPONOENSO HINT Bleed the air by the air bleed screw Connect SST turbocharger pressure gauge to the boost compensator SST 09992 00241 Turbocharger Pressure Gauge SST Inner Pressure Gauge Fuel Pressure Gauge NOlzle Fuel Filter Fuel Fe...

Page 169: ...auge 0 Secure the adjusting lever fully on the maximum speed side p Check the installation direction of the camplate as follows Disconnect the injection pipe from the position marked C on the distributive head Using SST remove the delivery valve holder as sembly and gasket SST 09260 54012 09269 54020 fun n Check that fuel is flowing out when the mark is in the position shown in the illustration If...

Page 170: ...r at least 30 seconds to discard all the fuel 2 PRE SET FULL LOAD INJECTION VOLUME a Set the adjusting lever to maximum position b Apply 67 2 kPa 503 7 mmHg 19 83 in Hg of vacuum to the SICS actuator 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 kgfjcm2 17 7 psi of pressure to the boost compensator e Measure the injection volume Pu...

Page 171: ...sition 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 f Remove the lock plate g Adjust the ...

Page 172: ... lever coun terclockwise approx 20 b Put a metal plate thickness of 5 0 8 0 mm 0 20 0 31 in between the cold starting lever and thermo wax plunger HINT Keep the cold starting system released until all measurements and adjustments are finished Piston strokes mm lin 0 63 1 6310 025 0 064 3 24 4 2410 128 0 167 5 85 8 8510 230 0 2701 7 7 8 7 0 303 0 3431 0 22 1 22 0 009 0 0481 2 83 3 83 0 1 O 1511 5 4...

Page 173: ...f pressure to the boost compensator Measure the time it takes for pressure to drop to 95 kPa 0 97 kgf cm 13 8 psi Pressure drop 10 seconds or more r d Long Spring I e Short Spring c EG Pump rpm FU3102 p OO P O PI2 I l 9 a b 10 ADJUST FULL LOAD INJECTION VOLUME a The adjusting lever angle for the adjustment below should be as shown in the illustration Adjusting lever ngl b Apply 67 2 kPa 503 7 mmHg...

Page 174: ...s the injection volume Ul Check that when the actuator rod for SICS is with drawn the most the gap between SICS lever and SICS adjusting screw is 3 mm or more If it less than 3 mm add 1 adjusting washer on the nut side and check that the gap is 3 mm or more k Check that when the actuator is not operating the gap between SICS lever and SICS adjusting screw is 0 mm II ADJUST MAXIMUM SPEED lal w o BA...

Page 175: ...me 100 41 2 15 60 19 60 Volume during w BACS Plus 21 3 0 42 6 0 200 10 95 1 20 starting 720 OtO O 7 4 34 0 44 0 51 1 800 121 9 17 74 1 24 17 7 1 081 1 080 79 14 92 16 52 1 6tO l0 Basic full load 0 81 11 5 O g 1 01 injection volume 00 0 0 0 14 00 15 00 Volume during 0 85 0 92 Starting w o SACS Plus 21_31 200 8 02 9 22 720 010 0 10 49 0 56 1 800 7 17 74 10 81 11 5 IUS l j C SST rSleeve Plug It m E R...

Page 176: ...etainers 2 Stop ring F I2112 Using a press press in the sleeve plug assembly to the governor sleeve 13 ADJUST FULL LOAD MINIMUM INJECTION VOLUME a Set the adjusting lever to maximum position b Apply 67 2 kPa 503 7 mmHg 19 83 in Hgl of vacuum to the SICS actuator c wlo BACS Release the pressure from the boost compensator dl wi BACS Apply 49 kPa 0 50 kgf cm2 7 1 psi of pressure to the boost compensa...

Page 177: ...iver adjust the injection volume by the guide bushing HINT When the guide bushing is turned clockwise as seen from above the injection volume will increase 15 CHECK FOR CHARACTERISTiC TENDENCY a Apply 67 2 kPa 503 7 mmHg 19 83 in Hg of vacuum to the SICS actuator b w o BACS Apply 15 7 kPa 0 16 kgf cm2 2 3 psi of pressure to the boost compensator e w BACS Apply 41 2 kPa 0 42 kgf cm2 6 0 psi of pres...

Page 178: ... 0 0 7 14 8 34 0 44 0 511 79 0 81 11 5 14 04 15 64 0 86 0 95l 40 0 41 5 8 12 70 14 3010 77 0 87 wlo BACS 720 200 15 7 to 16 2 3 8 80 10 00 0 54 0 611 0 6 10 10l or less 010 0 8 02 9 22 0 49 0 56 If not within standard value check each sliding part of the boost compensator and check whether or not there is any oil Starting point 01 the load sensing timer AdjUlLIting lever No of meesuring Pump rpm p...

Page 179: ...rease approx 3 cc 0 2 cu in with each 1 2 turn of the governor shaft Item Pump No of mesuring Injection volume of each cylinder Timer piston stroke pm strokes cc leu in mmlin 1 w BACS 440 200 Measured value at step If minus 1 56 2 56 3 8 0 231 1 0 0 06 0 061 0 1011 w o BACS 440 200 Me8Sured value a1 step 10 minus 29 2 29 3 810 231 1 0 0 061 0 051 0 090 HINT The end point is hard to identify so use...

Page 180: ...measuring limit Remarks lever angle cpm strokes each cylinder cc teu in 1 cc eu in Full position 400 7 86 10 6610 48 0 65 Europe 200 1 10 0 04 0 07 0 51O 03 Adjust Minus 12 220 350 q 0 70 Australia Full position 400 7 86 10 66 0 48 0 65 200 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 _ 220 400 q_0 70 1 10 0 04 0 07 0 5 0...

Page 181: ...etal plate between the cold starting lever and thermo wax plunger h Loosen the nut from the cold starting lever i Measure the clearance between the adjusting lever and idle speed adjusting screw Fuel lemperltUrl CI renee 2S C 68 F 0 95 mm 0 037 in SO C C12rFj omm 0 in GJ Adjust by turning the cold starting adjusting screw Measure the timer piston stroke k Fuel tempereture Timer pilton troke mm in ...

Page 182: ... 150 rpm q 3 1 cc 0 9 cu in or I b Check the adjusting lever movement Adjusting lever engle 38 480 21 w o AUltrelie MIT INSTALL THROTTLE POSITION SENSOR AND BRACKET a Europe Set the adjusting lever to the angle for the injection volume shown below Pump No of measuring Injection volume of each cylinder strokes cc leu in 1 000 200 6 66 DAG6 b Attach the portions of the throttle position sensor and a...

Page 183: ...at its output will be 0 6 0 025 V i Tighten the 2 screws holding the throttle position sensor to the bracket 22 SEAL PARTS a Seal the full load set screw with new lead seal b Install the lock plate to the maximum speed adjusting screw 23 INSTALL FUEL PIPE BRACKET Install the fuel pipe bracket with a bolt 24 INSTALL FUEL PIPES a Install the nozzle leakage pipe No 2 and 2 new gaskets with the union ...

Page 184: ... h i j Install the injection pump stay with the 2 bolts Torque 69 N m 700 kgf cm 51 t lbt NOTICE B for tightening to the tandard torque check whether the pump tay i up against the injection pump If there is a gap loosen the bolts joining the pump stay to the cylinder block and set the pump stay against the injection pump Install a new 0 ring to the injection pump drive gear Install the injection p...

Page 185: ...lt installation in Engine Mechanical 6 CHECK INJECTION TIMING See injection timing adjustment and inspection in Engine Mechanical 7 INSTALL INJECTION PIPES Se8 steps 3 5 and 7 in injection nozzle installation 8 FILL WITH ENGINE COOLANT 9 START ENGINE AND CHECK FOR FUEL LEAKAGE STARTING INJECTION CONTROL SYSTEM SICS ON VEHICLE INSPECTION INSPECT SICS a With the engine stopped after it is warmed Up ...

Page 186: ...ing an ohmmeter check that there is continuity between the terminals Resistance At 20 C 88 F 38 5 44 5 Q If there is no continuity replace the VSV Ohmmeter 00 o No continuiTy B Inspect VSV for ground Using an ohmmeter check that there is no continuity between each terminal and the body If there is continuity replace the VSV C Inspect VSV operation a Check that air flows from pipe E to the filter ...

Page 187: ...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 ur dju 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 ...

Page 188: ...10 039 in 1 1 5 mm 0 059 in 2 0 mm 0 079 in 0 15 0 35 mm 0 0059 0 0138 in 1 05 mm 0 0413 in 1 25 mm 0 0492 in 1 45 mm 0 0571 in 1 65 mm 0 0650 in 1 1 85 mm 0 0728 in 0 5 2 0 mm 0 020 0 079 in 0 48 0 52 mm 0 0189 0 0205 in 0 01 mm 0 004 in from 1 90 mm 0 0748 in to 3 20 mm 0 1280 in Shim ere available in 12 sized in increments 0 2 mm 0 008 in from 1 1 mm 0 043 in to 3 3 mm 0 130 in _ E TORQUE SPECI...

Page 189: ...butive h d plUV x Distributive MId 800 5 D phr gm x Push rod 7 35 75 65 inAbt a phr gm cover x Governor cove 7 35 75 85 inAb LIver control spring x Governor COYlr 11 3 115 FUll c Jt lo noid Distributive h d 22 225 LI d wire FUI cut solenoid 1 7 17 15 in lbf C p II Injeclion pump 11 115 SICS ctu tor br ckl II Governor cov r 9 3 95 82 inAbt SICS Clultor II SICS clullor br ckel 9 35 95 83 in lbl SICS...

Page 190: ...T _ 10 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 AIT 10 9 liters 11 5 US qts 9 6 Imp qts w o Heeter MIT 10 4 liters 11 0 US qts 9 2 Imp qts AIT 0 2 liters 11 1 US qlS 9 0 Imp qts SSM SERVICE SPECIAL MATERIALS 08826 00...

Page 191: ...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 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 1 0 DRAIN ENGINE COOLANT _ Orain e J Plug Seal Packing Dr...

Page 192: ...oolant Th coolant should be mixed with demineralized wat r or di tilled wat r Capacity wI Front and r r h t MIT 12 0 lit 12 7 US qt to 7Imp qt AIT 11 8 lit 2 5 US qt 0 4 Imp qtl w Front h t r MIT 11 1 Iita 7 US qt 9 8 Imp qt AIT 10 9 lit 11 5 US qt 9 6 Imp qt w o H t r MIT 10 lit r 11 0 US qt 9 2 Imp qt AIT 10 2 Iiten 11 1 US qt 9 0 Imp qt b Install the radiator cap e Start the engine and bleed th...

Page 193: ...l VVasher _ Clamp Jl Intake Pipe Assembly g J I C EGR Valve Bracket if Gasket J Inlake Pipe CYljn lnSulator Head C over Fluid Coupling EQ EQ fr l il 1S 1 Vacuum Hose Timing Belt Cover _ Vacuum Hose J Gasket Intake Heater Gasket Idler Pulley _ F n l Clip Intake Pipe i t Water Pump Pultey_ No 1 Camshaft __ _ Timing Pulley Timing Belt Tef sioner e EG Non reusable parI ...

Page 194: ...LUID COUPLING AND WATER PUMP PULLEY a Loosen the 4 water pump pulley nuts b Loosen the alternator pivot bolt and adjusting lock bolt c Loosen the adjusting bolt and remove the 2 drive belts d Remove the 4 nuts the fan fluid coupling assembly and pulley e Remove the 4 nuts and fan from the fluid coupling 3 REMOVE TIMING BELT See steps 1 to 3 in timing belt removal in Engine Mechanical 4 REMOVE IDLE...

Page 195: ...fluid coupling for damage and silicon oit leakage If necessary eplace the fiuid coupling 1 INSPECT WATER PUMP Turn the pulley and check that the water pump bear ing moves smoothly and Quietly If necessary replace the water pump 8 REMOVE WATER PUMP a Remove the 3 bolts and alternator adjusting bar b Remove the 2 nuts and disconnect the turbo water pipe from the wate pump c Disconnect the turbo wate...

Page 196: ...CAMSHAFT TIMING PULLEY See steps 1 and 2 in timing belt installation in Engine Mechanical 5 INSTALL IDLER PULLEY See step 4 in timing belt installation in Engine Mechanical 6 INSTALL TIMING BELT See steps 5 to 10 in timing belt installation in Engine Mechanical 7 INSTALL WATER PUMP PULLEY FLUID COUPLING FAN AND DRIVE BELTS a Install the fan to the fluid coupling with 4 new nuts Torque 6 4 N m 65 k...

Page 197: ...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 1 77u sM Y tll 2_ REMOVE WATER INLET AND THERMOSTAT a Remove the 3 bolts and water inlet b Remove the thermostat el Remove the gasket from the thermostat ...

Page 198: ...e lift V lve lift 10 mm 0 39 In or mor t 90 C 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 If not closed replace the thermostat 1 PLACE THERMOSTAT IN CYLINDER SLOCK a Install a new gasket to the thermostat b Ins1all the thermostat with the jiggle valve upward l 2 INSTALL WATER INLET a Temporarily i...

Page 199: ... 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 cml 10 7 14 8 pail Minimum opening pr ssur 59 kP 0 8 kgf cml 8 5 pII HINT Use the tester s maximum reading as the open ing pressure If the opening pressure is less than minimum replac...

Page 200: ...ipe D Ring I If Support Tank Plate Q Ring _ Lower Tank Oil Cooler Support Cushion f Non reusable part 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 Plate ...

Page 201: ...g washers and 2 nuts Torque 10 N m lOa kgt em 7 ft lbf d Install the 2 pipes Torque 15 N m 150 kgf em ft lbf HINT Face the pipes in the direction shown in the 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 Water leakage will result if the bottom of th...

Page 202: ...tration _ _ 3_ _ 3 __ 4_ _ 5 6 Tank Tank Plate Punch o SST Stopper Guide Block C00043 C O 06 Port SST NOTICE If the bottom of the cor plate i staked with the SST on the guide block stopper it may result in water leakage HINT Stake with just enough pressure to leave a mark on the claw The staked plate height HI should be as follows Plate height H 9 2 9 6 mm 0 362 0 378 in Do not stake the areas pro...

Page 203: ... Ring 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 test first swirl the radiator around in the water until all air bubbles disappear 6 PAINT TANK PLATE HINT If the ...

Page 204: ...NS SERVICE DATA TORQUE SPECIFICATIONS EG 191 EG Part tighllnld N m kgl em It lbf Drain plug x Oil cooler cover 29 4 300 22 W ter pump l Cylinder block 12 mm h d 19 6 2DD 14 mm he d 39 2 40D 2 F n II Fluid coupling 6 571nAbf Fluid coupling II WeIer pump pulley 19 6 200 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 c...

Page 205: ...010 Engin Adjull Kit 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 SSM SPECIAL SERVICE MATERIALS 08826 00080 Seal Pecking Bleck or equivetent O pump FIPG O pen 08833 00080 Adhesive 1344 O pressure s nd r gauge THREE BONO 13...

Page 206: ...il into a container 2 REPLACE OIL FILTER a Using SST remove the oil filter SST 0922B l 0002 b Clean the oil filter contact surface on the oil filter mounting c Lubricate the filter rubber gasket with clean engine oil d Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting e Using SST give it an additional 3 4 turn to seat the filter SST 0922B l 0002 3 REFI...

Page 207: ...ESSURE 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 cml 38 87 pai 7 REMOVE OIL PRESSURE GAUGE Adhesive 8 REINSTALL OIL PRESSURE SENDER GAUGE a Apply adhesive to 2 or 3 threads of the oil pressure sender gauge Adhesive Part No 08833 00080 THREE BOND 1344...

Page 208: ...r t c a m p l Gasket 61 J OirPipe Gasket Idler Gear Shaft Q I I L Q Q Injection Pump Drive I I I Gear Oil Seal Vacuum Pump 1 El Crankshaft Front Oil Seal Thrust Plate I _ _ _ 0 Rm9 j _ 1 lI 0 1 Pu p 0 V81 Shaft Gear Idler Gear i I Qr 1 r EG Non reusable pan ...

Page 209: ... Camshaft liming __ Pulley f 1t Clamp wi EGA System Timing Belt Seal Washer Il Gasket Intake Pipe Assembly Cii Ir EGR Valve Bracket 4i c Gasket r lntakePipe Insutalor wI EGR System F n jr5 1nr Clamp a Idler Pulley Clamp Vacuum Hose Intake Pipe vacuumHose GaSk Intake Heater Gaskel w o EGR System Non reusable part ...

Page 210: ...ainer should be removed and cleaned DRAIN ENGINE COOLANT 2 DRAIN ENGINE OiL 3 REMOVE TIMING GEARS See steps 1 to 3 in timing gears removal in Engine Mechanical 4 REMOVE OiL PAN a Remove the 27 bolts and 3 nuts b Insert the blade of SST between the cylinder block and oil pan and cut off applied sealer and remove the oil pan SST 09032 00100 NOTICE Do not use SST for the oil pump body side and r88 oi...

Page 211: ... case to the cylinder block Using a screwdriver remove the oil pump by prying the portions between the oil pump and cylinder block Remove the gasket and O ring REMOVE OIL STRAINER Remove the 2 bolts 2 nuts oil strainer and gasket ENGINE LU8RICATION SYSTEM 5 REMOVE WATER OUTLET EG 198 8 la b EG e d 7 COMPONENTS FOR DISASSEMBLY AND ASSEMBLY Plug G k J1 Driven Aotor Timing Gear Case Non reusable part...

Page 212: ... and quietly If necessary replace the oil pump assembly 3 INSPECT DRIVE AND DRIVEN ROTORS A Inspect rotor tip clearance Using a feeler gauge measure the clearance between the drive and driven rotor tips Standard tip clea ance 0 080 0 160 mm 0 0031 0 0063 in Maximum tip cI8 anc8 0 21 mm 0 0083 in If the tip clearance is greater than maximum replace the oil pump assembly B Inspect rotor body clearan...

Page 213: ...se b Install a new gasket and the plug Torque 42 N m 425 kgf cm 31 ft lbf 2 INSTALL DRIVE AND DRIVEN ROTOR OIL PUMP INSTALLATION 1 INSTALL OIL STRAINER Install a new gasket and the oil strainer with the 2 bolts and 2 nuts Torque 8 8 N m 90 kgf cm 18 In lbf 2 INSTALL OIL PUMP TIMING GEAR CASE a Remove any old packing FIPG material and be care ful not to drop any oil on the contact surfaces of the t...

Page 214: ...ation d install a new O ring to the injection pump e Install the timing gear case to the cylinder block with the 7 bolts Uniformly tighten the bolts in several passes Torque 19 6 N m 200 kgf cm 14 ft lbf f Install the 2 nuts holding the injection pump to the timing gear case Torque 18 N m 185 kgf cm 13 ft lbf 3 POUR ENGINE OIL INTO OIL PUMP a Using a 5 mm hexagon wrench remove the taper screw plug...

Page 215: ...ffect the paint ed lurfacel J Seal Width A s 4 5mm A Fie b Apply seal packing to the oil pan as shown in the illustration Seal packing Part No 08826 00080 or equivalent Install a nOlzle that has been cut to a 4 5 mm 0 16 0 20 in opening 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...

Page 216: ... AND INSTALLATION w o EGR System wi EGR System liming Belt J Gasket r EGR Valve Bracket 0 G k P __ as at Intake Pipe Assembly Timing Belt Cover Vacuum Hose Gasket Intake Heater o r Gasket Vacuum Hose wI EGR System Intake Pipe No 2 Flange Vacuum Hose Non reusable part ...

Page 217: ... O Ring 1 J I _ 1 I Water Bypass Hose l f tc c I Tt from Injection Pump j Gasket J _ I J J I l I j r0 I QilFilter fl I r I I I r 1 __ Check Valve 1 I I I ib _ to i _ I I I Gasket 1 l GaSket R fV Oil c o erature Cover Assembly Sensor c9lcGl _ Water Bypass Hose from Injection Pump _ Clamp D Ring Injection Pump I _J j l G NO 1 Cylinder Block Insulator Oil Cooler Cover Non reusable part ...

Page 218: ...il end filter replacement 7 REMOVE RELIEF VALVE Remove the relief valve and gasket 8 REMOVE CHECK VALVE Remove the check valve and gasket 9 REMOVE WATER TEMPERATURE SENSOR Remove the sensor and gasket 10 REMOVE OIL DIPSTICK AND GUIDE a Remove the bolt and pullout the dipstick guide to gether with the dipstick from the oil pan b Remove the 0 ring from the dipstick guide 11 REMOVE OIL COOLER AND COV...

Page 219: ...t lbf 2 INSTALL OIL COOLER AND COVER ASSEMBLY Install a new gasket the oil cooler and cover assembly with the 13 bolts and 2 nuts Uniformly tighten the bolts and nuts in several passes Torque 19 8 N m 200 kgf cm 14 ft lbf HINT Each bolt length is indicated in the illustration Bolt length A 20 mm 0 78 in B 40 mm 1 57 in 3 INSTALL OIL DIPSTICK GUIDE AND OiL DIPSTICK a Install a new 0 ring to the dip...

Page 220: ... 14 ft lbf 7 INSTALL OIL FILTER See step 2 in oil and filter replacement 6 INSTALL INJECTION PUMP See steps 1 to 3 in injection pump installation in Fuel System 9 INSTALL INJECTION PIPES Se8 steps 3 and 6 in injection nozzle installation in Fuel System 10 INSTALL NO 2 CAMSHAFT TIMING PULLEY See step 3 in timing belt installation in Engine Mechanical 11 INSTALL TIMING BELT S88 steps 5 to lOin timin...

Page 221: ... Check Valve a O IP n 6 x 27 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 OIL NOZZLES INSPECTION 1 INSPECT CHECK VALVES fJ ii jPush Push the valve with a wooden stick to check if it is Ir stuck If stuck replace the check valve ...

Page 222: ... 0 080 0 160 mm 0 0031 0 0063 in M dmum 0 21 mm 0 0083 in Body clellrance STO 0 100 0 170 mm 0 0039 0 0067 in Maximum 0 20 mm 0 0079 in Side clearance STO 0 030 0 090 mm 0 0012 0 0035 in Maximum 0 15 mm 0 0059 in TORQUE SPECIFICATIONS Pari tightened N m kgf cm It lbf 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...

Page 223: ... EG EG 210 MEMO ENGINE LUBRICATION SYSTEM ...

Page 224: ...N 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 ...

Page 225: ...n Pump Spline Sh ft Pul r 09820 00030 Alternator R Be ri l R pI c ArlTMllur H ring RECOMMENDED TOOLS 09082 00050 TOYOTA Eleel 1 Tnt r Set EOUIPMENT _ Dial indicator Comm Utor Magnetic finger Pull scale Bf lsh spring Sandpaper Comrnutltor TOrl tue wrench V block Vernier calipers Comrnutllor Brush ...

Page 226: ...nition 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 wJ EGR System Emission ECU G7EL _o l Dl 0 0 0 _ _00 DDUDD w o EGR System 10 Pre Heating Timer Grl E 120 Cl F After Glow 90 c E lime 1 4 light 60 3 II l 2 U9hti IQ 30 l Time C l 0 0 20 0 20 40 60 80 4 32 58 1041 140 176 1 2 1 Water Temperat...

Page 227: ...d Ignition switch OFF No voltage Ignition switch ON Battery voltage Voltage STA Ground Ignition switch OFF No voltage Ignition switch START Battery voltage Voltage VPWC Ground Ignition switch OFF No voltage Ignition switch ON Battery voltage Continuity GREl Ground Continuity Continuity 1 THW E2 Continuity Continuity 2 THW EG Continuity Continuity l E1 E01 E02 Ground Continuity wI EGR System Wire H...

Page 228: ...is continuity between terminals e and g b Check that there is no continuity between terminals B and G If continuity is not as specified replace the relay No Continuity Continuity Continuity B Inspect reley operation a Apply battery voltage across terminals e and g b Using an ohmmeter check that there is continuity between terminals Band G If operation is not as specified replace the relay 3 REINST...

Page 229: ... Vacuum Hose ba Intake Pipe Clamp EVRV Connector 1t TUrbo Pressure SensOr Connector l tl VSV for Turbo Pressure Sensor Connector wI EGR Syatem Intake Pipe Assembly Clamp e Clamp Air Hose t GaSket 000 V _ Gasket 1 r V H I r I acuum ose I J Gasket f lntakeHealer VSVfor lntakeHeater EGA Valve Connector Lead Wire Inlat e Pipe Insulator GaSket Intake Air COnnector Non reusable part ...

Page 230: ...Temp Sensor J WATER TEMPERATURE SENSOR INSPECTION L REMOVE WATER TEMPERATURE SENSOR 2 INSPECT WATER TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the terminals Re i tance Refer to the chart graph If the resistance is not as specified replace the water temperature sensor 3 REINSTALL WATER TEMPERATURE SENSOR 30 20 Acceptable 10 Ii w 3 L 2 Z Ohmmeter 1 0 V w 0 3 0 0 2 11 0 1 60 ...

Page 231: ...t and disconnect lead wire from the magnetic switch terminal STARTER DISASSEMBLY O Ring I Steel Ball Starter Housing 5 C II top 0 at Starter Clutch I Compression Spring Retrne r q Clutch Shaft b I __ 1 Snap Ring Pinion Gear Compression Spring t r dl 8 9 I l Rear Bearing Armature Front Beating g 1 1 Field Frame ft Brush Holder Field Coil a Ring End over Dust Protector Sl Oust Protector __ Lead Wire...

Page 232: ...ove these parts from the magnetic switch assem bly 1 Starter housing and clutch assembly 2 Return spring 3 Plate washer 4 Idler ge r 5 Bearing REMOVE STEEL BALL Using a magnetic finger remove the st8el ball from the clutch shaft hole 2 REMOVE STARTER HOUSING CLUTCH ASSEMBLY AND GEARS a Remove the 3 screws b 2 J 3 4 n 5 ST08IS 3 4 REMOVE BRUSH HOLDER a Remove the 2 screws and end cover from the fie...

Page 233: ... an ohmmeter check that there is no continuity between the commutator and armature coil core If there is continuity replace the armature 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 xi...

Page 234: ... check that there is continuity between the lead wire and field coil brush lead If there is no continuity replace the field frame No continuity Brush Holder Side ill 2 INSPECT FIELD COIL FOR GROUND Using an ohmmeter check that there is no continuity between the field coil end and field frame It there is continuity repair or replace the field frame Brushes Field Frame Side INSPECT BRUSH LENGTH Usin...

Page 235: ...nuity repair or replace the brush holder Clutch and Gears 1 INSPECT GEAR TEETH Check the g8ar t88th on the pinion gear idle gear and clutch assembly for wear or damage If damaged replace the gear or clutch assembly If damaged also check the drive plate ring gear for wear or damage 2 INSPECT CLUTCH PINION GEAR Hold the starter clutch and rotate the pinion gear clockwise and check that it turns free...

Page 236: ...ch 7 Compression spring 8 Clutch shaft B Assemble starter housing end clutch assembly a 1st assemble these parts 1 Clutch shah 2 Compression spring 3 Starter clutch b 2nd assemble these parts 1 Clutch shaft and starter shaft assembly 2 Starter housing 3 Compression spring 4 Retainer 5 Pinion gear 6 Stop collar nl 5 6 3 2 e Push down the pinion gear and starter housing e Using snap ring pliers inst...

Page 237: ... snap ring SlD 1 3 Bearings 2 IF NECESSARY REPLACE BEARINGS a Using SST remove the bearing SST 09286 46011 1 INSPECT BEARINGS Turn the bearing by hand while applying inward force If resistance is felt or the bearing sticks replace the bearing Using a press press in a new front bearing Using SST and a press press in a new rear bearing SST 09820 00030 Front Bearing Rear Bearing b I e L I SST H 1 tJ ...

Page 238: ...itch 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 2 INSTALL BRUSH HOLDER a Place the brush holder on the armature b Using a screwdriver hold the brush spring back and connect the brush into the brush holder Connect...

Page 239: ...tall the plate washer to the magnetic switch e Place these parts to the starter housing 1 Idler gear 2 Bearing d Assemble the starter housing and magnetic switch assembly and install the 3 screws Felt Washer 5 INSTALL FIELD FRAME WITH ARMATURE AND LEAD WIRE TO MAGNETIC SWITCH a Install a new felt washer to the armature mo b Align the protrusion of the field frame with the cutout of the magnetic sw...

Page 240: ...ests must b performed within 3 to 5 uconds to avoid burning out the call 1 DO PULL IN TEST a Disconnect the field coil lead wire from terminal C b Connect the battery to the magnetic switch as shown Check that the clutch pinion gear moves outward If the clutch pinion gear does not move replace the magnetic switch assembly 2_ DO HOLD IN TEST With battery connected as above with the clutch pinion ge...

Page 241: ...r rotates smoothly and steadily with the pinion gear moving out Check that the am meter shows the specified current Specified current 12 V type At 11 0 V 180 A or I 24 V type At 23 0 V 90 A or I wl24V Starter STARTER RELAY STARTER RELAY INSPECTION 1 REMOVE STARTER RELAY wI 12 V Starter 4 1 Ohmmeter oj3F 2 INSPECT STARTER RELAY A Inapect relay continuity wI 12 V St rter a Using an ohmmeter check th...

Page 242: ...ontinuity between terminals 1 and 2 If operation is not as specified replace the relay w 24 V Starter Ohmmeter 00 0 ST 8U Continuity B MG e Banery 215318 wI 24 V Starter 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 b Using an ohmmeter check that there is continuity between terminals B and MG If operation is not as sp...

Page 243: ...ontinuity 7 Ground Continuity 3 RECONNECT VOLTAGE CONVERTER TIMER CONNECTOR VOLTAGE CONVERTER RELAY wi 24 V Starter VOLTAGE CONVERTER RELAY INSPECTION 1 REMOVE VOLTAGE CONVERTER RELAY Continuity o Sl0ll81 Continuity o No continuity 2 INSPECT VOLTAGE CONVERTER RELAY A Inspect rellY continuity a Using an ohmmeter check that there is continuity between terminals 8 and g b Using an ohmmeter check that...

Page 244: ...RELAY ST 24 V HOLD WARNING RELAY w 24 V Starter 24 V HOLD WARNING RELAY INSPECTION 1 REMOVE 24 V HOLD WARNING RELAY Ohmmeter 00 o No continuity Ohmmeter 00 o Continuity BEOO10 Ohmmeter 00 o Continuity Battery 1 f 2 INSPECT 24 V HOLD WARNING RELAY A Inspect relay continuity a Using an ohmmeter check that there IS continuity between terminals 1 and 3 b Using an ohmmeter check that there is continuit...

Page 245: ...mm 0 807 0 827 in Minimum 13 0 mm 0 512 in Spring installed load 18 6 35 3 N 1 9 3 6 kgf 4 2 7 9 Ibl Commutator Diameter STO 36 0 mm 1 417 in Minimum 35 0 mm 1 378 in Undercut depth STO 0 7 0 9 mm 0 028 0 035 in Minimum 0 2 mm 0 008 in Circle runout Maximum 0 05 mm 0 0020 in TORQUE SPECIFICATIONS 0 0_ Part lightened N m kgf cm It lb Starter housing Magnetic switch 9 3 95 82 in lbl End cover Slarte...

Page 246: ...CH l CHARGING SYSTEM PRECAUTION CH 2 PREPARATION CH 2 ON VEHICLE INSPECTION CH 3 ALTERNATOR CH 5 SERVICE SPECiFiCATIONS CH 14 ...

Page 247: ...ARATION SST SPECIAL SERVICE TOOLS CH 09285 76010 Injection Pump Camshaft Bearing Rotor rear bearing covar Cone Replacer 09286 46011 Injection Pump Spline Shaft Rlctifie and frame Puller 09820 00021 Alternator Aear ataring Puller 09820 00030 Alternator Raar Be ring Replacer 09820 63010 Alternator Pulley Silt Nut Wrench So 09950 60010 Replacer Set Rotor front bearil lll O P 09951 00260 Replacer 26 _...

Page 248: ...t 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 1 CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL a Check the electrolyte quantity of each cell If insufficient ...

Page 249: ...tive lead of the ammeter Connect the positive lead of the ammeter to terminal B of the alternator Connect the positive lead of the voltmeter to terminal B of the alternator Ground the negative lead of the voltmeter bl Check the charging circuit as follows With the engine running from idle to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperege 10Aorle Standard voltage At 25 C...

Page 250: ...ed the indication will sometimes be less than standard amperage ALTERNATOR __m I H COMPONENTS FOR DISASSEMBLY AND ASSEMBLY Brush Holder Cover Bearing cov r Rear Bearing Rear End Cover __Alternator Washer lJ _ 6 Ie Regulator Z 4 Rectifier Holder L Rubber Insulator Seal Plate Reclifier End Frame _ Aotor Bearing Retainer Front Bearing Drive End Frame Stator Pulley ALTERNATOR DISASSEMBLY 1 REMOVE REAR...

Page 251: ...e the rear end covsr 2 REMOVE BRUSH HOLDER AND IC REGULATOR a Remove the brush holder cover from the brush holder b Remove the 5 screws brush holder and Ie regulator e Remove the seal plate from the rectifier end frame 3 REMOVE RECTIFIER HOLDER a Remove the 4 screws and rectifier holder ...

Page 252: ...ft Ie As shown in the illustration mount SST C in a vise and install the alternator to SST e d To loosen the pulley nut turn SST A in the direction shown in the illustration NOTICE To prevent damage to the rotor shaft do not loo n the pulley nut more than one half of turn e Remove the alternator from SST C f Turn SST B and romovo SST A and B g Remove the pulley nut and pulley 5 REMOVE RECTIFIER EN...

Page 253: ... At 20 C 66 F 2 9 0 If there is no continuity replace the rotor 2 INSPECT ROTOR FOR GROUND Using an ohmmeter check that there is no continuity between the slip ring and rotor If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using vernier calipers measure the slip ring diameter Standard diameter ...

Page 254: ...ard 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 CH Rectifiers Rectifier Holder 1 INSPECT POSITIVE RECTIFIER a Using an ohmmeter connect one tester probe to the positive terminal and the other to each rectifier terminal Reverse the polarity of the tester probes and repeat step a Check that one shows conti...

Page 255: ...that the bearing is not rough or worn CH 2 IF NECESSARY REPLACE FRONT BEARING a Remove the 4 screws bearing retainer and bearing b Using SST and a press press out the bearing SST 09950 60010 09951 00260 09952 06010 e Using SST and a press press in a new bearing SST 09950 60010 09951 00500 d Install the bearing retainer with the 4 screws 3 INSPECT REAR BEARING Check that the bearing is not rough or...

Page 256: ...d bearing cover SST 09820 00021 NOTICE Ba careful not to damage the fan b Place the bearing cover on the rotor c Using SST and a press press in a new bearing SST 09820 00030 d Using SST push in the bearing cover SST 09285 76010 ALTERNATOR ASSEMBLY 1 PLACE RECTIFIER END FRAME ON PULLEY 2 INSTALL ROTOR TO RECTIFIER END FRAME ...

Page 257: ... 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 N m 400 kgf cm 29 ft Jbf e Check that SST A is secured to the pulley shaft d As shown in the illustration mount SST C in a vise and install the alternator to SST C e To torque the pulley nut turn SST A in the direction shown in the illustratio...

Page 258: ...b Place the Ie regulator and brush holder on the rectifier end frame NOTICE B c r ful of the hold intt lI tion direction e Install the 5 screws d Place the brush holder cover on the brush holder 7 INSTALL REAR END COVER la Install the end cover and plate terminal with the 3 nuts and bolt Torque Bolt 3 8 N m 38 kgf cm 34 In Ibf Nut 80 A 4 N m 45 kgf em 39 in lbf 100 A 4 5 N m 48 kgt em 40 in Ibf b ...

Page 259: ... 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 n F 14 0 15 0V t 11S C 239 F 13 5 14 3 V TORQUE SPECIFICATIONS _0 Part tight ned N m kgf em tbf Raetit Ind tr me I Drive trim 5 0 in lbf Alternator pulley x Rotor 110 1 125 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...